05 CT2 Scribd

SOUTH OF THE BORDER BEARING TUTORIAL TRUMPS NEW EPA
GAS TRADE WITH MEXICO PART 1 OF A SERIES SLIMMER, TRIMMER
MAY 2017
Also in this Issue:

Doosan koda Power Invests In Georg
Sloan Lubrication Transitions Forward
Harvesting Profits From Emissions
WWW.COMPRESSORTECH2.COM/SUBSCRIBE/
n Customer:
Ethylene plant, Saudi Arabia.
n Challenge:
Overhaul and repair four critical steam turbines in 12 days.
n Result:
Elliott coordinated six months of pre-planning
and completed the project four days early.
They turned to Elliott

for planning and execution.
The customer turned to Elliott because they understood that planning is everything
and that few companies can match Elliott in turnaround planning and execution.
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 The world turns to Elliott.

www.elliott-turbo.com
May 2017
COMPRESSORtech2 is the premier resource for gas compression news and information.
Featured Articles
12 Mehrer Takes New Compressor Vertical
14 Sloan Lubrication Transitions Forward
20 A Change Is In The Air
34 A North To South Connection
44 Doosan koda Power Invests In Georg
Cover Designed By 48 A Tutorial On Hydrodynamic Bearings For Reciprocating Engines
Brenda Burbach
And Compressors
COMPRESSORtech2 (ISSN 1085-2468)
Volume 22, No. 4 Published 10 issues/year
(January-February, March, April, May, June,
July, August-September, October, November,
TECHcorner
December) by Diesel & Gas Turbine Publications, 26 Multiphysics Approach In The Torsional Analysis
20855 Watertown Road, Waukesha, WI 53186-
1873, USA Subscription rates are $85.00 per Of A Reciprocating Compressor Train
year/$10.00 per copy worldwide. Periodicals
postage paid at Waukesha, WI 53186 and at addi- 36 Harvesting Profits From Emissions
tional mailing offices. Copyright 2017 Diesel &
Gas Turbine Publications. All Rights Reserved.
Materials protected by U.S. and international
copyright laws and treaties. Unauthorized dupli-
cation and publication is expressly prohibited.
Departments
Printed in the USA. 4 Page 4 Fly Higher
Canadian Publication Mail Agreement # 40035419. 6 About The Business Regulatory Process Ensures Safety
Return Undeliverable Canadian Addresses to:
P.O. Box 456, Niagara Falls, ON L2E 6V2, Canada. Of Pipeline Compressor Stations
Email: ssmith@dieselpub.com. POSTMASTER:
Send address changes to: Circulation Manager, 8 Monitoring Government Trump Team Pushes Changes
COMPRESSORtech2, 20855 Watertown Road, Suite At Environmental Protection Agency
220, Waukesha, WI 53186-1873 USA.
www.compressortech2.com 9 Prime Movers
Follow @COMPRESSORtech2 on: 10 Events & Meetings
19 Featured Products
43 Literature
60 Scheduled Downtime
61 Marketplace
MEMBER OF
62 Advertisers Index
64 Cornerstones Of Compression The Worthington CUB And Super CUB
Page
COMPRESSOR
A Member of the Diesel & Gas Turbine Publications Group
PUBLICATION STAFF
Associate Publisher ................... Mark Thayer
Senior Editor ................................... DJ Slater
4
Fly Higher
Senior Editor ................. Michael J. Brezonick
Associate Editor ........................... Klinton Silvey
Associate Editor ............................... Jack Burke
Associate Editor ............................Chad Elmore
Copy Editor ............................... Jerry Karpowicz
Digital Publishing Manager
Content Manager ........... Paul Damon
...............Catrina Carne
Advertising
Advertising Manager
Manager ..................
.................. Katie
Katie Bivens
T
Bivens
Circulation
Circulation Manager
Manager ......................
...................... Sue
Sue Smith
Smith he headline aggregators and social media have been filled recently
Graphic
Graphic Artist
Artist ...........................Brenda
...........................Brenda Burbach
Burbach with news and opinion about the United Express Flight 3411 incident
Graphic
Graphic Artist
Artist .................................Carla
.................................Carla Lemke
Lemke
Graphic where a passenger was forcibly removed from his seat to make room
Graphic Artist
Artist ...............................
............................... Alyssa
Alyssa Loope
Loope
for must-ride employees.
PUBLICATION
PUBLICATION HEADQUARTERS
HEADQUARTERS
20855 There were so many things wrong with the situation that its hard for onlook-
20855 Watertown
Watertown Road,
Road, Suite
Suite 220
220
Waukesha, Wisconsin 53186-1873
Waukesha, Wisconsin 53186-1873 ers not to get their blood pressure up just reading about it: that the passenger
Telephone:
Telephone: (262)
(262) 754-4100
754-4100 Fax:
Fax: (262)
(262) 754-4175
754-4175 was already boarded and seated; that the staff and crew were not authorized
CONTRIBUTING
CONTRIBUTING EDITORS
EDITORS to make a compensatory offer at a price point someone would accept; that
Norm
Norm Shade
Shade Cambridge,
Cambridge, Ohio
Ohio overbooking is a thing at all; the mans unwillingness to comply with federal
Mauro Belo Schneider
Schneider
Rio
Rio Grande
Grande dodo Sul,
Sul, Brazil
Mauro Belo Brazil rules; the heavy-handed removal of the customer; the companys response
Patrick
Patrick Crow
Crow Austin,
Austin, Texas
Texas
after the incident; and on it goes.
HOUSTON,
HOUSTON, USA
USA Though there were a number of parties involved in the situation United,
Mark
Mark Thayer,
Thayer, Associate
Associate Publisher
Publisher
12777 Jones Republic Airlines, Chicagos OHare International Airport Dept. of Aviation secu-
12777 Jones Road,
Road, Suite
Suite 225
225
Houston,
Houston, Texas
Texas 77070
77070 rity officers United took the brunt of the blame. United CEO Oscar Muoz, in
Telephone:
Telephone: (281)
(281) 890-5287
890-5310 his best attempt at public relations repair, has took responsibility for the incident,
GERMANY
GERMANY saying it would never happen again.
Lisa
Lisa Hochkofler,
Hochkofler, Advertising
Advertising Manager
Manager The situation will undoubtedly end up as a case study in a management text-
Gabriele Dinsel,
Gabriele Dinsel, Advertising
Advertising Manager
Manager book one day soon. Perhaps there are some things we can take away from it now.
Niemllerstr. 9
Niemllerstr. 9
73760
There are a couple of parallels that can be drawn between the airline industry
73760 Ostfildern,
Ostfildern, Germany
Germany
Telephone:
Telephone: +49
+49 711
711 3416
3416 74
74 0
0 Fax:
Fax: +49
+49 711
711 3416
3416 74
74 74
74 and the oil & gas industry. And maybe there are some parallels between United
UNITED and your company.
UNITED KINGDOM
KINGDOM
Ian
Ian Cameron,
Cameron, Regional
Regional Manager/Editor
Manager/Editor Both industries have many government regulations. Both have demanding
Linda
Linda Cameron, Advertising
Cameron, Advertising Manager
Manager safety practices and systems. Both industries rely heavily on tightly managed
40 Premier Avenue processes for manufacturing and operations.
Ashbourne, Derbyshire,
One airline analyst noted that at United, these conditions have resulted in a
DE6 1LH, United Kingdom
Telephone: +44 20 31 79 29 79 Fax: +44 20 31 79 29 70 corporate culture where employees are strictly bound by the book. They have
ITALY
become unable or unwilling to bend to find a satisfactory solution that benefits
Roberta Prandi, Regional Manager/Editor both the customer and the company.
Via Cerere 18 Amazon.com founder and CEO, Jeff Bezos, in his 2016 letter to shareholders,
38062 Arco, Italy warned about the process becoming the thing.
Telephone: +39 0464 014421
This can happen very easily in large organizations, Bezos said. The process
SWEDEN becomes the proxy for the result you want. You stop looking at outcomes and just
Bo Svensson, Field Editor/Business Manager
Dunderbacksvagen 20
make sure youre doing the process right. Its always worth asking, do we own
612-46 Finspong, Sweden the process or does the process own us?
Telephone: +46 70 2405369 Fax: +46 122 14787 Processes are useful. They save time, resources and lives. But the best pro-
JAPAN cesses and rules undergo continuous review and improvement to make sure
Akiyoshi Ojima, Branch Manager they help achieve intended outcomes.
51-16-301 Honmoku Sannotani, Naka-ku Is there a policy or process in your purview that has lost its focus, no longer
Yokohama, 231-0824 Japan
functions correctly or could have unintended consequences? Maybe its time
Telephone: +81 45 624 3502 Fax: +81 45 624 3503
for a review.
KOREA
You can bet United will be reviewing its practices very carefully in the coming
D. S. Chai, Sales Manager
Dongmyung Communications Inc. weeks and months. CT2
82 Pyeongchangmunhwa-ro, Jongno-gu
Seoul, 03011 Korea Mark Thayer, associate publisher
Telephone: +82 2 391 4254 Fax: +82 2 391 4255
mthayer@dieselpub.com
DIESEL & GAS TURBINE PUBLICATIONS
President .................................
& CEO .................... Michael J. Osenga
Executive Vice President ....Michael J. Brezonick
About The Business
Regulatory Process
Ensures Safety Of Pipeline
Compressor Stations
New INGAA Foundation report provides
informative overview
BY NORM SHADE
W
ith growing opposition to new pipelines and While FERC is required to perform a comprehensive re-
compressor facilities, its imperative that we view, other agencies must perform additional detailed re-
help the general public better understand our views of the impacts from these facilities and must issue per-
industry and protections that are in place. In January, the mits to allow the project to proceed. For example, the U.S.
INGAA Foundation released an excellent report: How The Environmental Protection Agency (EPA) must ensure that
Regulatory Process Protects Those Living Near Natural Gas emissions from natural gas compressor stations are safe.
Transmission Compressor Stations (http://www.ingaa.org/ State and local agencies are also often heavily involved
foundation/foundation-reports/31569.aspx). in the review of air emissions from natural gas transmis-
The new report provides an overview of what interstate sion compressor stations. The U.S. Dept. of Transportation
natural gas compressor stations are, what they do and why (DOT) is required to ensure that the design of the pipeline
they are needed. It summarizes the impacts of stations and and compressor station will be sound and will prevent pipe-
reviews the current permitting process and the regulations. line or compressor station accidents or failures.
When interstate natural gas transmission compressor sta- Agencies have established construction- and operation-
tions are proposed, constructed or modified, various agen- related air pollution limits in accordance with their statutory
cies at the federal and state level are required under law to requirements, including extensive air dispersion modelling
ensure that the station and its associated impacts will not and conformance with State Implementation Plans (SIP) and
pose a threat to the health and safety of those who live near- the National Ambient Air Quality Standards (NAAQS). Similar
by. Pre-construction regulatory oversight of compressor sta- governance applies to drinking and surface water and noise
tions is distinct from many other industrial facilities, because and vibration prior to the construction or modification of a natu-
it is subject to a comprehensive independent environmen- ral gas transmission compressor station. Importantly, the pre-
tal evaluation performed by the Federal Energy Regulatory construction review process allows opportunities for the public
Administration (FERC) in accordance with the National and other stakeholders to raise concerns unique to specific
Environmental Policy Act of 1969 (NEPA). The Clean Air Act, projects during the public notice and comment process.
Clean Water Act, the Pipeline Safety Act and their associ- Natural gas transmission operators take safety very se-
ated regulations establish a system of checks and balances riously. Stations must be designed, constructed, operated
to ensure accountability throughout the permitting process. and maintained in ways that protect the public and prevent
Multiple government agencies provide both direct review natural gas facility accidents and failures. The regulatory and
and oversight of compressor stations, ensuring a detailed permitting process is complex and robust, but it is important
evaluation of the project with checks and balances. FERC for protecting the health and safety of the public living near
and other government agencies have oversight before, compressor stations. That said, extensive and sometimes
during and after compressor stations are constructed. The conflicting government regulations are burdensome, and
pre-construction permitting process ensures that only those there are certainly opportunities to reduce that burden.
projects that are safe for the public are allowed to move Time moves too quickly, and this will be my last About
forward, and these permits provide the government with the Business column. Since 2003, I have enjoyed writing
the authority to take enforcement action against permittees hundreds of articles for COMPRESSORtech2, including
both during and after construction (e.g., inspections). this column for the past five-and-a-half years. The asso-
ciated networking has been enlightening and the positive
Norm Shade is senior consultant and president emeritus of ACI Ser- feedback very much appreciated. I do plan to continue the
vices Inc. of Cambridge, Ohio. A 47-year veteran of the gas com- Cornerstones of Compression series for the foreseeable
pression industry, he has written numerous papers and is active in future, but otherwise will be focused on completing several
the major industry associations. books on my bucket list. CT2
6 MAY 2017 COMPRESSORtech2

Get The Power of Big Data
A PROGNOST diagnostic system acquires and diagnoses 65 terabytes of sensor data
every day. Impressed?
Data itself means nothing

The challenge is to convert data into meaningful information. Our intelligent machine
and component diagnostics retrieve the knowledge operators need, to boost uptime
while reducing costs. PROGNOST keeps operators informed. Non-stop and in real-time.
Thats impressive.
reply@prognost.com www.prognost.com
Monitoring Government
Trump Team Pushes Changes At

Environmental Protection Agency
Global warming, methane emissions reporting
rules to be slashed
BY PATRICK CROW
T
he Trump administration has begun to implement The Interstate Natural Gas Association of America added,
its promised reforms at the U.S. Environmental For pipelines, NEPA continues to require FERC (Federal
Protection Agency (EPA), including a rollback of vari- Energy Regulatory Commission) to issue an environmental
ous Obama administration global warming initiatives. impact statement or an environmental assessment de-
In one of his first acts as administrator, Scott Pruitt with- pending on the scope of the pipeline project as it con-
drew an EPA request that 15,000 oil and gas companies siders the need for the pipeline. This new executive order
report on their onshore methane releases. The EPA wanted returns the scope of the climate review to that which existed
the data in order to draft standards for 1.7 million oil and gas before the 2016 CEQ guidance was issued.
wells, more than 300,000 mi. (482,803 km) of pipelines and The Natural Resources Defense Council called Trumps
associated compressor stations, 500 natural gas process- multipoint executive order an all-out assault on the protections
ing facilities and 400 underground gas storage facilities. we need to avert climate catastrophe. It said if Trump blocks
The Independent Petroleum Association of America ap- standards for methane releases, The oil and gas industry will
plauded the reversal. While this information-gathering effort continue leaking hundreds of millions of dollars worth of this
should have been a real opportunity for the decision-makers potent climate change pollutant into the air every year.
at EPA to better understand the complexities of the U.S. oil The Trump administration also released its proposed
and natural gas industry, it ended up not being the case, 2018 budget. No federal agency fared worse than EPA;
it said. The exercise imposed significant costs on compa- funding would be slashed 31%, the workforce 19%, and
nies to produce additional paperwork and added unneces- more than 50 programs would die.
sary burdens on producers technical teams to prepare and Former administrator Gina McCarthy described it as a
submit rushed comments under enormous time constraints. scorched-earth budget that represents an all out assault on
In late March, President Trump also issued an executive clean air, water and land.
order that reversed a series of Obama orders establishing Mick Mulvaney, director of the Office of Management
climate change policies, including those specifically regard- and Budget, said the EPA still would have enough funds to
ing methane. perform its core functions. But he stressed, The president
The order directed federal agencies to review their exist- wants a smaller EPA.
ing actions that restrain domestic energy production and Congress, not the administration, ultimately will deter-
suspend, revise or rescind any regulations not mandated mine EPAs funding. And legislators are unlikely to debili-
by law within six months. tate the agency and many of its programs, such as those
The order dismantled the Interagency Working Group protecting the Chesapeake Bay and the Great Lakes that
on the Social Cost of Greenhouse Gases and rescinded a have broad political support.
Council on Environmental Quality (CEQ) guidance, issued Going forward, Administrator Pruitt said, We are not
last August, regarding greenhouse gas emissions under the going to allow regulations here at the EPA to pick winners
National Environmental Policy Act (NEPA). and losers. The EPA should pass rules that are within the
The Natural Gas Supply Association said the CEQ guid- framework that Congress has established.
ance attempted to broaden the way federal agencies in- We are rejecting the narrative that this country cannot be
terpreted NEPA in a way that did not serve the acts goals both pro-energy and pro-environment. We have done that
or purpose. The existing NEPA project review process is throughout our history. We can actually achieve good jobs,
already stringent, extensive and thorough. good growth and pro-energy policies at the same time as
protecting our environment.
Patrick Crow is an Austin, Texas, writer and a former COMPRESSORtech2 Secretary of the Interior Ryan Zinke said the Trump ad-
editor. He has reported for oil and gas publications since 1967 ministration is trying to put the nation on track for energy
and has written extensively about energy issues before Congress, independence. We cant power the country on pixie dust
federal agencies and the courts. and hope, he said. CT2

Prime Movers
CECO industrial and commercial services company. The com-
James R. Hutton, a mechanical engi- bined business will have an estimated US$5 billion in
neer with Compressor Engineering Corp. annual sales.
(CECO) died in Houston, Texas on April Brand, which operates on six continents from more than
8 at the age of 96. 210 branches, is a provider of specialized services includ-
Hutton was a Fellow of the Ameri- ing work access, corrosion management, atmospheric and
can Society of Mechanical Engineers. In immersion coatings, insulation services, fireproofing and
October 2012, Hutton also received the refractory, mechanical services, forming and shoring and
Edward N. Henderson Award from the Gas other complementary specialty services in the global energy,
Machinery Research Council (GMRC). The award honors dis- industrial and infrastructure markets.
tinguished service to the GMRC and the natural gas industry. Safway is a provider of scaffolding and motorized aerial
Mr. Hutton was an inspiration to so many young engi- access solutions and insulation and coating services to
neers over the course of his career, said Mike Grubb, commercial, industrial and infrastructure customers in
president of the GMRC. His passion for mentoring, espe- North America. The companies will continue to operate
cially in the area of ethics, helped many professionals in our independently until the transaction closes.
industry grow into the positions they enjoy today.
Richard Hotze, president of CECO, said, It has been NARUC
an honor and a pleasure to have worked with Mr. Hutton The National Association of Regulatory Utility Commis-
over the past 30 years. He will always be remembered as a sioners (NARUC) has released a new and updated third
leader, a friend, and a consummate salesman and extraordi- edition of Cybersecurity for State Regulators.
nary engineer. He was an integral part of the CECO family. Since its first release in 2012, most state commissions
have used the primer to engage with utilities using a series
Brand and Safway of sample questions to explore how utilities are making pru-
Brand Energy & Infrastructure Services (Brand) and Saf- dent investments in cyber-preparedness. Although intended
way Group (Safway) are combining to create an integrated primarily for state commissions, the manual is readable and
continued on page 45
Spreader Beams
Experts in the design Trunnion Spreader

and manufacture of Beams
standard and custom

lifting equipment within
the oil and gas industry
Active Link
Modular Spreader Beams up to 400t in stock Spreader Beam
and available worldwide for distribution
Experts in custom lifting solutions and
projects requiring high QA standards
All products fully tested and certied with Spreader
DNV Type approval as standard & Lifting
In house rig design team building the ideal Frames
solution for your lifting needs For more information contact
Reduce your rigging weight and health & Head Ofce: +44 (0) 1202 621511
safety concerns by using the shackle-free Email: sales@modulift.com
Trunnion Spreader Beam system www.modulift.com
COMPRESSORtech 2
201704CT_A3129_Modulift_ActiveSpread_HH.indd 1 MAY
3/7/17 2017
10:30 AM9
Events & Meetings
Boldface indicates shows and conferences in which COMPRESSORtech2 is participating
MAY & Conference 2017 May 23-25

May 1-4 Nairobi, Kenya Eastern Gas
Offshore Technology +968 24660124 Compression Roundtable
Conference (OTC) www.ogmaexpo.com Pittsburgh, Pennsylvania
Houston, Texas +1 (412) 372-4301
+1 (972) 952-9494 May 17-19 www.egcr.org
http://2017.otcnet.org OGU 2016
May 23-25
Tashkent, Uzbekistan
Gas Africa 2017
May 9-11 +998 71 205 1818
Sandton Gauteng, South Africa
Oil, Gas & Mines Africa Exhibition www.oguzbekistan.com +27 11 883 0802
http://ingadaevents.co.za/current/
gas-africa
May 30-June 1
Sensor+Test 2017
Nuremberg, Germany
+49 5033 9639-0
www.sensor-test.de
May 31-June 3
Caspian Oil & Gas
Baku, Azerbaijan
+44 207 596 5147
www.caspianoil-gas.com
JUNE
June 13-15
Global Petroleum Show
Calgary, Alberta, Canada
+1 (403) 209-3555
www.globalpetroleumshow.com
June 20-22
9th Annual Developing Unconventional
Gas (DUG) East Conference & Exhibition
Pittsburgh, Pennsylvania
+1 (713) 260-6492
www.dugeast.com
June 26-30
ASME Turbo Expo
Charlotte, North Carolina
+1 (281) 810-5457
www.asme.org/events/turbo-expo
June 27-29
Power-Gen Europe
Cologne, Germany
+44 1992 656 637
www.powergeneurope.com
June 27-29
Sensors Expo & Conference
San Jose, California
+1 (617) 219-8300
www.sensorsexpo.com
JULY
July 17-19
SGA Operating Conference
Atlanta, Georgia
+1 (972) 620-8505
www.southerngas.org
SEPTEMBER
Sept. 11-14

For a complete listing of upcoming events,
please visit our website at www.compressortech2.com/events/
Turbomachinery Symposium
Houston, Texas
+1 (979) 845-7417
http://turbolab.tamu.edu
Sept. 12-14
Wyoming Natural Gas Fair
Casper, Wyoming
+1 (307) 258-4708
https://wyogasfair.org
Sept. 19-21
Power-Gen Asia
Bangkok, Thailand
+44 1992 656 634
www.powergenasia.com
Sept. 19-21
Gas Compressor Short Course Conference
Norman, Oklahoma
+1 (405) 325-3136
www.ou.edu/outreach/engr/gascompressor_home.html
Sept. 25-28
Argentina Oil & Gas Expo
Buenos Aires, Argentina
+54 11 4514 1400
www.aogexpo.com.ar
OCTOBER
Oct. 1-4
Gas Machinery Conference
Pittsburgh, Pennsylvania
+1 (972) 620-4026
www.gmrc.org
Oct. 15-18
2017 Gasification and
Syngas Technologies Conference
Colorado Springs, Colorado
+1 (703) 276-0110
www.gasification-syngas.org/events/2017-conference
Oct. 24-26
Black Sea Oil and Gas
Sofia, Bulgaria
+44 845 868 8234
www.globuc.com/blackseaoilgas
NOVEMBER
Nov. 13-16
ADIPEC
Abu Dhabi, U.A.E.
+971 2 444 4909
www.adipec.com
Nov. 14-16
International Petroleum
Technology Conference
Bangkok, Thailand
+971 4 457 5800
www.iptcnet.org
Nov. 15-17
SIPPE 2016
Shanghai, China
+86 21 65929965
www.sippe.org.cn/en
COMPRESSORtech2
Mehrer Takes New Compressor Vertical
Crosshead design of new two-stage,
oil-free compressor ensures clean process gas
BY ROBERTA PRANDI
M
ehrer Compression GmbH has launched the
TRZ 1000, a new two-stage, oil-free crosshead
piston compressor. The TRZ 1000 can reach a
mass flow up to 22,800 scfh (600 NM3/h) at atmospheric
suction pressure.
The water-cooled TRZ 1000 operates at a suction pressure
up to 29 psi (2 bar) and a final pressure up to 375 psi (26 bar).
The process gas machine follows a lean, space-saving
vertical design, which means that it requires significantly
less space compared to horizontal compressors, said
Hartwig Alber, marketing and business development at Meh-
rer Compression.
The main components of the new compressor are crafted
from ductile iron for more robustness and durability, giving them
a operating life of more than 20 years, the company said.
While its main application is CO2 recovery in the food and
beverage industry, the unit is ideal for toxic and process gas-
es as well, such as methane, hydrogen, biogas, nitrogen or
biomethane.
Sealing elements with polytetrafluoroethylene (PTFE) com-
pound have been used. Mehrer said that this, together with the
use of wear-resistant materials in the area of piston and rider n The vertical design of the TRZ 1000 makes it suitable for
rings, as well as an optimized gas packing, brings the service compact spaces.
life of the sealing elements way above the usual maintenance
intervals of 8000 operating hours.
The manufacturer added that the oil-free operation of the TRZ
1000 makes the contamination of downstream systems impos-
sible; therefore, a clean process gas is ensured without addi-
tional cleaning systems.
Mehrer Compression delivers the TRZ 1000 as a single
compressor block or as complete lean compressor package
including drive, piping and monitoring system. A further option
is represented by the delivery of a complete compressor plant,
which includes components such as dryer, water-cooling unit, or
sound protection hood.
Mehrer Compression, based in Germany, is a specialist in oil-
free, dry running piston compressors in vertical and V-construc-
tion, ranging from 2.2 to 334 hp (1.6 to 250 kW). These units
are designed with a crosshead principle and real free stroke.
They operate at low rotational and piston speeds and feature
a design suitable to withstand continuous operation with little n Relatively low rotational and piston speeds and a robust
maintenance, the company said. CT2 design help keep maintenance intervals low.

STASSFURT HOUSTON
GERMANY USA
SEALING EXPERTS SINCE 1920
SDS100
STASSKOL DynamicSeal
Suitable for high pressure
gas applications
Labyrinth Ring
Newly developed with special
dimensions and inner grooves
Further Benefints
More efficient
Easy to assemble
Shorter installation length
Less expensive
www.stasskol.de
Sloan Lubrication Transitions Forward
Company has seen its share of changes in 95-year history
n Sloan Lubrication Systems is situated in Freeport, Pennsylvania. The company moved its operations there in the summer of 2008.
BY DJ SLATER
S
loan Lubrication Systems knows all about transition. I have been with Sloan nearly 45 years and have never
Over the companys 95-year history, it has evolved from worked anywhere else, Walter Sloan said. While it has
handling sales to manufacturing lubrication systems been enjoyable and rewarding, it is time to do something
and components, occupied eight different locations across else just for fun. It is also time for me to let the next genera-
Pennsylvania and seen four generations of the Sloan family. tion make their own decisions and take every opportunity to
In another year, change will strike Sloan Lubrication Sys- develop their own successes.
tems again as Walter Sloan, the companys CEO, hands The fourth generation, which includes Brian Sloan, chief fi-
over the reins to his son, Brian. The move will come of- nancial officer, and C.J. Sloan, chief technology officer, already
ficially at the end of 2018. has played a part in the companys recent developments. C.J.

BENEFIT FROM REDURA
www.recip.com/redura
PUSH THE LIMITS!

FORMING THE WINNING TEAM OF RINGS REDURA SEALING SYSTEMS
REDURA REliable, DURable and Advanced sealing systems for REDURA
reciprocating compressors. The product line includes standard rings, Longest MTBO at lowest leakage
packings as well as specifically in-house developed, designed and Highest availability
patented products. Lowest life cycle costs
The heterogeneous design of Redura Piston and Rod Sealing UPGRADE YOUR RECIPROCATING
Systems stands for a unique selection of rings, provides optimized COMPRESSORS NOW
distribution of the dynamic and static pressure differences, reduces Burckhardt Compression AG, Switzerland
wear on each element and increases the overall sealing perfor- Tel. +41 52 262 55 00
mance. The Redura Oil Sealing Systems consist of a combination aftersales@burckhardtcompression.com
of different ring types, ensuring enhanced sealing efficiency while
fulfilling the requirements of dynamic tightness.
REDURA REDURA REDURA

OIL SEALING SYSTEM ROD SEALING SYSTEM PISTON SEALING SYSTEM
Sloan Lubrication Systems Timeline, 1922-Present
1922 1995
Sloan Brothers Co. is founded by Walter, Paul and Ralph The company moves around the corner to 204 Pennsyl-
Sloan. The company is located at the Farmers Bank Build- vania Ave. (Oakmont, Pennsylvania) for shop/office expan-
ing in downtown Pittsburgh, Pennsylvania. sion. The local supply chain also expands for filters, switch-
es and sheet metal components.
1931 2008
The company moves to the East Liberty section of Pitts- The decision is made to integrate full-line manufacturing,
burgh (5536 Penn Ave. at Negley). which requires more space. That summer, the company
moves to its current location at 168 Armstrong Drive in
Freeport, Pennsylvania. Later that year, the companys
1944 CNC machining operation starts building divider blocks.
The company moves to 6218 Penn Ave. (also East Liberty)
above Joyce McClements restaurant. Early 2009
The first Sloan-manufactured divider assemblies and prox-
Mid 1940s imity switches ship to customers.
John and Margaret Sloan Walters son and daughter
join the company after World War II. Both appear as stock- 2010
holders in company minutes in 1950. Margaret celebrates Enterprise Resource Planning (ERP) software implementa-
tion. It is a database system that helps the company man-
her 100th birthday in October 2017.
age its day-to-day operations.
1957 2011
Building is destroyed by fire started in the restaurant kitch- The first Wizard Vs ship to customers.
en. The filing cabinets and records are recovered from
basement. The company moves offices to 711 Highland 2012
Building at 121 S. Highland (also East Liberty). The first SLS lubricators ship to customers.
1975 2013
The company determines more space is necessary and
Walter Sloan joins the company after graduating from Penn
builds manufacturing annex. The company also adopts
State with a degree in architecture. He begins stocking Sloan Lubrication Systems name.
parts to meet customer deliveries.
2014
1981 The first SLS lubricator pumps ship to customers.
The company moves offices to 1350 Old Freeport Road
(OHara Township, Pennsylvania). Walter begins assem- 2014
bling panels in Johns basement in Oakmont, Pennsylva- The company forms the Quality Department and develops
nia. A shop and office are constructed behind the garage to the Quality Management System, an internal program of
procedures, documentation and reports.
build complete systems. The company begins working with
local suppliers to build accessories and also starts offering
on-site service to compressor industry. 2016
The company decides to increase sales force to cover the
market better. It increases outside and inside sales staff
1984 and brings a vice president of sales on board.
Walter purchases 830 Third St. in Oakmont, Pennsylvania
for leased office/shop expansion. The company adopts 2017
SBCo logo. The first Sloan-manufactured products (check The company obtains ATEX and CE mechanical certifica-
valves and Wizard monitor) are developed. tion on SLS pumps and lubricators.

Sloan joined the company in 2003, with Brian Sloan and Eric necessary move after its supplier refused to adapt to the
Sloan following in 2008. needs of the compression market, C.J. Sloan said.
Since that time, the company moved to its current location We took it upon ourselves to make the components that
in Freeport, Pennsylvania, and expanded from 20,000 sq.ft. we needed, he said. That slowly proceeded with filters
(1858 m2) to 31,000 sq.ft. (2880 m2). Sloan Lubrication Sys- and several other small parts until the mid 2000s, at which
tems is also a fully integrated manufacturer of lubrication point we started our plan to redesign and manufacture all
products for the gas compression industry, thanks to a tran- lubrication system components ourselves.
sition plan it launched in 2008. As the company began manufacturing more compo-
Our best path forward was to dictate our own destiny, nents, the need for additional space became apparent.
Brian Sloan said. That primarily required us to take control Sloan Brothers moved to its Freeport location in the sum-
of our supply chain in terms of sourcing, design, manufac- mer of 2008, which gave the company all the floor space
ture and quality. it needed for manufacturing tools, such as its four-axis
The move from sales company to manufacturer, how- horizontal machining center. With CNC capabilities, Sloan
ever, began well before the fourth generation came on Brothers began manufacturing divider blocks, as well as di-
board. In 1971, when Walter Sloan was cutting his teeth vider assemblies and proximity switches.
in a part-time role, the company only dealt with lubrication C.J. will be the first to tell you that the day we had our
system sales. Sloan Brothers, as it was known at the time, first piece of CNC equipment delivered was probably the
would take orders and send them off to Manzel Lubrica- scariest of his career, Brian Sloan said. Theres no ques-
tors in Buffalo, New York. tion that we took a bit of a leap of faith in the initial decision
Problems arose with this setup, such as incomplete or- and implementation of our plan (to be a manufacturer).
ders, shipping interruptions and long lead times on com- But I dont think anyone within the organization would
ponents. Even after another company bought out Manzel change it for anything, he said. Our decision to begin in-house
Lubricators, the same issues persisted, causing Sloan manufacturing has completely transformed our company.
Brothers to start stocking common components. The transformation continued in 2013 when the company
By the early 1980s, Sloan Brothers exposed itself to the realized it needed more space to accommodate its manu-
manufacturing world by making its own check valves, a facturing operations. The 11,000 sq.ft. (1022 m2) expansion
n Walter Sloan, CEO of Sloan Lubrication Systems, stands in between two family portraits the fourth generation (left) and first
generation (right). Walter Sloan will retire at the end of 2018.
gave the company a climate-controlled space for its ma- eral customers state that the oil draining out of a packing
chining centers, a manufacturing office and a research and case during normal operation was still good oil. The oil re-
development department. covery system gives them a way to recycle that oil back into
These moves gave the company firm footing in the com- the supply stream, C.J. Sloan said.
pression world right as the industry downturn arrived. The The system also prevents the accidental discharge of oil
slowdown, however, allowed Sloan Lubrication to focus on from vent lines and reduces emissions where fuel gas is
ways to make internal improvements, such as to its product used to empty blow pot style collection systems. It fea-
lines, processes, operations and sales strategies, said Mi- tures stainless steel Swagelok tubing and fittings, a 2000
chael Bechtold, chief operating officer. psi (138 bar) maximum discharge pressure and a flow ca-
As machine capacity opened due to market conditions, pacity of 100 gpd (379 L/d).
we vowed to keep our employees working, Bechtold said. With all of its products and capabilities under one roof in
We accomplished this by re-designing products and then Freeport, Sloan Lubrication Systems transition plan is near-
insourcing the manufacturing year over year, which allowed ly complete. While the company has become a fully inte-
us to reduce purchases by nearly 70% since 2012. grated manufacturer, the final step is still several months off.
While market conditions continue to evolve, Sloan Lu- Walter Sloan doesnt have any reservations about passing
brication hasnt sat idle. This year, the company obtained Sloan Lubrication Systems onto the next generation. Hes
ATEX and CE certification on its SLS pumps and lubri- invested nearly 45 years into the company and has seen his
cators and also released its newest product the oil share of change. Even though the next change involves his
recovery system. absence, hes not worried about the companys future.
The oil recovery system automatically recovers oil from Over a year-and-a-half from retirement, I can already
packing and distance piece drain lines. In most cases, the see wonderful things happening around me without my
recovered oil can be directly filtered and reused. In other input, and I couldnt be more proud, Walter Sloan said.
cases, it can send the waste oil stream to a disposal tank. I have great confidence that their (my sons) accomplish-
Sloan Lubrication crafted this product after hearing sev- ments will far outshine mine. CT2

Featured Products
Arial Drone Inspection
Aeromon, a Finnish clean tech startup, has suc-
cessfully completed a pilot program for detecting
fugitive emissions via drone-mounted sensors.
The pilot program took place at the mmssuo
waste treatment center (operated by the Helsinki
Region Environmental Services Authority HSY,
Finland). Using hand-held measurement tools, historical data was obtained and
compared with aerial measurements taken by a remotely piloted aircraft (RPA)
fitted with Aeromons sensor package. The composition and concentration of the
biowaste stack and treatment facility emissions were also studied.
The results showed closely corresponding data to the HSY reference results,
which demonstrated the accuracy of the Aeromon platform.
www.aeromon.fi
Industrial Spark Plug

Federal-Mogul Powertrain has introduced a new industrial spark plug with
increased mechanical and electrical strength. The Pokal has a new u-shaped
core nose on the insulator. It is designed to provide increased robustness in new
engine applications with high-peak cylinder pressures, while also enabling the
use of larger electrodes.
The Pokal spark plug, which has been in production since 2016, is suitable
for engines rated between 100 and 600 KW. The technology is applicable for
marine, off-highway and stationary industrial engines using gaseous fuels.
www.federalmogul.com
Emissions Analyzer
E Instruments has announced a new handheld industrial combustion gas and
emissions analyzer. The E6000 can measure up to six gases simultaneously.
The measurable gases are O2, CO, NO, NO2, SO2, CxHy(HC) and H2Os.
Measurements can be made up to 50,000 ppm including low NOx and total
NOx. Temperature and pressure measurements can be taken as well.
The internal memory can store 2000 tests, and the software package can be
accessed via USB and Bluetooth. The device also includes a built-in printer.
www.e-inst.com
Handheld Transducer Simulator

Meggitt Sensing Systems has launched the Endevco 4830B handheld trans-
ducer simulator designed to aid in troubleshooting and calibrating test systems
when measurement chain verification is important.
The Endevco 4830B is a portable, battery-operated signal gen-
erator that facilitates confidence in system setups before running
vibration tests. It simulates the electrical output of accelerometers
with adjustable parameters for frequency and amplitude. This tool
performs repetitive verifications/calibrations with minimal inputs.
It is ideal for any testing application including general laboratory,
vibration or condition monitoring systems.
The device features multiple transducer outputs (single-
ended/differential charge, single-ended voltage, Isotron [IEPE]
and tachometer) and a built-in vibration calculator that can be
adjusted for displacement and velocity. Parameters can be
adjusted for waveform type, frequency, sensitivity, acceleration (g) and tach ratio.
It also features fundamental frequency and order of magnitude feedback, custom
simulation profiles, fast fourier transform (FFT) input and a PC interface.
www.meggittsensingsystems.com
COMPRESSORtech2
A Change Is In The Air
Alfa Laval breathes new life into mature ACE
air-cooled exchanger business
n This upstream installation includes

six natural gas compressor packages
with ACE Model A air-cooled exchangers.
BY NORM SHADE
A
lfa Laval Air-Cooled Exchangers, historically known Today, a third of the way into its second century, Alfa
as ACE, is undergoing a major transformation. Laval is a global supplier of products for heat transfer,
ACE, founded in 1964, enjoyed nearly five decades separation and fluid handling. Key products heat ex-
of success in the manufacture of air-cooled heat exchang- changers, separators, pumps and valves are used in
ers under private ownership. Although its products and pro- many diverse industries including the manufacturing of
cesses served ACE well over that time, a much needed re- food, chemicals, pharmaceuticals, starch, sugar, ethanol,
newal began after the company was acquired by Alfa Laval nuclear power, marine vessels, mining, refineries, waste-
in December 2012. water treatment and indoor climate control. The acquisi-
Among the worlds oldest industrial companies in con- tion of ACE strengthened its position in the oil and gas
tinuous business, Alfa Lavals roots date to 1883, when and power industries.
founder Gustaf de Laval started a company in Sweden to Alfa Laval targets the entire oil, gas and power supply
manufacture his new centrifugal cream separator that was chain. We have provided custom-designed and manufac-
marketed to dairy industries throughout the world. tured air-cooled exchangers for upstream, midstream and
n Six large ACE Model E air-cooled

exchangers support a large central gas
gathering pipeline compressor station.

downstream applications, said Chris Jungers, general man- A computerized order data sheet linked to an automat-
ager of Alfa Laval Air-Cooled Exchangers (ACE) and Alfa La- ed engineering process can generate drawings and bills
val Niagara (Niagara Blower). With the global strength and of material in minutes, allowing sales engineers to select
reach of Alfa Laval, ACE air-cooled heat exchangers are a from literally billions of possible combinations of features
key part of an even more comprehensive array of heat trans- and options for each cooler frame size. Drawing files are
fer products for cooling air, natural gas, oil and water. downloaded directly to CNC machines for burnout, header
ACE moved to its current Broken Arrow, Oklahoma, loca- production and machining.
tion in 1974. Over time, this grew into a multiple-building Through a series of carefully phased steps, the factory
facility that covers 150,000 sq.ft. (13,936 m2) under one is being steadily transformed from a legacy of mature, dis-
roof on 18 acres (7.3 ha). Notably, ACE celebrated its 50th continuous and erratic production flow with old machinery
anniversary in 2014, just as the oil and gas industry was into a modern, well-organized, safe and efficient operation.
headed into one of its worst downturns in decades. continued on page 22
With the backing of Alfa Laval, we
were able to use the downturn to fo-
cus on improvements, Jungers said.
Four years into the transformation,
our efforts are paying dividends, with
much more to come in the next one
to two years.
ACEs core market is wellhead gas
compression, but the company also
manufactures air-cooled heat ex-
changers for the entire oil, gas and
power spectrum from the upstream
through the midstream and the down-
stream supply chain.
More than 50% of our business
is now engineered coolers for mid-
stream and downstream markets
including pipeline compressor sta-
tions, LNG peaking facilities and
power generation, said Misty Ingle,
inside sales manager. Wellhead
compression is still very important,
but diversification has made the
company stronger through the busi-
ness cycles.
With a focus on safety, quality, de-
livery and cost, ACEs intensive trans-
formation extends from order entry,
through engineering, manufacturing
and product development.
With a streamlined quotation pro-
cess, and an in-house proprietary
rating program, we can quickly and
efficiently customize the right air-
cooled exchanger, providing cus-
tomers with fast, accurate quotes
and advanced engineering informa-
tion, said Rusty Kight, sales and en-
gineering manager. Our extremely
flexible engineering team utilizes
proprietary drawing and sizing tech-
nologies to reduce lead times and
rapidly produce detailed 3-D CAD
models and fabrication drawings.
COMPRESSORtech2 MAY 2017 21

n This new CNC burn and bevel table, installed in Alfa Laval ACEs Broken Arrow, Oklahoma, facility last year, increased productivity and
throughput by a factor of three.
Our entire manufacturing operation was thoroughly Three separate assembly lines have been developed
mapped with our extended teams input, emphasizing the for small, medium and large coolers. Portable, expandable
customer connection, said Mark Gorgas, factory manager. paint booths allow painting the coolers in line without extra
With a cultural transformation, our workforce is helping handling. Gorgas and his team stress safety, organization,
drive continuous improvement. This is evident throughout tool storage and proper identification and maintenance of
the facility with job tracking, visual backlog and job status all utility services throughout the plant. Modern metalizing
prominently displayed in each department. and painting processes have been implemented to im-
To meet the quick deliveries that customers demand, prove environmental compliance and safety, and storage
ACE manufactures nearly all the components that go into has been improved to better utilize available space and
its coolers, including not only the structure and headers, ensure accessibility.
but also the louvers and fin tubes. A number of new CNC ACE provides a full range of air-cooled heat exchanger
machines have been added with more on the way. Gorgas products. Its Model A has vertical, sloped sections with a hor-
said a new CNC burnout and beveling machine increased izontal-forced draft fan with vertical air ejection. The sloped
productivity and throughput by a factor of three. Ten tube sections provide an optimized center of gravity for safer load-
finning lines keep up with peak production needs, and an ing and transport. Offered with fan diameters from 2 to 14 ft.
improved tube rolling process has resulted in fewer leaks (0.6 to 4.3 m), this model typically supports engine drive com-
and failures and more consistent production. pression applications from 50 to 1500 hp (37 to 1119 kW).
n Shown here is one of three portable and

collapsible paint booths installed by Alfa
Laval ACE in 2015. The paint booths are
moved into position on tracks built into the
floor, allowing coolers to be painted in line
without extra handling.

n Three large two-fan Model E coolers shown in one of the as-
sembly lines at Alfa Laval ACEs Broken Arrow, Oklahoma, facility.
Model J has vertical sections with an induced draft fan

and vertical air ejection. With fan diameters of 2 to 14 ft.
(0.6 to 4.3 m), it typically supports engine drive applications
from 50 to 800 hp (37 to 597 kW). The smaller Model C with
vertical sections and fan with horizontal air ejection is an
economical and compact alternative to vertical air ejection
models. It typically supports engine drive compression ap-
plications from 50 to 400 hp (37 to 298 kW) with fan diam-
eters of 2 to 10 ft. (0.6 to 3.1 m).
Models E and T support larger applications. Model E has
horizontal sections and fans with vertical air ejection. It is
available in single- to four-forced or induced draft fan configu-
rations with electric or hydraulic drives. Fan diameters range
from 2 to 34 ft. (0.6 to 10.4 m). Model T has horizontal sec-
tions and vertical forced draft fans with vertical air ejection. It
is available in single- to five-fan configurations with diameters
from 2 to 14 ft. (0.6 to 4.3 m), typically matched to engine
drives from 50 to more than 4500 hp (37 to 3356 kW). Its rela-
tively narrow width enables increased transportability. Alumi-
num fan guards are available on both models for increased
maintenance safety and weight reduction.
Another aspect of ACEs transformation is in product de-
velopment. In 2015, ACE introduced its Model V air-cooled
n The new ACE modular,

compact, V-type cooler with
sloped sections and stan-
dardized horizontal fan as-
semblies reduces plot space
and reduces operating costs
due to optimization of motor/
fan power consumption.
Standard variable frequency
drive motor-driven fans are
prewired to a control system on the unit. Available with section
lengths up to 60 ft. (18.3 m) with two to nine pairs of 3 to 6 ft. (0.9
to 1.8 m) diameter fans, the induced draft, vertical discharge design
reduces noise, increases safety and reduces transportation costs
relative to conventional solutions.
COMPRESSORtech2
n Shown here is the Alfa Laval wet/dry hybrid auxiliary cooling system installed at the Ivanpah solar electric generating system in
Californias Mojave Desert. Operated by NRG Energy, the system began commercial operation in 2013 and delivers power to PG&E and
Southern California Edison. The Alfa Laval hybrid system was created to maximize site water conservation while still enabling consistently
low process outlet temperatures during all seasons by running dry during cooler ambient periods, then utilizing available water only during
the hotter summer ambient air temperatures. An Alfa Laval Niagara wet surface air cooler (WSAC) is combined with an Alfa Laval ACE dry
air cooler to maximize system efficiency while taking advantage of fluctuating ambient air temperatures.
exchanger for power generation and other upstream and two to nine pairs of 3 to 6 ft. (0.9 to 1.8 m) diameter fans, the
downstream applications. induced draft, vertical discharge design reduces noise and
This adaptation of Alfa Lavals Alfa-V cooler fuses increases safety relative to conventional solutions by inher-
European design with the ruggedness expected in North ently eliminating confined space entry requirements. It also
American natural gas and power generation industries, reduces transportation costs as the compact design fits with-
said Blake Minton, sales engineer. in standard shipping containers for international applications.
The modular, V-type cooler with sloped sections and Smart controls are another ACE development that can be
standardized horizontal fan assemblies reduces plot space applied to most of its cooler models. The factory-installed
and reduces operating costs due to optimization of motor/ motor controls eliminate the need for plant motor control cen-
fan power consumption. Standard VFD motor-driven fans ters, which reduces installation costs for customers. Seeing
are prewired to a control system on the unit. Optional hy- a need and an opportunity for reducing the power consump-
draulic drives are also offered. tion of cooler fans, ACE introduced its Vspeed magnetically
Available with section lengths up to 60 ft. (18.3 m) with modulated adjustable speed fan drive in 2016 (see June
n Shown here on test is the ACE

Vspeed magnetically modulated ad-
justable-speed fan drive that was
introduced in 2016. It can be applied
to both new and retrofit applications
of engine and electric motor driven
cooler fans

2016 COMPRESSORtech2), which is designed for engine
and electric motor-driven cooler fans.
Another recent development is the Alfa Laval wet/dry hy-
brid auxiliary cooling system. Its a system design approach
created to maximize site water conservation while still en-
abling low process outlet temperatures. To reduce a sites
cooling water usage, typically influenced by cooling tower
consumption, an Alfa Laval Niagara wet surface air cooler
(WSAC) is combined with an Alfa Laval ACE dry air cooler
to maximize system efficiency while taking advantage of
fluctuating ambient air temperatures.
This allows for a consistently low process outlet tempera-
ture during all seasons by running dry during cooler ambient
periods, then utilizing available water only during the hotter
summer ambient air temperatures. Unlike typical cooling
tower solutions, poor quality water can be collected and re-
used up to 10 times with the hybrid system. Alfa Laval pro-
vides total system responsibility for thermal performance. n A two-fan Model E horizontal cooler is in process in the large cooler
Further transformation has occurred in the develop- assembly line at Alfa Laval ACEs plant in Broken Arrow, Oklahoma.
ment of an expanded service portfolio. ACE offers a suite
of performance agreements and service offerings that in- exchangers, while also helping to reduce our overall invest-
clude startup, monitoring, maintenance, improvements, up- ment by leveraging our global purchasing and sourcing capa-
grades, retrofits and support. bilities, Jungers said. This helps reduce delivery times and
With additional factory investments and enhancements, overall equipment costs. We offer service and support around
Alfa Laval ACE will continue to advance our manufactur- the clock for the complete air cooler range, which helps to de-
ing capabilities to supply customers with air-cooled heat liver peace of mind regardless of our customers location. CT2
techc
orner
Multiphysics Approach In The
Torsional Analysis Of A
Reciprocating Compressor Train
Electric behavior of motor plays key role in evaluation
BY ANDREA FUSI, FRANCESCO GRASSO,

ALESSANDRO USSI AND ALESSANDRO BAYLON
Introduction
R
eciprocating compressors generate considerable
torque variations that cause torsional vibrations into
the drive train that, if excessive, could cause the com-
ponents of the train to fail (e.g., coupling failure, Figure 1).
If the rotor has a superimposed torsional vibration over
the steady rotation, the flux linkages, produced by the in-
duction motor, start to oscillate. This phenomenon modifies
the electromagnetic fields across the air gap between sta-
tor and rotor, generating an additional torque, which acts in
conjunction with the rotors harmonic excitations. The air
gap effect influences the natural frequencies of the electro-
mechanical system. This means that the electric behavior of
the motor has a significant role in torsional vibration analy- n Figure 1. Coupling failure due to torsional vibrations.
sis and is necessary to accurately evaluate its contribution.
For this reason, a simplified approach was developed [1,
2] to include the air gap effect inside the study of the torsional
analysis, adding one spring and one damper in the mechani-
cal model obtained from the equivalent shaft of the rotor.
The API 618 standard code for reciprocating compres-
sors recommends that the torsional natural frequencies
of the complete driver-compressor system (including cou-
plings and any gear unit) shall not be within 10% of any
Andrea Fusi is an executive R&D manager at Compression Service

Technology S.r.l. (CST). Contact him at: andrea.fusi@cstfirenze.
com. Francesco Grasso is an assistant professor at Universiti degli
Studi di Firenze, Dept. of Telecommunications. Contact him at:
Francesco.grasso@unifi.it. Alessandro Ussi is an instrument and
control engineer at CST. Contact him at: alessandro.ussi@cstfi-
renze.com. Alessandro Baylon is an R&D engineer at CST. Contact n Figure 2. Induction Motor Torque reaction (T) due to motor
him at: alessandro.baylon@cstfirenze.com. speed (n) variation.

OUR RAPID RESPONSE
WE PROMISE IMMEDIATE SUPPORT. THEN WE OVER DELIVER.
Responsive Aftermarket Support from our Advanced Facility.
When every minute of downtime matters, you need responsive support you can rely on.
Mitsubishi Heavy Industries has established a world-scale manufacturing and service facility in
Pearland, Texas to provide rapid response for your products entire lifecycle. This state-of-the-art
facility, Pearland Works, offers 24/7 emergency response for MCO-I machinery and all other
manufacturers equipment, as well as advanced machine tools, field service, spare parts
support and over 50,000 sq. ft. of storage space.
www.mhicompressor.com/en
variations induce a current pulsation on the
power supply line, which can produce problems
like transformers overheating, electromagnetic
interference and flickering. To prevent these
risks, API codes recommend that current varia-
tions shall not exceed respectively 40 or 66% of
the full load current, when an induction or syn-
chronous motor is adopted [3].
To satisfy the API standard, the traditional
simulation is performed in two steps, separat-
ing the mechanical and the electrical part of
the system. In fact, torsional vibration analysis
(TVA) is usually carried out by the packager
and, based on its results, source current pulsa-
tion analysis (SCPA) is performed by the electric
motor manufacturer.
n Figure 3. Induction motor air-gap effect. C = Cm dy-
In this paper, a new approach to performing
+ C(t)
namical simulations of reciprocating compressors
driven by an induction motor is presented, con-
sisting in the simultaneous simulation of the com-
plete electromechanical system and performed
using an internally developed multiphysics model
tool in MATLAB.
2
C = Cm +k C(t) x
Induction motor air-gap effect on = n
torsional
M
Tvi-
p B
1+ x 2
brations and current pulsations
The absorbed torque of a reciprocating com-
pressor can be represented by a variable and a
constant term:
C = Cm + C(t)
x2
k M = np TB
C = C + C(t) 1+ x 2
n Figure 4. Air-gap stiffness and damping with Jordan et al. equations. Induction motors react
m to these torque fluctua-
tions with their own air-gap torque variations. kThis
dM = by2ob-
phenomenon can be intuitively understood
M
x
serving the induction motor torque-speed charac-
TL
teristic curve (Figure 2).
These torque variations have x 2 an important ef-
k =
fect on system torsional
n T
p dynamics
M B
1+ x 2 and must be
included in the lumped parameter
x2 model used to
kM = n
calculate torsional T
natural
p B
frequencies. Knop [1]
and Hauptman [2] reported 1+ xa 2method
k M to model
this effect by adding a spring
dM =and2 a damper to
x TL
C= Cthe
m
C(t) equivalent shaft. The spring
+original x = and
TL the
damper value are easily obtainable from two sim-
plified equations (shown in Figure 3 for a system
with only 2 of freedom [DOF]) that require only a
few common electric motor parameters (number
k M slip, etc.):
of poles, breakdown torque,
n Figure 5. Electromechanical model system. dM =
x 2TL
operating shaft speed and within 5% of any multiple of op- x 2 d = k M x = T T = 1 1 TR
k M = np TB M
erating shaft speed in the rotating system up to and includ- 1+ x 2 ; x 2TL ; L
;
L
L
2SR TB
ing the 10th multiple.
Regarding to the electrical part of the system, torque where TL is the electric motor time constant

[s], TR is the rated torque [Nm], TB is the breakdown torque
Electric Motor J1 15.2 kgm2
[Nm] and SR is the rated slip.
Half Coupling J2 0.27 kgm2 Jordan, et al. [4, 5], presented more detailed equations
that consider also negative damping effect near the supply
Half Coupling + Flywheel +
J3 55.89 kgm2 frequency, which represents not an energy dissipation but
Compressor
a phase shift between excitation and vibration, causing an
Second Compressor Cylinder J4 1.23 kgm2 increase of vibration amplitudes (Figure 4).
CST has developed a new method to perform TVA
First Compressor Cylinder J5 1.24 kgm2 and SCPA together by means of a multi-physics model in
MATLAB environment, thus considering the reciprocal ef-
Pump Side Compressor J6 0.06 kgm2 fect that the mechanical and electrical parts have on each
other. Figure 5 shows a scheme of the model with a 2 DOF
mechanical system and a three-phase induction motor.
This method guarantees a more accurate evaluation of
k1 2.43E+06 Nm/rad c1 4.69E+02 Nms/rad
the dynamic interaction between electrical and mechanical
systems in steady-state conditions and allows the simula-
k2 5.80E+04 Nm/rad c2 1.01E+02 Nms/rad tion of transient conditions (start, stop, short circuits, volt-
age re-closure) evaluating the electromagnetic torque am-
plification and current pulsations. This allows the packagers
k3 6.12E+06 Nm/rad c3 1.18E+03 Nms/rad
to identify the best selection of the main items of the system
in accordance to API 618 standard code from the earliest
k4 1.14E+07 Nm/rad c4 2.20E+03 Nms/rad stages of the project.
k5 1.12E+07 Nm/rad c5 2.16E+03 Nms/rad Case study

A reference case of a compression train composed of
n Table 1. Inertial moments, stiffness and damping of shaft intervals. a two-cylinder reciprocating compressor, flywheel, highly
Leading in Technology
and Efficiency
This means always having the best possible solutions to match
our customers widely varying requirements. Our custom-
tailored gear units with parallel and coaxial shaft concepts for
a wide range of turbine, pump and compressor applications,
which are engineered precisely for these purposes.
Pre-engineered high speed gear type TA..I

Standardized API concept
Customer gearbox pre-selection
in early project stage
3D data design and interfaces
available in project phase
Low noise emission: 82 dB(A)
for 90% of applications
www.renk.eu
ve 6000 V Rs 0.71 wLs 11.23
fe 50 Hz Rr 0.65 wLr 10.04
Tn 3853 Nm Rm 7680 wLm 191
n Table 2. Electrical induction motor data.

No Air Gap Simplified Approach MATLAB Model
TNF
Hz rpm Hz rpm Hz rpm
First 0 0 3.1 187 3.1 186
Second 10.8 650 13.3 796 13.3 796
- - - - 49.6 2976
Third 234.8 14088 234.8 14088 234.9 14094
Fourth 487.2 29232 487.2 29232 487.2 29232
n Table 3. Torsional natural frequencies comparison.
n Figure 6. Electromagnetic (blue), starting (red) and load (green) n Figure 8. Three-phase current pulsation in steady-state conditions.
torques at startup.
flexible coupling and induction motor (nr. 6 DOF) has
been studied. Table 1 lists the parameters of the system
model, while Table 2 lists the electrical parameters taken
from the induction motor data sheet. Table 3 shows the
influence of the air gap effect over the value of the natu-
ral frequencies, simulated with the simplified approach
and with the multiphysical model in MATLAB that CST
developed. As it is well known, first and second natural
frequencies fluctuate, when the air gap effect is included,
while the higher frequencies (related to mechanical side
of the model) do not change. When the electric motor
model is included, induction motor self-excited torques
appear at vibratory frequencies near the supply one
(negative damping effect).
As mentioned, the electromechanical model allows si-
multaneous solving of TVA and SCPA in the early stage of
n Figure 7. Motor (blue), compressor (red) and coupling (green) the job, thus avoiding possible later expensive modifica-
speed ramp at startup. tions in terms of time and money.

This CST tool allows transient analysis. These kinds of in- circuits, voltage re-closure) and estimates the current pul-
vestigations are not always strictly required by the standards, sations at an early stage during the project, which is also a
but they can provide some useful information in any case. design criterion of API 618.
The simulation revealed that almost no torque oscillations In further works, the focus will be on development proce-
are present when the steady state is reached. This fact can be dures that optimize the choice of parts, such as the coupling
explained with the use of a soft coupling that tends to soften and the flywheel, and reducing the costs during the design
the alternate torques. By observing Figures 6, 7 and 8, some phase. In addition, the focus will be also on the investiga-
considerations regarding the transient phase can be made: tion of negative damping effects in reciprocating compressor
The torque oscillation at the startup remains within ac- trains with all-steel couplings, which are generally more sen-
ceptable limits (2x nominal torque). sitive to this phenomenon than the highly flexible ones. CT2
The induction motor has a torque oscillation that oc- See references at: ct2.co/references
curs at line frequency (50 Hz) as
expected. This justifies the API
requirement to separate torsional
natural frequencies from the first
and second multiplies of the elec- COMPRESSOR LUBRICATION SYSTEMS
trical power supply frequency by
more than 10 and 5%, respectively.
The coupling torque oscillations
are not amplified when passing
through the resonance (796 rpm,
2.8 s). This is due to the presence
of damping in the system and to
the short time in which the com-
pressor passes through the reso- WHEN
MACHINES
nance region.
The maximum torque acting on the
coupling occurs at the electric motor
breakdown torque as expected.
Starting from these, the current
STOP,
pulsations percentage for the
reference case (estimated as PROBLEMS
per [6]) is 1.3%, so it is possible
to affirm that they are allowable.
Furthermore, it allows getting an
START.
estimation of the current pulsa-
tions much earlier in the project.
Let our certified lubrication technicians visit
Conclusions your location and conduct a survey of all your
A new method to conduct torsional lubrication systems. Its a simple, time-saving
vibration and source current pulsation evaluation that will give you peace-of-mind,
analysis has been developed. The
and a well-running compressor.
study has been carried out considering
the reciprocal effect that the mechani-
cal and electrical parts have between
each other.
For this purpose, a multi-physics Sloans Service is the key to
model in Matlab environment has been flawless compressor operation.
developed to perform the TVA and the
SCPA at the same time.
This new approach, theoretically
more accurate than the ones in the 1.800.722.0250
literature, allows the simulation of Sales@SloanLubrication.com
not only steady state conditions but SloanLubrication.com
also transient ones (start, stop, short
Sloan_WhenMachinesStop_Mar16_CT.indd 1 2/22/16 3:56 PM

A North To South Connection
Natural gas exports from US to Mexico continue to grow
n Natural gas exports from the United States to Mexico have steadily increased since 2009.
T
he United States will continue to be known as a natural SENERs five-year plan makes that obvious, especially
gas exporter for the foreseeable future, especially when when it also calls for 12 pipeline additions, which would in-
its southern neighbor keeps seeking the resource. crease the countrys network capacity and add more than
Natural gas exports from the U.S. have doubled since 3200 mi. (5150 km) of pipelines through Mexico, according
2009, and kept growing in 2016, according to the U.S. to the EIA.
Energy Information Administration (EIA). A prime reason for In SENERs July 2016 update, seven of 12 pipeline proj-
this growth is Mexicos thirst for natural gas. The country ects have received contracts, the largest being the Sur de
has accounted for more than half of the United States Texas-Tuxpan pipeline. That project will move natural gas
natural gas exports since April 2015. from southern Texas through the Gulf of Mexico, supplying
Thats around the same time SENER, Mexicos energy it to the Mexican states of Tamaulipas and Veracruz. The
ministry, declared a five-year plan to expand the countrys nearly 500 mi. (805 km) pipeline has a transport capacity of
natural gas pipeline network to accommodate more imports 2.6 Bcfd (73.6 x 106 m3/d).
from the U.S., according to the EIA. The imports would be This year, four U.S. pipeline projects with ties to Mex-
used to meet increasing power demand, reduce liquefied ico are under construction. They include the Roadrunner
natural gas (LNG) import reliance, offset declining domestic (Phase II), Comanche Trail, Presidio Crossing (also known
natural gas production and create new markets for natural as Trans-Pecos) and Nueva Era, which combined will
gas in supply constrained regions, the EIA said. supply 3.5 Bcfd (99.1 x 106 m3/d) of natural gas to power
Mexico has seen a growth in its domestic electricity plants in the states of Chihuahua, Nuevo Leon, Sonora and
market, driven primarily by its increasing natural gas us- Sinaloa, the EIA said.
age, according to the EIA. The affordability and availabil- A portion of the Comanche Trail Pipeline project already
ity of natural gas from the United States has played a role has received Federal Energy Regulatory Commission ap-
in this, encouraging the country to meet its energy de- proval (Jan. 27, 2017). The segment, known as the San Eliz-
mand by new natural gas-fired power plants. U.S. natural ario Border Crossing project, consists of 1086 ft. (331 m) of
gas exports are expected to grow in short- and long-term 42 in. (107 cm) pipe that will provide 1.1 Bcfd (31.1 x 106 m3/d)
outlooks, the EIA said. of natural gas from San Elizario, Texas to San Isidro,

n Mexicos energy ministry, SENER, has a five-year plan to expand the countrys natural gas pipeline network. The plan includes 12
pipeline additions.
Chihuahua, Mexico, the EIA said. The Texas Railroad Com- the Eagle Ford play in southern Texas to Mexicos northeast
mission, which regulates the 195 mi. (314 km) Comanche and central regions, the EIA said.
Trail intrastate pipeline, is expected to grant in-service ap- As of Dec. 1, 2016, natural gas exports to Mexico from
proval this year. the U.S. stood at 7.3 Bcfd (0.21 x 109 m3/d), according to the
There doesnt appear to be any slowdown next year, EIA. These exports mainly supply the northeast and central
either. By the end of 2018, two additional pipelines total- regions of Mexico, but new capacity in the next several
ing 3.3 Bcfd (93.4 x 106 m3/d) KM Mier-Monterrey and years will provide natural gas to the countrys central and
Neuces-Brownsville will begin sending natural gas from northwest regions as well. CT2
Featured Products
Compressor Sizing Software EcoShield 386 uses
Ariel Corp. has released an updated version of its com- a mixture of nano-sized,
pressor sizing software the Ariel Performance Program. nontoxic organic inhibitors
Release 7.7.4.0 features several updates and additions, designed to provide pro-
including a new lube configuration report that summarizes tection above traditional
and simplifies project lube requirements; a feature that allows corrosion prevention coat-
users to generate estimated rod load charts for tandem cylin- ings. Cortec said the coating works with any metal substrate
ders; and an updated project engineering report, providing a for nearly any application, such as industrial, oil and gas,
summary of project details needed for package design. energy and marine.
www.arielcorp.com The fast-drying coating features a low VOC at less than
0.6 lb./gal. (0.07 kg/L), as well as UV and sagging resis-
Coatings tance. It can be used as a DTM coating or as a topcoat over
Cortec Corp. has developed a water-based coating to a primer. The coating can be applied by spray, dip or brush,
withstand a minimum of 1000 hours of intense salt spray the company said.
under thin coverage. www.cortecvci.com

techc
orner
Harvesting Profits From Emissions
Smart Vapor Recovery increases profits, not greenhouse gases
BY LOU HEAVNER AND THOMAS HOOPES
I
mpact of environmental regulations on oil and a primary component of natural gas, is a significant con-
gas operations tributor to greenhouse gases (GHGs), with 25 times the
The U.S. oil and gas industry has been drilling for heat-trapping potential of carbon dioxide (CO2). The goal
hydrocarbons trapped under the earths surface for more of the proposed GHG regulation is to curb methane emis-
than a century. Although existence of unconventional hy- sions by as much as 45 percent from 2012 levels by 2025.
drocarbon reservoirs such as oil shale, shale oil, shale gas,
coal bed methane, heavy oil/tar sands, bitumen, methane Targeted sources of VOC and GHG emissions
hydrates, etc., has been known for a long time, extraction of As described earlier, it has been a common industry prac-
hydrocarbons from them has been uneconomical. Recently, tice for an oil and gas site to flare or vent VOC emissions
however, advances in horizontal drilling and fracking tech- to the atmosphere, presumably because it was viewed as
nology whereby water, mixed with sand and chemicals, is the least costly option. New Source Performance Standards
injected underground at high pressure to release trapped (NSPS) Quad O, EPA and state regulators now require that
oil and gas has changed the economics of drilling for oil VOCs in the form of fugitive emissions be controlled by a
and gas products. Dramatic increases in domestic energy control device that captures and recovers 95% of the emis-
production has made the United States one of the leading sions. Fugitive emissions are unintended releases of gases
energy producers in the world. such as equipment leaks, evaporation losses, etc. The previ-
Concurrent with the increase in domestic production, emis- ously vented or flared hydrocarbon emissions may now be
sions from the oil and gas sites are also rapidly increasing. economically recovered and put to profitable use by separat-
In 2012, the U.S. Environmental Protection Agency (EPA) is- ing the high-value, Btu-rich Natural gas liquids (NGLs) from
sued 40 CFR 60, Subpart OOOO regulations (Quad O) for the recovered VOCs and distributing the high-value NGLs
controlling volatile organic compounds (VOC) and hydrocar- and natural gas products for sale via pipelines or may be
bon emissions from sources such as compressors, storage used as on-site fuel. In some cases, the recovered VOCs
vessels, pneumatic controllers, equipment leaks, etc., com- may be properly disposed of as permitted waste.
monly found at oil and gas sites. For example, a storage tank Efforts to recover the fugitive emissions have largely fo-
that emits 6 tpy (5.4 T/yr) of VOCs or greater must now be cused on top-tier emissions sources. The top tier fugitive
equipped with a control device to reduce the VOC emissions emissions sources that contribute to a majority of site wide
by at least 95%. To claim an exemption from Quad O, an VOC and GHG emissions include equipment such as com-
owner/operator of the tank must demonstrate that emissions pressors, storage tanks and leaks from components such as
have dropped to less than 4 tpy (3.6 T/yr) without emissions valves, flanges, connectors, seals, pressure relief devices,
controls for 12 consecutive months. etc. Leaks or fugitive emissions may also occur from equip-
The next phase of environmental regulations, finalized ment that is not operating correctly, such as an open thief
in 2016, targeted methane emissions. Methane, which is hatch of a storage vessel or separator dump valves that are
stuck open. Thus, control devices may be designed to cap-
Lou Heavner is a control engineer with Emersons Automation ture and recover emissions from these top-tier sources for
Solutions and has been with the company for more than 30 years. providing maximum benefit. Commonly used control devices
Contact him at: lou.heavner@emerson.com. Thomas Hoopes is di- may include combustion devices (such as a vapor combus-
rector of marketing and business development for Vilter Mfg. tion unit, flares or incinerators) or vapor recovery unit (VRU).
LLC and has more than 30 years of experience working with
compressors in gas compression and refrigeration. Contact him Traditional VRU for recovering storage tank emissions
at: thomas.hoopes@emerson.com. Traditional VRUs are designed to recover up to 95%

n Figure 1. Traditional VRU schematic.
of VOC emissions from sources such as storage tanks, generated in these storage tanks due to flash losses that
compressors, product loading/unloading racks and others. occur when liquid is transferred from a gas-oil separator at
Production storage tanks typically store liquid hydrocarbons higher pressure to a storage tank at atmospheric pressure,
such as oil, condensate, and/or produced water. Vapor is working losses that occur when liquid in the tank is agitated,
WHEN CATALYST ELEMENT

FAILURE PUTS YOU IN A BIND,
DCL WILL BE ON THE SPOT.
Catalyst elements work hard under extreme conditions, and even with regular maintenance,
a failure is always possible. And a plant operation shutdown is never a good thing.
A quick replacement with top quality DCL Metalcor products is the key to getting you out of
trouble. We stock a wide range of products in our Houston facility, ready for rush delivery
anywhere in the U.S.
So you wont be on the spot we will.
1-877-965-8989 www.dcl-inc.com
OKLAHOMA CITY DALLAS GILLETTE HOUSTON LOS ANGELES TORONTO DENVER
n Figure 2. Smart vapor management (SVM) system.
or standing losses that occur due to changes in atmospheric pressure and tem-
perature. The vapor is typically described as a wet gas since it also includes a
small amount of liquid hydrocarbons. Recovering VOC emissions in a wet gas
stream may carry greater risk since wet gas may foul valves, damage seals and
contaminate lube oil used in compressors.
Recovered vapor may include methane and other VOCs, aromatic hydrocar-
bons such as benzene, toluene, xylenes and ethylbenzene (BTEX), NGLs, hazard-
ous air pollutants (HAPs) and some inert gases. The Btu content of the recovered
vapor may be greater than 2000 Btu/scf (74,500 kJ/m3), which is about twice that
of pipeline quality natural gas. Thus, the recovered vapor adds about two times
the value compared to the natural gas product itself. If uncontrolled, it is estimated
that a typical storage tank may vent between 5 and 500 Mcf (142 to 14,200 m3) of
VOC emissions to the atmosphere each day. The vented gas may be easily and
economically captured, recovered and sold for an incremental profit. In addition to
storage tanks, VRUs can also be set up to capture VOC emissions from compres-
sors, product loading/unloading racks, and other sources.
Figure 1 illustrates a traditional VRU that may include one or more storage
tanks, a suction scrubber, a compressor to boost the pressure of recovered gas
to match pipeline distribution requirements, a bypass valve designed to divert a
portion of the discharge stream back to the suction scrubber. The suction scrub-
ber is designed to separate condensate from the gas and drain the liquid back
to the storage tank. A VRU controller that is typically based on programmable
logic controllers (PLCs) is installed in an electrical control panel to regulate VRU
process variables like tank pressure, outlet gas pressure, compressor operation,
bypass valve operation and others.
Challenges associated with controlling emissions using a traditional VRU

Reliability and uptime of traditional VRUs has to be typically built into the system
by selecting components that have duty cycles that match process conditions and
by selecting components that have fewer moving parts and have fewer routine
maintenance requirements. Selection of the compressor unit and robustness of
the controls strategy are critical decisions for VRU selection since they have a
significant impact on the reliability and hence operations and maintenance (O and
M) expenses over the life cycle of these components.
COMPRESSORtech2
n Figure 3. Piping and instrumentation diagram for controlling an SVM.
During normal operation, the VRU controller detects off operation, or else it must continuously recirculate a re-
pressure changes inside the storage tank and controls the cycle gas stream. Selection of a compressor unit that is not
compressor operation (on or off status) as the inside tank designed for frequent on/off operation may reduce the reli-
pressure exceeds or falls below a set point. When the com- ability of the traditional VRU and increase life-cycle costs.
pressor is on, it passes the captured VOC vapors through As described earlier, contamination of the lube oil used
the suction scrubber. Any liquid hydrocarbon is knocked in a compressor by presence of wet gas is a critical issue
out and returned to the storage tank, while the captured since operating a compressor with contaminated lube oil
vapor is compressed for pipeline distribution. Since the in- may result in loss of oil viscosity and cause catastrophic
side pressure of the storage tank fluctuates due to various failure of the compressor. Many operators/owners of tradi-
types of losses, the compressor is subject to frequent on/ tional VRUs have to carry an on-site day tank to frequently
HOTSTART is your
CONTINUOUS partner for heating and
HEATED lubricating systems for gas
LUBRICATION compression applications.
HOTSTART hazardous
location equipment is
MAINTAIN designed and manufactured
ENGINE TEMPERATURE to meet approval agency

requirements across the
globe. Visit HOTSTART.com
REDUCE to see the heating systems
available for North American
MAINTENANCE and International installations.
ELIMINATE
CONDENSATION
hotstart.com
Production/Business Smart Vapor Management
Traditional VRU
Requirements Vapor Recovery Solution
Reliability And Uptime Of VRU Dependent on selection of compressor type. Scroll compressors have fewer moving parts, are well suited for
Under Varying Load Conditions Some compressor types may experience lube oil frequent start/stop operation, and have a built-in protection for
dilution that may reduce reliability. scroll compressor lube oil from hydrocarbon dilution.
Supplier Service, Support Typically supplied and supported by a local Typically supplied and supported by a global automation supplier
Structure And Track Record systems integrator who fabricates and installs who provides a solution that includes products, applications
the VRU skid. knowledge and support expertise throughout the life cycle of the
asset.
Reduction In Operations And Some compressor types may need installation of Use of hermetically sealed scroll compressors virtually eliminates
Maintenance Expenses day tanks for lube oil. Some compressors may leaks and emissions. Duty cycle may vary from 0-100%.
need continuous runtime.
Improvement In Health, Safety Reduction in VOC emissions by 95%. Reduction in VOC emissions by 95%. Optimized, field proven
And Environment standardized ROC platform may be used to cut costs and
improve safety.
Investment And Payback Payback is typically < 12 months. Payback may Payback is typically < 12 months but may be further enhanced by
not be enhanced for additional VRUs installed standardization and integration efforts.
at the site.
Availability Of Real-Time Data Local, standalone, non-integrated, piecemeal, Owners and investors of oil well sites are able to utilize real time
For Decision Making disparate approach to information integration. production data and capitalize on real time trading opportunities
Decisions are typically made on historical data. in oil and gas commodity markets.
n Table 1. Smart vapor vs. traditional VRU.

replace the contaminated lube oil or install a lube oil moni- from the gas and drain the liquid back to the storage tank.
toring system both of which increase the O and M expens- A remote operations controller (ROC) may be installed in a
es. Oil-free or dry-seal type compressors may be available control panel to regulate SVM process variables like tank
but they carry a substantial price premium and may have a pressure, outlet gas pressure, compressor operation, by-
limited range of operation. pass valve operation and others.
Also, compressors that use rotating components such A key component of the SVM is a scroll compressor that
as pistons, screws, etc., are susceptible to more wear-and- compresses vapor using two spiral elements, one of which
tear and vibrations. The presence of vibrations may have a is stationary and the other moves in an eccentric motion.
negative impact on other skid-mounted components such The scroll compressor is designed for frequent on/off op-
as valves, pumps, sensors, etc. eration saving valuable horsepower over traditional VRU
VRU controller may be typically packaged along with technology, which requires recycling. Due to its variable
other VRU components, mounted on a skid and installed on speed operation, the duty cycle may be adjusted from 0 to
site by the VRU supplier. While the VRU controller may be 100%. This ensures that a constant storage tank pressure
programmed for providing basic control functions, adding is maintained, independent of gas volume output. The scroll
more complex control requirements such as adaptive con- compressor has very low vibrations and noise since it has
trol strategies based on wet gas detection above a thresh- very few moving or rotating components.
old, or integration of VRU operation with wellhead automa- The scroll compressor unit has low operation and main-
tion or tank manager may become difficult. tenance expenses and has zero leaks or emissions due
to its hermetically sealed design that eliminates the need
Smart Vapor Management vapor recovery solution for shaft seals, drive belts, drive couplings, lube points or
Figure 2 illustrates a Smart Vapor Management (SVM) a system oil pump.
recovery solution that is designed to incorporate advanced Modular design of the SVM can be designed to recover
temperature and pressure control strategies to eliminate up to 530 Mcfd (15 Mm3/d) of rich gas vapor with discharge
hydrocarbon dilution of the compressor oil system. pressures of up to 190 psig (1411 kPa).
The SVM draws vapor from one or more storage tanks, Figure 3 illustrates a P and ID diagram for controlling an
and includes a suction scrubber, a scroll compressor to SVM. A unique, heated, multistage horizontal gas/oil sta-
boost the pressure of recovered gas to match pipeline dis- bilizer and oil cooler are used in a closed loop to protect
tribution requirements, a bypass valve designed to divert a scroll compressor lube oil from hydrocarbon dilution. This
portion of the discharge stream back to the suction scrub- eliminates the need for installing day tanks for oil. Inlet gas
ber, a heated multistage gas/oil stabilizer, and an oil cooler. composition may be used to optimally control the variable
The suction scrubber is designed to separate condensate speed of the scroll compressor.

Advanced control strategies for investment to harvest VOC emissions that pays for itself in a short time in-
the SVM described above are imple- terval. Standardization and integration of site-wide, as well as upstream and
mented in a remote operations con- midstream solutions builds a business infrastructure that is used to gain market
troller (ROC). The ROC also performs share and reduce costs. Table 1 compares the benefits delivered by a Smart
data capture, storage, and transmis- Vapor Recovery Solution compared to a traditional VRU installed at an oil and
sion (SCADA) and includes a 32-day gas site.
EPA report accessible by SCADA or
USB download directly from the local Gross revenues per year may be estimated by using Equation 1.
display. The ROC is fully integrated
with an application software suite for GR/Y = (QxPx365) + NGL
oil and gas production and transmis- n Equation 1 continued on page 42
sion applications. ROC also supports
a local or remote display to interact
with the SVM. Since the same ROC
unit can be, and often is, used as a
platform to automate other produc-
tion well sites and well pads, it is
much easier to achieve true site-wide,
as well as upstream and midstream
integration.
Having access to real-time SVM
information boosts profitability and
accelerates decision making while
improving health, safety and environ-
ment for all employees. Smart instru-
ments may be used to continuously
monitor operating conditions of critical
assets such as high-pressure pumps
and compressors. These instruments
wirelessly communicate the assets
condition in real time to a local or re-
mote operator. A change in vibration
pattern or a bearing temperature pro-
file of a pump or a compressor may
be measured by the smart instrument
and used by a predictive maintenance
application to automatically alert an
operator before a failure occurs.
Benefits of using smart vapor re-

covery solution vs. traditional VRUs
Some oil and gas companies view
installation of a traditional VRU as
an unavoidable expense to remain
in compliance with the environmen-
tal regulations. VRUs are often pur-
chased on a piecemeal basis for
local, standalone (non-integrated)
operation. The VRUs typically contain
disparate measurement and control
technology that may be difficult to
standardize and integrate across mul-
tiple sites.
Leading oil and gas companies
view an SVM solution as a strategic

Where: Q = Rate of vapor recovery (Mcf per day); P = smart investment options that lower operating costs, im-
Price of natural gas; and NGL = Value of natural gas liq- prove health, safety and the environment, and deliver
uids sold fast payback from small capital investments. A strategy
Thus, sale of NGLs in the recovered vapor can now di- used by leading oil and gas companies is to leverage
rectly add to company profits while concurrently reducing the standardization and integration knowledge and ex-
up to 95% of VOC and GHG emissions. perience of leading automation suppliers to build on
their expertise in oil and gas production, processing and
Conclusions transmission solutions to deliver increased profits while
As the oil and gas industry shifts focus due to changing simultaneously achieving substantial decreases in hy-
market conditions, there is renewed interest in exploring drocarbon emissions. CT2
Featured Products
Ultralow Emissions System with four high-pressure hoses; an air, hand or electric pump;
Continental Controls received a U.S. patent for a new and a calibration certificate.
ultralow emissions system that provides for automatic long- Atlas Copco acquired U.K.-based Tentec Ltd., which devel-
term emissions compliance without the normally required ops and markets bolt-tightening products, in November 2013.
operator intervention. www.atlascopco.com
The key to the system
is the addition of a NOx NO gas emissions analyzer
sensor downstream of E Instruments new E8500 cooled NOx gas analyzer has
the Nonselective Catalytic been designed to operate without compromised accuracy in
Converter (NSCR). This high ambient temperatures.
NOx sensor provides feed- The new portable emis-
back and confirmation that sions analyzer keeps the NO
the engine is running well, the catalyst is working correctly, sensor cool and accurate
and the entire emissions control system is working as it with an internal cooling
should. As the NSCR ages and the oxygen sensor drifts over system. It measures, dis-
time, adjustments to the air/fuel ratio (AFR) system are made plays and records the NO
automatically based on input from the NOx sensor. sensor temperature, making
To overcome the issue of keeping the AFR correct, a venturi compliance with U.S. EPA
mixer, designed specifically to help keep the AFR constant, is conditional test methods such as CTM-030 easier. The unit
used in place of the carburetor, helping the engine run at the also comes with Sample Conditioning Unit (SCU), which
same ratio all the time, regardless of load. cools and dries the stack gas at the probe handle to mini-
This system is a quantum step forward in controlling mize gas contact with the condensate.
emissions for natural gas engines over an extended period of www.e-inst.com
time, said Rick Fisher, vice president, Sales and Marketing
at Continental Controls. Bearing Isolator
In some applications, improving AFR control and improv- Inpro/Seal has released a new version of its bearing
ing the mixing to control emissions has the side benefit of isolator. The VB45-S Bearing Isolator provides bearing
reducing fuel consumption, with maximum savings of up to protection to rotating equipment and prevents contami-
15% converting from an uncontrolled engine running rich to nation and lubrication loss. The isolator has achieved an
a controlled engine running lean burn. IP66 rating, which is the standard in protection from dust
www.continentalcontrols.com and water jet spray from all directions. The VB45-S uses
an enlarged D-Groove to capture oil and
return it back to the bearing housing or a
Tensioner For CAT Engine grease band to block grease from travel-
Atlas Copco Bolt Tightening Solutions has launched a ing down the shaft and escaping from the
new tensioner kit designed for maintaining and repairing bearing housing.
Caterpillar 3600 series diesel engines for gas compression The VB45-S has a 0.625 in. (15.88
applications. The tensioner kit is part of the Tentec range of mm) overall (axial) length, making it
bolt-tensioning tools. the shortest IP66-rated bearing isolator
The kit, which simplifies the way the compression head available, the company said.
(head swing) is tensioned, features four direct fit tensioners www.inpro-seal.com

Literature Compressor Unit
Compressor Services Valve Services Control Panel Box Lubricators
NRG Energy Services is M&J Valve has been in Basic Systems has pub- Graco has published a
offering an exchange and the compressor repair lished a flier on its control brochure on its Manzel
rebuild program for natu- business for 27 years. panel for compressors. MB specialty box lubrica-
ral gas compressors. New New literature from the The modular design of the tors. Options for 60:1 and
fliers from the company company outlines their panel can be customized 118:1 gear reduction are
outline their full range of wide range of compressor to work with 100 to 10,000 on offer and are designed
reciprocating compressor services and highlights bhp (75 to 7457 kW) drives to work in extreme
and engine shop services, their commitment to as well as accommodate a environments. Graco also
which covers every aspect 24/7 availability and plethora of monitoring and offers GBL7500 pumps to
of the machinery. fast turnaround. M&J control systems. work in conjunction with
www.parts.nrg.com has 10 service centers www.basic-systems.com the lubricators.
nationwide. www.graco.com
www.mjvalve.com continued on page 46
Doosan koda Power Invests In Georg
New center reduces rotor manufacturing time
n Doosan koda Power said

that the new machine, called
Georg by the new owner, can
perform three basic machining
operations on its own.
BY IAN CAMERON
D
oosan koda Power has found a way to cut its companys portfolio includes steam turbines ranging from 10
rotor manufacturing time in half. That solution to 1200 MW.
comes in the form of a turning and milling center, Georg can be operated by just one person during a shift
which the Czech Republic-based steam turbine producer watching the entire cutting process with three internal cam-
recently inaugurated. eras. The machine measures more than 16 ft. (5 m) tall, 98 ft.
The center, crafted by Georg, a German machine tools (30 m) long and 33 ft. (10 m) wide. It is sunk into a concrete
manufacturer, is the only one of its kind in operation in Eu- foundation pit, and the axis of the rotors rotation is positioned
rope, Doosan koda Power said. at the level of the operators eyes due to the ergonometric de-
Doosan koda Power said that until now, turbine rotors sign of the machine, which is operated from the floor level.
have had to go through three manufacturing stages. First, There are only two such modern large Georg machine
all the rotating planes of the rotor are turned. Next, the sus- tools in Europe. One is in Germany and the other is installed
pensions for attaching blades are milled. Lastly, apertures in Russia. The machine was transported to Doosan koda
for balancing and couplings are drilled. Three different ma- Powers Plze premises disassembled, and was gradually
chines on three different work sites were needed for these reassembled in less than two months.
operations, the company said. It took another four months for engineers to activate the
The new machine, called Georg by the new owner, can machine. Engineers then fine-tuned the equipment tie-ins
perform the three basic machining operations on its own. and carried out test measurements and compensated for
Machines capable of doing both operations unlike geometrical inaccuracies.
the history of separate turning and milling have been Although the machine is primarily intended for rotor man-
developed on the market for a long time, said Jaroslav ufacturing, it can be used universally.
Milsimer, turbine division head at Doosan koda Power, We can make any rotating component with a size of up
which makes equipment for power stations and machine to the working space, such as rotors for generators, roll-
rooms especially equipped for steam turbines. Thanks ers for paper mills, large-diameter gears including hubs and
to its accessories, such as the cutter head and the lathe also, under certain conditions, crankshafts, Milsimer said.
chuck, Georg is able to turn 30% quicker compared to our In addition, we can drill or mill any number of any apertures
old equipment. It can even perform drilling and milling up on such components.
to 50% quicker, so the total time for making an average ro- Doosan koda Power said the machine cost US$7.1 mil-
tor is reduced from approximately 1000 to 550 hours. The lion, with a five-year payback period. CT2

Prime Movers
continued from page 9
useful to a range of policymakers. The microturbine to power a Horizon Power Systems
new edition is updated to include the natural gas compression station in southern
most recent guidelines and tools for Wyoming. This is the first order for a three-bay
regulators and the companies they package C600S microturbine, which has a
regulate to improve security, with more smaller footprint and is lighter than the previous
than double the sample questions and five-bay package.
guidance on how to use them. The dual-mode C600S microturbine will be
fueled by natural gas from a nearby pipeline and provide primary power to the
Woodward compression station. Although Capstone has smaller units running statewide, the
Woodward has appointed Daniel larger 600 kW microturbine will be the first to be installed in the state of Wyoming.
G. Korte and Eileen P. Drake to serve Horizon is Capstones oil and gas distributor for the Eagle Ford, Permian, Bar-
on its Board of Directors. The pair will nett, Mancos, San Juan and Wattenberg Shale plays. The units are expected to
also serve on the Audit Committee of be commissioned in September 2017.
the Board.
Korte joined St. Louis, Missouri- Bacharach
based LMI Aerospace in 2014, where Bacharach Inc. has appointed Karl Roberts as regional sales manager. He
he serves as CEO. Prior to joining will cover the U.K., Ireland and Northern Europe.
LMI, he was president of the Rolls Roberts has more than 11 years of experience selling gas detection prod-
Royce Defense Group in Washing- ucts. Before joining Bacharach, Roberts was territory sales manager with Tyco
ton, D.C., and London, U.K. Prior Gas & Flame Detection, responsible for industrial safety portable and fixed gas
experience includes various senior detection product ranges in the U.K., Nordic and Eastern Europe regions.
level roles at the Boeing Co. in sup- Roberts primary focus will be developing Bacharachs key food retail, industrial
ply chain, program management and and commercial refrigeration and air conditioning accounts, growing Bacharachs
general management. continued on page 61
Drake joined El Segundo, Cali-
fornia-based Aerojet Rocketdyne in
2015 and serves as CEO and presi-
dent. She was previously with United Experience, Reliability, Integrity...
Technologies Corp. (UTC), where
she served as president of Pratt &
Whitney AeroPowers auxiliary power
unit and small turbojet propulsion
business. Prior experience includes
various senior level roles at UTC and
Ford Motor Co.
Enbridge/Spectra
Enbridge has completed the acqui-
sition of all of the outstanding common
stock of Spectra Energy Corp. in a
stock-for-stock merger.
The merged company will oper-
ate as Enbridge, has an estimated
US$126 billion in enterprise value and
is the largest energy infrastructure
company in North America.
Former Spectra CEO, Greg Ebel, is
now chairman of the board of directors The AXH manufacturing complex consists of
of Enbridge. Al Monaco will remain six plants, totaling 559,100 SF on 67 acres.
Enbridges president and CEO.
Capstone
Capstone Turbine has received (918) 283-9200 Fax (918) 283-9229 www.axh.com
an order for a C600 Signature Series

Literature Centrifugal
Oil Analysis Cylinder Liners ABB Compressors
Chevron has crafted M. Jrgensen, a manufac- ABB has released a Elliott Group has literature
literature on its oil analysis turer of cylinder liners for 120-page U.K. product on its website regarding
program called LubeWatch. medium-speed, four-stroke catalogue for 2017. its multi-stage centrifugal
The program allows users engines, has released a Smart sensors, apps and compressors. These com-
to track the performance of new brochure. The German services that enable users pressors are designed for a
equipment, allowing them companys products are of motors, variable speed variety of applications, such
to optimize oil replacement primarily used in diesel, drives (VSDs) and controls as oil refineries, chemical
intervals and identify lubrica- gas and dual-fuel engines to tap into the opportuni- and petrochemical plants,
tion needs. It includes six as well as in compressors, ties offered by the Internet gas lifting and gas gather-
test packages for standard, but also in plant engineer- of Things (IoT) headline ing, and LNG facilities.
used oil analysis. ing and the petrochemical the catalogue. The literature includes
chevronlubricants.com/rbl industry among others. www.abb.co.uk/energy specification tables on the
www.m-juergensen.de compressors.
www.elliott-turbo.com

A Tutorial On Hydrodynamic Bearings For
Reciprocating Engines And Compressors
Part 1: Functionality And Important Design Considerations
Of Hydrodynamic Bearings
BY NORM SHADE
Editors Note: This is the first part of a five-part tutorial on vibration than many other types of bearings. Hydrodynamic
hydrodynamic bearings based on training materials devel- bearings using water as the lubricant date back to at
oped by Miba Bearings US LLC with significant contribu- least the 1850s [1]. They are frequently used in high-load,
tions of knowledge, time and resource material from Greg high-speed or high-precision applications where ordinary
Bone, application engineering manager and key account ball bearings would have short life or would cause high
manager for the Miba Bearing Group in McConnelsville, noise and vibration.
Ohio. All specific bearing designs and materials referenced Hydrodynamic bearings rely on the rotating speed of the
in this tutorial, as well as included charts and figures, were shaft journal, which is the part of the shaft resting on the
provided by Miba Bearings US LLC for educational pur- fluid, to pressurize the oil in a wedge between the mating
poses only. The Miba Bearing Group retains the rights and surfaces of the journal and the bearing. Fluid film lubrication
ownership of all technical data and intellectual property occurs when two mating surfaces are separated by a cohe-
contributed for this tutorial. sive film of lubricant. Successful fluid film bearing opera-
The Miba Bearing Group is headquartered in Austria, with tion depends on maintaining an adequate film of lubricant
facilities in Laakirchen, Austria; McConnelsville, Ohio; and between the mating surfaces of the journal and the bearing.
Suzhou, China. Miba develops and produces bearing shells, This involves several essential elements:
bushings, thrust washers, fixed profiled journal and thrust The lubricant must behave as a viscous fluid.
bearings, direct coatings of tribologically active surfaces, and The lubricant must flow between the bearing and journal.
manufacturing equipment and tools for bearing production. The surfaces between which the fluid film moves must
This first part introduces hydrodynamic bearings, their func- be convergent.
tionality and important design considerations. The thickness of the lubricant film must exceed the
combined roughness of the mating surfaces. Normal oil film
Introduction thicknesses are on the order of micro inches, and the con-
B
earings are a very old machine element that was al- vergence of mating surfaces creates pressures normal to
ready used in antiquity. Leonardo da Vinci identified the surfaces they contact, forcing them apart.
and formulated the first laws of friction. Today, sliding Lubricant viscosity, velocity and the load determine the
bearings are very widespread, particularly due to their use in characteristics of a hydrodynamic condition. More spe-
reciprocating engines. Nevertheless, because of its complex cifically, film thickness increases with increased viscosity
operation, especially under highly dynamic load conditions, and increased velocity, but it decreases with increased
the bearing continues to defy exact analytical examination. load. Properly designed and operated hydrodynamic
Most industrial reciprocating engines and compressors bearings required little or no maintenance and have al-
used in the gas compression industry utilize hydrodynamic, most unlimited life. However, problems can occur, either
or fluid film, bearings. These are bearings in which the load suddenly or over time, when their operation is not as in-
is supported by a thin layer of oil between the moving parts, tended. There may be high friction and short life at speeds
allowing the fluid bearings to have lower friction, wear and lower than design, such as during starts and stops, when

Static ing material can handle the loads, the require-
Friction ments of operational safety can be met.
For success, a bearing design must reli-
ably perform the following functions:
Mixed Friction Overcome the friction generated by the
s
Fluid rotating shaft journal. This requires that
Friction
d
the bearing material has a low coeffi-
p An
rage
Mixed Coefficient Of Friction
Ave cient of friction.
Friction Sustain all applied loads from the gas
pressures on the piston and inertia
loads from the reciprocating masses.
T
Fluid Friction
Accommodate misalignment between
components. Softer bearing materials
nt Sliding Speed n can accommodate more misalignment,
but they can carry less load.
Absorb foreign particles. Soft bearing
materials can absorb foreign particles,
n Figure 1. The Stribeck curve. but carry less load.
Direct oil flow to itself and other compo-
there is misalignment between the shaft journal and bearing or when the nents via appropriate holes and grooves.
lubricating fluid is not maintained at the required viscosity. Remove heat generated by frictional
Hydrodynamic fluid film bearing design is complex. It involves optimizing shearing of the oil. This heat has to be
clearances, bearing length, minimum lubrication films, viscosity, flow rate removed by the flowing oil and by con-
and inlet slots for directing fresh lubricant to the loaded surfaces of the duction through the back of the bearing
bearing. Design equations have been developed, as well as charts avail- shell into the surrounding housing.
able in the literature [3], so that bearing design is much more robust with Bearing design always requires a com-
todays computing power. promise between these functions. Despite
Effective lube oil viscosity for the bearing has to be obtained from the advances over many decades, there is no
mean oil operating temperature. With mineral oil-based lubricants, this perfect bearing material. There are con-
temperature typically ranges from 120 to 180F (49 to 82C). As an ap- flicting characteristics. Stronger materials
proximation, an oil temperature rise of 20F (11C) above the oil inlet tem- provide excellent fatigue life, but they have
perature to the bearing can be assumed. That said, the mean oil tempera- poor dirt and misalignment tolerance. Softer
ture (between inlet and outlet supply and drain) is not a reliable indicator materials have greater embeddability and
of maximum bearing metal temperatures. conformability, but poor fatigue life. Mate-
High pressures and temperatures generated in a hydrodynamic film must rials must also be resistant to corrosion,
be considered when selecting bearing materials. Bearings subjected to cy- which in some compressor applications in-
clic stresses can fail by fatigue. The bearing material should also be com- cludes exposure to H2S.
patible with the journal material, so when metal-to-metal contact occurs at
starting and stopping, minimal surface damage occurs. Friction states in a
This tutorial presents the fundamentals of bearing functionality, design hydrodynamic bearing
considerations, and their relationships that help provide fail-safe design The interrelationships of the various fric-
and operation of engine and compressor bearings. tion states in the bearing are depicted in
Figure 1 by means of the Stribeck curve.
The task of a bearing With no rotational speed, the shaft journal
The task of a bearing is to support and guide rotating or pivoting parts. It rests on the bearing surface with little or
must withstand the loads generated by rotational and direct motion, have rea- no oil film, and the friction coefficient is the
sonable wear rates and be easily replaceable. This leads to direct contact static value, which is the highest.
between the shaft journal and the bearing surfaces, causing friction, which in Once rotation begins, even though there
turn causes heat and wear. In order to meet the requirements of operational is partial physical contact between the shaft
safety, low friction and long service life, friction must be reduced by lubrication. journal pin and the bearing surface, the
The ideal condition is achieved when the bearing running surfaces and the dynamic friction coefficient decreases sig-
shaft journal surfaces are kept fully separated by a lubricating film. In this case, nificantly, resulting from mixed friction from
friction is only a fraction of what is generated by the direct contact of surfaces shearing of the lubricating oil and contact
without lubrication. However, this reduction comes at the expense of increased with the peaks of the shaft journal and bear-
heat generation as the oil film is sheared by the rotation. As long as the heat ing surfaces.
can be dissipated, the lubricating film is maintained. Then, provided the bear- As rotational speed increases further to

Influencing Components Of Oil Films
b
Shaft Speed b pmax
Bearing Width (mm) Maximum Lubricant Film
Loads dL Bearing Diameter (mm) Pressure (Mpa)
Lubrication Viscosity L
dW Shaft Diameter (mm)
Bearing Clearance h
e Excentricity pDmax Maximum Lubricant Film
Bearing Length F
W
pVmax
MW ML F Bearing Load (N) Pressure Caused By Rotation
FD,FV Bearing Load Portions And Squeeze Effect (Mpa)
h0
FV Caused By Rotation And
dW
dL
FD Squeeze Effect (N) Angular Position of h0 Relative To FD
ax
p Vm h Lubricant Film Thickness (mm) Angular Position Of h0
h0 Minimum Lubricant Film Angular Position Of Bearing Load F
MW (ML at n=)
L
ax
Thickness (mm) Angular Velocity Of Bearing

pDm
e0=(1/2)
pmax
e
W Angular Velocity Of Shaft
x
Mw
ma
p
Relative Clearance (dL-dW)/dL

Mw (at n=0)
Gmbel circle
PVMax Squeeze Film Pressure
PDMax Rotational Film Pressure
PMax Maximum Oil Film Pressure
n Figure 2. Bearing hydrodynamic operation.
the transition point and beyond, hydrodynamic lubrication Hydrodynamic operation of a bearing (fluid friction)
occurs as the pin and the bearing surfaces are continu- To minimize power losses, the bearing design strives
ously separated by a wedge of oil film, which is the desired for a state of pure fluid friction. Related studies of the
operating condition for a hydrodynamic bearing. The fric- physical processes have been conducted by Reynolds,
tion coefficient increases moderately with speed due to the Sommerfeld, Gmbel and many others. Figure 2 shows
shearing effects of oil being pulled into the pressure wedge, the hydrodynamic operation of a bearing. The space be-
but remains much less than the static friction coefficient. tween the shaft journal and the bearing surface is called
The external forces acting on the oil
Piston Pin Bush (load from the shaft journal or pin, etc.)
Rocker Arm Bushing and the oil film pressure form a dynamic
balance. If rotational speed, magnitude
and direction of the load are constant, the
Camshaft Bearing
pin remains at a position with constant ec-
Main Bearing centricity (e). This eccentricity determines
the smallest oil film thickness (h0), which
designates the smallest distance between
Conrod Bearing
the pin and the bearing.
Depending on the operating conditions,
the center of the pin moves along a near
semicircular curve, called the Gmbel circle.
At infinitely high rotational speed, the pin
center (MW) theoretically coincides with the
bearing center (ML). The minimum oil film
n Figure 3. Important engine bearings. thickness (h0) and the pressure depend on
the bearing dimensions, rotational speed,
a) 1 3 2
4
bearing load, viscosity of the oil and bear-
6 7
Bearing Shells And Thrust Washers
5
9
ing clearance. The oil film becomes thicker
10 8
with declining load, increasing oil viscosity
1. Free Spread 17. Lug (Tang) Length
2. Lug (Tang) Width 18. Thrust Washer Thickness and increasing rotational speed. Due to the
3. Lug (Tang) Position 19. Running Surface
4. Lug (Tang) Relief 20. Thrust Face 11
interaction of multiple parameters, changes
5. Bearing Width 21. Oil Groove
b) 12 in bearing clearance cannot be formulated
6. Partial Oil Groove 22. Locating Lug (Tang) 13 15
7. Parting Line Relief 23. Bearing Length 14 as a general rule. Examples of influential
8. Bearing Internal Diameter 24. Distance Between Flanges 16 18
9. Countersunk Oil Hole 25. Locating Notch 17 parameters include the load capacity, tem-
10. Bearing Back 26. Relief On Thrust Face
11. Wall Thickness 27. Relief
perature increase due to friction losses, re-
12. Outside Edge
13. Inside Edge
28. Flange Thickness
29. Lubrication Slot
19 duction of oil throughput and thus the cool-
14. Lug (Tang) Protrusion 30. Relief On Thrust Face 20 ing capacity, reduced tolerance for balance
15. Joint Face 31. Oil Groove
16. Oil Pocket 32. Flange Diameter 21 22 and form, and dimensional deviations.
c)
25
24
23
Some minimum clearance values that
26
27
28
can be referenced for the lower clearance
30
29 limits are 0.6% of the pin diameter for con-
n Figure 4. Bearing nomenclature. 31
32 necting rod bearings and 0.75% of the pin
diameter for main bearings [4]. The associ-
ated upper clearance limits result from the
respective tolerances of the bearing bore
and shaft journal diameters. If improve-
Bushings
ments of the bearing operating conditions
1. Oil Pocket
4 1
are to be achieved by changes of the bear-
2. Oil Hole 3
3. Inside Diameter
2 ing clearance, they need to be assessed
5
4. Outside Diameter on a case-by-case basis.
5. Length
6. Mating Faces
7. Clinch Butt
Bearing design
8. Oil Groove Important bearing locations in a typi-
9
9. Location Notch 7
cal four-stroke gas or diesel engine are
10. Axial Oil Groove 10 6
8 depicted in Figure 3. Due to the different
functional requirements of the various
n Figure 5. Bushing nomenclature. bearing positions, different methods of
bearing design and interpretation criteria
are used [4]. All bearings must be able
the lubrication gap and is filled with lubricating oil. The rotating shaft to support the specific unit load require-
pulls oil into the diminishing gap, which forms the pressure profile in the ments. Connecting rod and main bearings
oil film. In most cases, ambient pressure is acting at the bearing edges, are the most challenging designs in recip-
so that a pressure profile forms in the axial direction as well as in the rocating engines and compressors, and
circumferential, or rotational, direction. they therefore utilize the most advanced

Lateral Force Of Piston Cylinder
+pgas Pressure +pmass
Stroke
Rod Force
Cylinder Pressure
Inertia Force Of Piston
Radial Inertia Force Of Conrod
n Figure 6. Internal com-
Radial Inertia Force Of Conrod bustion engine forces.
Reaction Of The TDC
Conrod Pin Force
Force Onto Conrod Pins
Force Onto Neighboring
Bearing Pins Tangential Force
Onto Crankshaft
Conrod Force Including

Translational Inertia
BDC Force Of Conrod
Rotating Inertia Force
Of Crank Throw
types of bearings that have plain half shells. Other types Load behavior
used in reciprocating engines and compressors are The most complex analyses are required for the con-
flange bearings or thrust washers, for axial guidance, necting rod and main bearings, which are present in
and bushings, with and without a flange. The nomencla- two- and four-stroke engines, as well as reciprocating
ture for important features of these bearings is given in compressors. The bearing loads for connecting rod and
Figures 4 and 5. main bearings in an engine or compressor result from
COMPRESSOR
ECT
Dedicated To Gas Compression Products & Applications
E-NEWSLETTER
Industry News Delivered Straight To Your Inbox
u t er
m p
Co ( 1)
ox
Inb red
r
SUBSCRIBE TODAY!
Sta t
S e n
www.compressortech2.com/subscribe/
The ECT e-newsletter is a benefit of your current COMPRESSORtech2 magazine subscription.
Subscribe, renew or update your email address at www.compressortech2.com/subscribe/
0
Upper Shell
30
180
540
90
450 630
270
690
0.75 0.50 0.25 0.25 0.50 0.75
420 300
390 330
360
Lower Shell
Cranktrain Bearings Need

To Withstand Dynamic
Loads
n Figure 7. Example of connecting rod big end bearing forces.
Pin Orbital Path Typical Four-Cycle Engine
Upper Shell 0 0
1 179539 89 1 719
45 315 45 315
0.75 629 449 0.75
0.5 0.5
269
0.25 0.25
0 90 270 0 90 270
629 89
135 225 135 269 539 449 225

359 h0,min=1.95 m 179
Lower Shell
180 180
Pin Orbital Path Typical Reciprocating Compressor

0 Pin orbittal Path 0
1 230184 138 1
45 315 0.75 45 315
0.75 276
0.5 0.5
0.25 92 0.25
0 90 270 0 90 270
Relative To
Bearing Shells 276
Relative To Journal
46 92 322
135 322 225 135 230 225
0 0
h0,min=2.38 m
180 180
n Figure 8. Typical orbital paths.

the interaction of gas and inertia forces. Gas forces re- Hydrodynamic calculation
sult from time-varying pressures acting on the piston overview and results
combustion face, and inertia forces result from the rota- A summary example of NHD calculation output is
tional position, acceleration and deceleration of moving shown in Figure 9. The NHD calculations provide results
components in the power train components of the engine for MOFT and maximum oil film pressure (MOFP) values
throw. Thus, the direction and magnitude of the bearing based on the bearing design and operating conditions
forces change continuously as the shaft journals or pins of the engine or compressor. These parameters are im-
rotate. The forces that cause these dynamic loads are portant, since higher oil film pressures lead to thinner oil
depicted in Figure 6. Figure 7 shows the typical bearing films that increase bearing wear and require the use of
force behavior of the big end bearing of a four-stroke stronger bearing materials.
engine connecting rod, applied by magnitude and direc- NHD calculations for reciprocating compressors are
tion from the center [4]. Due to the periodic nature of continued on page 56
engine and compressor cycles, a
closed curve results. On the curve,
the respective crankshaft position
is given in degrees, with two revo-
lutions (720) for a complete four-
stroke engine cycle.
Pin orbital path and rigid

hydrodynamic oil film calculation
Prior to finalizing any bearing de-
sign, rigid hydrodynamic (NHD) cal-
culations are used to determine the
pin orbital path resulting from the
various loads generated in operation
of an engine or compressor. For dy-
namic loaded bearings, the position
and magnitude of the minimum oil
film thickness (MOFT) varies. For ev-
ery complete cycle, the resulting path
of the pin center, called the pin or-
bital path, can be readily computed.
Miba commonly uses a computation
method based on the Holland-Lang
method with the Sommerfeld num-
bers, according to Butenschn for
the design of main, connecting rod
and camshaft bearings. Figure 8 il-
lustrates a typical pin orbital path for
the big end connecting rod bearings
of a four-cycle engine compared to a
high-speed reciprocating compres-
sor. In both cases, the pin changes
its position not only circumferen-
tially, but also radially. As the pin ap-
proaches the bearing surface, the pin
displaces oil from the reduced gap.
This displacement results in a sig-
nificantly increased oil film load pres-
sure. Typical values for the MOFT,
or h0min, are 0.4 to 1.9 mils (1 to 5
m), which is less than the bearing
clearance and also significantly less
than the size of many particles trans-
ported by the oil.

Hydrodynamic Calculation Local Extremum Of Hydrodynamic Pressure bar
0.5 3000
Bearing Design Features
2500
Bearing Width
2000
0 1500
ANCH ANCH
Condrod1 Condrod2 1000
500
-0.5 0
EHD2 EHD2 -90 0 90 180 270
Condrod Bearing1 Condrod Bearing2
Sequence Number:10-1337-1 Conrod Bearing 1
SMOT SMOT 0 Peak Oil Film Pressure (POFP) 0
CB-Pin1 CB-Pin2 1 1
45 315 45 315
SMOT SMOT SMOT SMOT 0.75 719 0.75 719
MB-Pin1 MB-Pin3 MB-Pin5 MB-Pin7
0.5 0.5
SMOT SMOT SMOT
MB-Pin2 MB-Pin4 MB-Pin6 0.25 629 0.25
EHD2 EHD2 EHD2 0 90 270 0 90 MIBA BEARING GROUP 270

EHD2 Main Bearing3 Main Bearing5
Main Bearing1 Main Bearing7 Niigata 17HLX 6L 1200rpm 195bar 27.10.2010
EHD2 EHD2 EHD2
Main Bearing2 Main Bearing4
Main Bearing6
ANCH
ANCH ANCH ANCH 135 225 135 225
MB-H5
MB-H1 MB-H3 MB-H7 pmax = 2698bar
180 180
ANCH ANCH ANCH Conrod Bearing Type Limits: Truck

MB-H2 MB-H4 MB-H6 Considering max. 15% Peak Torque Operation
9000
8000 Miba 69
Peak Oil Film Pressure (bar)
Miba 48
7000
Bearing Type Limits Based 6000
Miba 63
Miba 37
On NHD Calibration 5000 Miba 67

Miba 26
Using: 4000
Miba 03
3000 Miba 15
Miba Test Rig Data 2000
Conrod 1
Engine Bearing Experience 1000
Conrod 2
0
0 1 2 3 4 5
Min. Oil Film Thickness (m)
n Figure 9. Hydrodynamic calculation overview and results.

Gas Force Pin Inertia
50,000
Pin Inertia
40,000
30,000
20,000
Pin Force
10,000
Forces (lbf)
0 PD
-10,000
n Figure 10. Bearing load variation
-20,000
Gas Force
in a reciprocating compressor.
-30,000
-40,000
-50,000
-60,000
0 30 60 90 120 150 180 210 240 270 300 330
X-Pin Deg/%Rvrst: 160/76.08 (Limits: 30/25.00)
always performed on connecting rod bearings with only bearing shells in the big end of the connecting rod. This
inertia loads at the maximum speed rating for the com- load profile is unique to compressor applications and dif-
pressor. In general, the inertia loads generate the highest fers from engine bearing applications, where the high-
forces on the big end connecting rod bearings. They also est loads are normally isolated to the upper shell bearing
create highly loaded zones on both the upper and lower in the big end of the connecting rod. Gas compression

boundary conditions that dis-
Finite Element Modeling Elasto-hydrodynamic (EHD)
turb the hydrodynamic pres-
Con Rod And Bearing Shells Oil Film Calculation Results
sure formation. The formation
Crush Relief Oil Groove of the oil film can be studied
0
27
0
Hydrodynamic Pressure
in discrete steps over the com-
24
0
18
0
21
0
plete cycle. On the basis of
15
Specific 90
12
0
Asperity Contact Pressure
the results shown in Figure 11
60
30
and the interpretation criteria
Wall 0
0
0 27
0.5 -3 24
0
Thickness 0 -6
0
10
-0. 0 2
Profile 5 -9
itemized in Figure 15, bearing
0
18
0
15
0
12
0
30
60
90
24
02
70 Oil Fill Ratio
Fully Filled Gap
optimization is possible, and
0 10
0.5
an estimate of remaining ser-
-3 2 Poorly Filled Gap
New Assembly Simulation 0 80
0
-0. 0
-6 01
Notch As Base 5 -9 15
20
60
9 01
Oil Film Thickness vice life can be aided with the
ResultsOf EHD Calculation 03
0
27
0
help of damage accumulation

0
0.5 -3 24
0
60
+ Film Pressure 0
-0.
5 -9
0-
0
21
0 Low Film Thickness
18
+ Film Thickness 1 20
15
0
methods.
90 Friction Loss
+ Rate Of Pressure Change 0
30
60
27
0
0 0
0.5 -3 24
0
Bearing shell interference fit
0 0
-6 21
-0. -90 0 .)
5 0
18 eg
15 (D
le
and stresses
0
12 g
90 ll An 0
e Reference 60
Sh 30
0.5
0 a r in
g System For
0
-3
0
0
Positioning the bearing half 90 270
Be
ari -0. Be Shell Angle
0
-6 180
ng
Wi
dth
5 -9
shells in an installed state in-
sures good contact between
n Figure 11. EHD oil film computation. the bearing and its housing.
This contact is necessary to
loads tend to counterbalance the inertia loading and re- prevent the bearing shell from turning in the housing and
sult in lower forces on the bearing as shown in Figure 10 to assure proper heat dissipation to the housing. The
for a typical high-speed reciprocating compressor. To be housing may be an engine or compressor base or frame
safe, however, the best practice is to check the vectorial continued on page 58
superposition of gas and inertia loading at multiple oper-
ating conditions.
Guidelines for MOFT and MOFP have been developed
from the analysis of NHD calculation results and actual
compressor bearing performance for over two dozen dif-
ferent reciprocating compressors [5]. Based on NHD cal-
culations for a wide variety of compressor connecting rod
bearings, Miba publishes general guidelines of 0.8 mils
(2 m) and 43,000 psi (3000 bar) for the baseline MOFT
and MOFP, respectively [5], for tri-metal reciprocating
compressor bearings. Many compressors are operated
below these requirements. However, bearing problems
tend to increase when these conditions are not met.
Elasto-hydrodynamic oil
film computation
The elasto-hydrodynamic (EHD) computation is a
powerful method based on the numeric solution of an
extended Reynolds differential equation [4]. It affords
the incorporation of the stiffness of the bearing hous-
ing, special geometric properties and pressure boundary
conditions of the bearing and the pin. Figure 11 shows
a finite element (FEA) model of a typical connecting rod
bearing and its housing, as well as the most important
boundary conditions. The FEA model is used as an in-
put for the EHD calculation, which determines the elastic
deformation of the bearing environment and the oil film
peak pressure declines in comparison to the computa-
tion of the pin orbital path. The smallest oil film thickness
declines and often shifts to the edge of the bearing or to

SN SN
PS PS
Pr Radial Holding Pressure (MPa)

PS Bolt Force (N)
SN Crush Height (mm)
W Bearing Wall Thickness (mm)
d Angle Of Section Cut Out
Friction Coefficient
L Circumferential Pressure In The Bearing (MPa)
W
d
L G Circumferential Pressure In The Housing (MPa)
Tangential Stress Caused By Friction (MPa)
pr G
d L pr
L+
prL

n Figure 12. Bearing shell crush height.
Influencing Expected Bearing Life

Effect On
Factors
Half Life Inspection
Maximum Oil Film
Fatigue Life
Pressure 3000 To 5000 Hours Inspection
Minimum Oil Film Wear Rate, Operating
500 To 1000 Hours Inspection
Thickness Temperature
Fatigue Life, Material Erosion, Functional Test And Break-In Inspection
Cavitation Disturbance Of Hydrodynamic
Functionality
Change In Tribological End Life

Characteristics, Material
Corrosion
Removal Disturbance Of
Hydrodynamic Functionality Inspection
New
Lube Oil Quality Wear Rate, Change In Tribological
(Dirty Or Old Oil) Characteristics
n Figure 13. Factors influencing bearing service life. n Figure 14. Bearing service life predictions.
Design Method Interpretation Criteria

Bearing Mechanical Design Radial Contact Pressure, Hoop Stress, Bolt Torque
Specific Unit Load Comparison To Field Experience And Bearing Test Results
Specific Unit Load X Sliding Speed Comparison To Field Experience And Bearing Test Results
Pin Orbital Path, Minimum Oil Film Thickness, Maximum Oil Film Pressure,
Rigid Hydrodynamic Bearing Calculations
Oil Temperature Rise
Elastic Deformation Of Housing And Bearing Assembly Generated By:

Elasto-Hydrodynamic Bearing Calculations Minimum Oil Film Thickness, Maximum Oil Film Pressure, Thermal Load,
Asperity Contact, Gap Fill Ratio
Fatigue Life Safety Factors To Guard Against Early Bearing Lining Fatigue
Cavitation Oil Flow Timing, Minimum Oil Film Thickness Vs. Oil Film Gap Film Gradients
Cyclic Run Of Contact Sliding And Contact Pressure Between Bearing

Fretting
And Housing
Wear Run Of Asperity Contact Pressure Vs. Minimum Oil Film Thickness
n Figure 15. Bearing design methods and evaluations.

and a cap or saddle, or it may be a connecting rod with its
cap. In all cases, the housing is split across a diametral
plane and held together by bolts that secures the joint
and maintains the bore geometry.
The circumferential length of the bearing shell is larger
than the base bore of the housing by a factor of the crush
height (2 x SN). Upon installation, as shown in Figure 12,
the bolting of a properly designed and assembled bearing
housing and cap assembly stretches the base bore while Host Supported By
elastically reducing the circumferential length of the bear-

ing. The compressive strain in the bearing causes a con-
tact pressure (pr) between the bearing back and the hous-
ing, which ensures a sufficient press fit between bearing
and housing.
FORGING TIES, DRIVING GROWTH
Factors determining
service life
In addition to functionality assessments by means of
standard calculations, service life estimates have be-
come increasingly important. Figure 13 summarizes the
primary influencing factors of service life. How these
individual factors influence the service life must be as-
sessed for different engine and compressor applications
(load profiles) under consideration of the bearing type
used. Accompanying field studies are normally required ADIPEC 2016 FAST FACTS
for an examination of service life. Concurrent engineer-
ing featuring CAD, CAE, bearing testing, bearing on-site 135,000 96,374 25
Gross sqm Attendees Country
judgment and laboratory investigation, with collaboration Pavilions
of all stake holders through design, manufacturing, ap-
plication and end use. 2,034 162 850+
Field-testing and evaluation of new engine and com- Exhibiting Conference Expert
Companies Sessions Speakers
pressor bearing designs is essential in the validation and
prediction of service life. Figure 14 provides recommenda- 10,009 21 15
tions for the frequency of these field evaluations to help Delegates NOCs IOCs
extrapolate total bearing life. Field evaluations are also
beneficial in identifying phenomena such as cavitation or
corrosion, where additional investigation or calculations
might be necessary, depending on their severity. Metallur-
WHY ADIPEC?
gical studies and test rig results help provide data for the Purchasing Power - Over US $9 billion of contracts were signed
during the 4 days of ADIPEC. With 81% of attendees either a
determination of remaining service life based on material decision maker, purchaser or influencer, ADIPEC delivers real
fatigue strengths and other factors 4. business opportunities.
Knowledge Exchange - With over 750 speakers from around
Bearing design the world and over 160 sessions, ADIPEC provides one of the
interpretation criteria most comprehensive conference programmes in the world.
More detailed investigations of fatigue life, wear rate, International Perspective - 21 NOCs, 15 IOCs and 25
cavitation and fretting are performed on the bearings international country pavilions along with 2,000+ exhibiting
for the mains and the big end of the connecting rod. companies make ADIPEC unrivalled.
Experience and cutting-edge computational tools are
important for the successful design of high-performance
fluid film bearings. Figure 15 shows the corresponding BOOK YOUR STAND NOW
interpretation criteria used for the individual methods. adipec.com/bookastand
It is important to note that technology continues to ad-
vance over time, so the bearings in older engines and
compressors can often be improved with the technology Host City Official Media Partner Conference Organiser ADIPEC Organised By
available today. CT2

See references at: http://ct2.co/references
COMPRESSORtech2
2
3 Scheduled Downtime DJ SLATER, PUZZLEMASTER
4 Visit www.compressortech2.com/scheduled-downtime/ for answers
7 5
6
Just A Test
Analysis Lesson
N D N Q L P O W K F S E G M C C N P L A
Answers Midterm
F P C B R E V I E W L U V O B S E R V E Assay Notes
G J F O C Q U E S T I O N N A I R E C S Assessment Observe
Y G B L M X D I D I A G N O S I S P Q I Check Points
G E U S D B N I J K T G O F S T C A F V Choices Preparation
Courses Probe
B J M Y A S S E X P E R I M E N T R V E
Cram Query
B H S C C C K N Y D D K T T S T R A A R Data Questionnaire
U T K R O W E M O H C R A E S E R T B M Details Questions
Y O P V L O S E C I O H C R M E T I P N Diagnosis Quiz
T D E M I T G A Y E T R U R E A V O A X Discover Reading
Education Report
C R R C E A N S W E R S D C N P H N N L Essay Research
M A X E X E R C I S E L E C T I O N I M Exam Review
B D A T A S K A G S I X A U X Y X R Q H Exercise Revise
Q N T K F D Z N R Y P S T N Q K B X T U Experiment Scan
Explore Seek
S A I W I Z I U Q L S E Y R I U Q N I E
Facts Selection
I T W K K D O N O S S E L L G F E D K C Feedback Standard
N S N M N C J R G T K K Y E A A U R J V Final Study
K O M I D T E R M U T V K X S N T J Y H Findings Task
Homework Test
N G F T O P V H A D V R Y A S S A M A V
Inquiry Timed
T R D I I P R U C Y J R O Z R P K M E B Investigate Trial
Because ... The Illustrated Dictionary Of

Essential Process Machinery Terms
Why struggle through useless
Internet search results for
technical terms?
GAS Order your copy today:
CONSTANT
http://dieselpub.co/dictionary
1.800.558.4322
dictionary@dieselpub.com
has nothing to do with eating beans. Paperback, 204 pages US$24.95
Plus Shipping
U.S. Energy Corp 1k x 1" 3/11/03 11:06 AM Page 1
Marketplace
EXPLOSION PROOF
AC&DC ENGINE STARTING SYSTEMS
STARTER MOTORS ALTERNATORS
SWITCHES CLASS I, DIV. 1&2, GROUP D Custom Reprints Available
UNITED STATES ENERGY CORPORATION Articles in COMPRESSORtech2 can be reprinted at a very reasonable cost and used
1600 MISSILE WAY, ANAHEIM, CA 92801
(714) 871-8185 (714) 871-9229 FAX for effective direct mail purposes, answering inquiries, trade show distribution and
WWW.USENERGYCORPORATION.COM
many other sales development activities. These reprints can be produced to your
specifications in one or multi-color formats on selected paper in standard 8 x 10 1/2 or
DIN A4 sizes. Layout and production services are also available.
2017 CLASSIFIED AD RATES Contact Reprint Manager for information.
Katie Bivens Mary Graesing mgraesing@dieselpub.com
Email: kbivens@dieselpub.com Phone: (262) 754-4147 Fax: (262) 754-4177
Phone: (262) 754-4140
Prime Movers
continued from page 45
combustion and emissions analysis and refrigerant leak GEA will supply process-
detection portable instrumentation position and supporting ing units for shale gas areas
Bacharachs channel partners market development. in the southwestern United
States for a natural gas proces-
Sulzer, ABB sor. The units, comprising 15
Sulzer is now the U.K. maintenance and repair services custom-engineered propane
provider for ABB medium- and high-voltage motors and refrigeration compressor pack-
generators. ABB customers will have direct access to Sul- ages, will be used in cryogenic
zers service centers in Birmingham and Falkirk. Sulzer will natural gas processing facilities. Thirteen of the units fea-
provide inspection, remedial work, modifications, repairs ture GEA model 1210GL screw compressors, while the
and rewinds of ABBs large machines rated at 6.6 kV and other two use GEA model 675GL screw compressors. The
above. All repairs will use ABB parts. GEA compressor packages will be used in a midstream
Sulzer, which has been investing in its electromechanical application.
equipment sector recently, received the agreement after an The Oman project calls for a process refrigeration sys-
audit of it facilities, core competencies and quality, all of tem, including a chiller unit for hydrocarbon dew point
which are required to meet ABBs standards. control and a water-chiller package. The plant uses oil-
The service center in Birmingham has invested in addi- injected screw compressors.
tional equipment in its coil shop, as well as 3-D design The Pakistan project, a first for GEA in the oil and gas
software to enhance the capability of bespoke coil and bar market, features three fuel-gas booster centrifugal com-
designs, which are manufactured in-house for a wide range pressor packages and a gas treatment station. The 747
of motors and generators. MW gas-fired power plant is designed to alleviate power
Centrally located in the U.K., the Birmingham facility also shortages in the area.
has machining capabilities and overhead crane capacity
for larger components as well as the largest independent DCL
over-speed balancing in the country, the company said. DCL, a manufacturer of emissions, noise and heat
The Falkirk Service Center was selected to cover the recovery products, recently bolstered its U.S. gas
northern areas of the U.K. The facility has experience with compression sales team with the addition of Michael
offshore applications and expertise in repairing equipment Kourkoubes. In the newly created role of regional sales
designed for operations in potentially explosive atmo- manager for the Houston, Texas, area, Kourkoubes will
spheres. The service center will double its high-voltage be responsible for the management of DCLs growing cor-
testing capacity in the first half of 2017 to enable 2 MW load porate midstream and packager accounts.
testing across a full range of voltages up to 13.8 kV. Kourkoubes has several years of experience with
managing projects and selling air-cooled heat transfer
GEA equipment.
GEA has obtained orders for oil and gas projects in the The company said its two-year-old North Houston
United States, Oman and Pakistan, all of which will be com- manufacturing facility would support Kourkoubes sales
pleted in 2018. efforts by enabling the fast delivery of products.

Advertisers Index
*Further information on this companys products can be found in the 2016 Edition of the Diesel & Gas Turbine Sourcing Guide
(at www.Dieselandgasturbineguide.net) and/or 2017 Compression Technology Sourcing Supplement (at www.CTSSnet.net).
ACI Services Inc. ........................................................ 51 * HOERBIGER ................................................................ 19
ADIPEC 2017 ............................................................... 59 HOTSTART .................................................................. 39
Air-Cooled Heat Exchangers ..................................... 45 KB Delta Compressor Valve Parts, Mfg. ..............32-33
* ARIEL CORPORATION ................................................. 1 MHI Compressor Intl. ................................................. 27
ARMCO Compressor Products Corp. .......Third Cover Modulift .......................................................................... 9
ASME 2017 .................................................................. 49 MOTORTECH GmbH ................................................... 43
The BG Service Co. Inc. ............................................. 21 Neuman & Esser Group ............................................... 3
Boll & Kirch Filterbau GmbH ..................................... 23 PROGNOST Systems GmbH ....................................... 7
* Burckhardt Compression AG .................................... 15 * RENK AG ..................................................................... 29
Compressor Products International ......................... 25 Sloan Lubrication Systems ....................................... 31
Cook Compression ....................................................... 5 STASSKOL GmbH ...................................................... 13
DCL International Inc. ................................................ 37 Sullair ........................................................................... 38
E Instruments International ....................................... 57 Summit Brand - Kluber Lubrication NA LP .............. 41
* Elliott Group ............................................Second Cover * Testo Inc. ..................................................................... 55
Exline Inc. .................................................................... 17 Turbomachinery/Pump Symposia ............................ 47
FW Murphy Production Controls ........... Fourth Cover United States Energy Corp. ....................................... 61
Gas Machinery Conference (GMRC) ......................... 10 Zahroof Valves Inc. ..................................................... 11

Cornerstones Of Compression story continued from page 64
Worthington CUB And Super CUB Compressor Model Ratings (Maximum Specification, 1988)
Rated Piston
Stroke Max. Max. Power
Model Model No. Of Frame Load Rod Dia. First Year
in. Speed hp
Type Number Throws lb. in. Produced
(mm) rpm (kw)
(kg) (mm)
Standard 500/900 20,000 2.0
OF-5S 2/4 5.0 (127) 1000 1961
CUB (373/671) (9070) (50.8)
Standard 960/1800 27,500 2.0
OF-5H 2/4 5.0 (127) 1200 1964
CUB (716/1342) (12,472) (50.8)
Standard 960/1800 33,000 2.0
OF-5XH 2/4 5.0 (127) 1200 1986
CUB (716/1342) (14,966) (50.8)
Super 1000/2000/3000 25,000 2.0
OF-6S 2/4/6 6.0 (152) 1000 1967
CUB (746/1491/2237) (11,338) (50.8)
Super 1400/2700/4000 30,000 2.5
OF-6M 2/4/6 6.0 (152) 1000 1978
CUB (1044/2013/2983) (13,605) (63.5)
Super 1400/2700/4000 35,000 2.5
OF-6H 2/4/6 6.0 (152) 1000 1970
CUB (1044/2013/2983) (15,873) (63.5)
Super 1680/3240/4800 42,500 2.5
OF-6XH 2/4/6 6.0 (152) 1200 1977
CUB (1253/2416/3579) (19,274) (63.5)
35,000 lb. (15,873 kg), two-throw rating of 1000 hp (746 kW) The CUB and Super CUB were sold via packaging
and four-throw rating of 2000 hp (1491 kW). distributors that included CSI, SEPCO, PAMCO, ARKLA
The Super CUB kept pace with the economy minded in- and others. In the early 1970s, Worthington made com-
dustry and provided more power and higher frame loads puterized sizing programs available to its distributors,
than the standard CUB frame. A six-throw frame, rated at which made them self-sufficient for sizing and allowed
3000 hp (2237 kW), further expanded the line. much quicker responses to customers requests for
By 1974, after a period of development and some early quotes. Worthington reportedly held a 50% share of the
field failures, all of the CUB and Super CUB frames evolved 200 to 4000 hp (149 to 1491 kW) separable compressor
to a robust, one-piece unitized design with the crosshead market through the rest of the 1970s and well into the
guides integral with the frame case. Foundation bolts ran 1980s. Over 3000 of the popular units had been sold by
through the frame from top to bottom. The standard CUBs mid-1986.
had a box type, closed-top frame, with the crankshaft re- An extra-heavy frame, the OF-6XH had been introduced
movable from either end of the frame. The Super CUB in 1977. In 1988, as larger 1200 rpm gas engines became
frames had an open top with heavy steel tie bars, keyed accepted, Worthington responded with the 1200 rpm, 5 in.
and bolted in place over each main bearing for extra rigidity. (127 mm) stroke, 33,000 lb. (14,966 kg) frame load, OF-
Rounding out the CUB line in 1978 was the OF-6M 5HX and 6 in. (152 mm) stroke, 42,500 lb. (19,274 kg) OF-
frame. This was a paper frame, an OF-6H with a different 6HX. Among the design changes were upgrading the crank-
nameplate, used as a ploy to sell the OF-6H at a lower price shafts from ductile iron to forged alloy steel. These were the
with a lower frame load rating. This 6 in. stroke, medium- highest-rated frames in the series.
duty model had a 30,000 lb. (13,605 kg) frame load and the The CUB and Super CUB with their lined, water-
two-, four- and six-throw frames were rated at 1000, 1800 cooled cylinders were said to be really fine machines,
and 2750 hp (746, 1342 and 2051 kW), respectively. This but by the late 1980s, they were destined to compete with
gave Worthington 12 different frames to choose from, the the growing success of Ariel using lower-cost unlined, air-
widest range in the industry at the time. cooled cylinders. Two severe industry downturns in the
Early CUB cylinders were equipped with Worthingtons 1980s made it increasingly difficult for traditional heavy
feather valves, but by 1973 these had been replaced with manufacturers, such as Worthington, to survive.
Worthington plate valves as standard. An extensive line In 1985, with the bulk of the company already merged
of cylinders evolved as frames were uprated to match the into McGraw-Edison and then Cooper Industries, the com-
growth of available gas engine drivers. Cast nodular iron pressor lines were sold to Dresser Industries. Within a year,
cylinders were available in bore diameters from 4.25 to it became part of the Dresser-Rand joint venture and com-
26 in. (108 to 660 mm) and pressure ratings to 2500 psig pressor manufacturing moved from Buffalo to Painted Post,
(172 bar). Forged-steel cylinders with bore diameters from New York. CUB and Super CUB sales dwindled rapidly and
2.5 to 5.5 in. (63 to 140 mm) were available for pressures mostly ended by 1993. Ultimately, the CUB line ended with
as high as 6600 psig (455 bar). Most cylinders were lined Dresser-Rands rationalization of its multiple high-speed
and jacketed type. separable compressor product lines. CT2

Cornerstones Of Compression
n Worthington produced a wide range of CUB

and Super CUB (shown here) high-speed sepa-
rable compressor frames that were direct driv-
en by early 1000 and 1200 rpm gas engines.
Frames were available in two- to six-throw
configurations.
The Worthington CUB And Super CUB

Popular high-speed separable compressor lines
captured large market share for two decades
BY NORM SHADE
C
lark Brothers changed the gas compressor indus- shipped in early 1961. The CUB OF-5, a 350 hp (261 kW),
try in 1957 when it introduced the first short-stroke, a 1000 rpm machine, was an immediate success, with 14
multithrow, high-speed separable compressor that units sold in the first year of production. In 1962, this two-throw
could be directly connected to gas engines without using CUB was uprated to 375 hp (280 kW), and a 500 hp (373 kW)
belts. Other manufacturers, including the Worthington Co., four-throw CUB was introduced, both with an 18,000 lb.
quickly scrambled to counter this new competitive threat. (8163 kg) frame load rating.
Worthington, with well over half a century of success pro- In mid-1964, Worthington introduced a 5 in. (127 mm)
ducing reciprocating compressors, had a strong presence stroke, 25,000 lb. (11,338 kg) heavy CUB frame. With this
in the upstream oil and gas markets with its single-throw, line expansion, the earlier frame designation was changed
belt-driven HBB frames. However, Clarks new frames had to OF-5S, and the new heavier one became OF-5H with
higher power ratings and were designed to be more com- ratings of 800 hp (597 kW) for a two-throw and 1000 hp
pact for skid-mounting on semi-portable packages. (746 kW) for a four-throw.
Leveraging considerable experience with its balanced- Next came a 1000 rpm, 6 in. (152 mm) stroke compres-
opposed BDC compressor line, Worthington had built its sor in 1967. The two-throw OF-6S was rated at 800 hp (597
first high-speed separable compressor by 1959. The model kW) and the four-throw was rated at 1400 hp (1044 kW),
was dubbed the CUB, which stood for compressor, unitized both having the same 25,000 lb. (11,338 kg) frame load rat-
frame, balanced opposed. This two-throw, 5 in. (127 mm) ing as the OF-5H frames. In 1970, the 1000 rpm OF-6H was
stroke frame was the forerunner of the first production unit introduced as the Super CUB, with a frame load rating of

05 CT2 Scribd

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

05 CT2 Scribd

Uploaded by

Copyright:

Available Formats

SOUTH OF THE BORDER BEARING TUTORIAL TRUMPS NEW EPA

GAS TRADE WITH MEXICO PART 1 OF A SERIES SLIMMER, TRIMMER

Also in this Issue:

They turned to Elliott

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 The world turns to Elliott.

6 MAY 2017 COMPRESSORtech2

Data itself means nothing

Trump Team Pushes Changes At

8 MAY 2017 COMPRESSORtech2

Experts in the design Trunnion Spreader

standard and custom

MAY & Conference 2017 May 23-25

10 MAY 2017 COMPRESSORtech2

12 MAY 2017 COMPRESSORtech2

14 MAY 2017 COMPRESSORtech2

PUSH THE LIMITS!

REDURA REDURA REDURA

16 MAY 2017 COMPRESSORtech2

18 MAY 2017 COMPRESSORtech2

Industrial Spark Plug

Handheld Transducer Simulator

n This upstream installation includes

n Six large ACE Model E air-cooled

20 MAY 2017 COMPRESSORtech2

COMPRESSORtech2 MAY 2017 21

n Shown here is one of three portable and

22 MAY 2017 COMPRESSORtech2

Model J has vertical sections with an induced draft fan

n The new ACE modular,

n Shown here on test is the ACE

24 MAY 2017 COMPRESSORtech2

BY ANDREA FUSI, FRANCESCO GRASSO,

Andrea Fusi is an executive R&D manager at Compression Service

26 MAY 2017 COMPRESSORtech2

WE PROMISE IMMEDIATE SUPPORT. THEN WE OVER DELIVER.

Responsive Aftermarket Support from our Advanced Facility.

28 MAY 2017 COMPRESSORtech2

k5 1.12E+07 Nm/rad c5 2.16E+03 Nms/rad Case study

Pre-engineered high speed gear type TA..I

fe 50 Hz Rr 0.65 wLr 10.04

Tn 3853 Nm Rm 7680 wLm 191

n Table 2. Electrical induction motor data.

First 0 0 3.1 187 3.1 186

Second 10.8 650 13.3 796 13.3 796

Third 234.8 14088 234.8 14088 234.9 14094

Fourth 487.2 29232 487.2 29232 487.2 29232

n Table 3. Torsional natural frequencies comparison.

30 MAY 2017 COMPRESSORtech2

COMPRESSORtech2 MAY 2017 31

Sloan_WhenMachinesStop_Mar16_CT.indd 1 2/22/16 3:56 PM

34 MAY 2017 COMPRESSORtech2

COMPRESSORtech2 MAY 2017 35

BY LOU HEAVNER AND THOMAS HOOPES

36 MAY 2017 COMPRESSORtech2

WHEN CATALYST ELEMENT

Challenges associated with controlling emissions using a traditional VRU

ENGINE TEMPERATURE to meet approval agency

n Table 1. Smart vapor vs. traditional VRU.

40 MAY 2017 COMPRESSORtech2

Benefits of using smart vapor re-

COMPRESSORtech2 MAY 2017 41

42 MAY 2017 COMPRESSORtech2

n Doosan koda Power said

44 MAY 2017 COMPRESSORtech2