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MAYEKAWA LEGACY RECIPS ALTRA’S TRI-BUSHING MAN, ABB COLLABORATION

40 YEARS RUNNING FLEXING IN THE HEAT ENERGY STORAGE SYSTEM


A KHL Group publication

AUGUST-SEPTEMBER 2018 | VOLUME 23 | ISSUE 7 www.compressortech2.com/subscribe

Turbine Specs-At-A-Glance

The Launch of
TurboTides

Early Caterpillar
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War
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L.A. Turbine unleashes Ares
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AUGUST-SEPTEMBER 2018

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COMPRESSORTECH (ISSN 1085-2468) Volume 23, No. 7
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53186-1873 USA. software launched DEPARTMENTS MAYEKAWA LEGACY RECIPS
40 YEARS RUNNING
ALTRA’S TRI-BUSHING
FLEXING IN THE HEAT
MAN, ABB COLLABORATION
ENERGY STORAGE SYSTEM
OUTSIDE
A KHL Group publication

www.compressortech2.com 7 Editor’s comment AUGUST-SEPTEMBER 2018 | VOLUME 23 | ISSUE 7 www.compressortech2.com/subscribe

RECIPROCATING The Age of Misinformation


Turbine Specs-At-A-Glance

The Launch of
TurboTides

Follow @COMPRESSORTECH2 on:


COMPRESSORS 9 Monitoring Government
Early Caterpillar
Engines

33 Mayekawa keeps legacy Trump team tries to protect


recips running coal from cheap gas
11 Gas Lines War
games
MEMBERS OF:
TECH CORNER 12 Events & Meetings CT2 08-092018 Front Cover_DJ.indd 1
L.A. Turbine unleashes Ares

17/08/2018 09:56:42

51 Upgrading general purpose


steam turbine
68 Industry News
71 Marketplace
73 Cornerstones of
29 L.A. Turbine’s
new Ares
turboexpander puts
PRODUCT FOCUS compression the controls on the
41 Cartridge bearings with Early Caterpillar natural gas skid and uses active
EPP technology engines magnetic bearings.

AUGUST-SEPTEMBER 2018 | COMPRESSORTECH2 | 5


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FROM THE EDITOR
DJ SLATER

EDITORIAL
Publisher:
Michael J. Brezonick
mike.brezonick@khl.com
The Age of
Tel: +1 262-754-4112
Cell: +1 262-366-9452
Senior Editor:
DJ Slater
dj.slater@khl.com
Misinformation
L
Jack Burke adies and gentlemen, welcome to the Age of Misinformation. It may
jack.burke@khl.com
not be as official as the Industrial Age or the Gilded Age from the
PRODUCTION pages of history, but that doesn’t discredit its obvious presence.
Production & Circulation Director: Social media appears to be the biggest culprit. Anyone can post
Saara Rootes
saara.rootes@khl.com any falsehood they want and watch it spread like a virus. Even if their
Production Manager - KHL Group: message is later discredited, many already assume it as fact.
Ross Dickson
ross.dickson@khl.com This can be destructive in any circumstance, and the natural gas
Production Manager - KHL Americas: industry is no exception. Consider the relationship between pipeline
Brenda Burbach companies and environmentalist.
brenda.burbach@khl.com
Design Manager: “Not in my backyard” is the common rallying cry. On the surface,
Jeff Gilbert reading about these protesters’ concerns can make anyone view the
Designers:
Mitchell Logue natural gas industry in a negative light, but a lot of times, the full picture
Jade Hudson isn’t in focus.
CIRCULATION I’ve spoken to both sides on this issue on multiple occasions. I
Subscriptions: understand where the animosity comes from. Protesters aren’t fond of
subscriptions@khl.com sharing the landscape with what they consider an industrial eyesore
Circulation & Data Manager:
Helen Knight that disrupts the peace.
helen.knight@khl.com But when you talk to pipeline companies, you quickly learn
Office Manager:
May Hyde that getting approval to build a compressor station isn’t easy (see
may.hyde@khl.com COMPRESSORTECH2, October 2017, p. 38). I think this point is lost on the
protesters. The impression I get is they think pipeline companies simply
SALES
Vice President, Sales wink at the top brass from the Federal Energy Regulatory Committee
Alister Williams (FERC) and, voilà, their compressor station proposal is approved. In
Tel: +1 843 637 4127
Cell: +1 312-860-6775 actuality, there are multiple layers to the approval process.
alister.williams@khl.com The protesters, however, only notice when the approvals go through
Regional Sales Managers
Katie Bivens and then get upset that their voices aren’t heard. I can’t speak for every
Tel: +1 262-754-4140 situation, but I know their comments don’t fall on deaf ears. Pipeline
Cell: +1 262-327-4899
katie.bivens@khl.com
operators must weigh the pros and cons accordingly, and the prime
Linda Cameron issue is bringing natural gas to paying customers. Yes, profits are
Tel: +44 20 31 79 29 79 involved as well, but what company survives without profits?
linda.cameron@khl.com
Gabriele Dinsel The energy landscape is shifting, and natural gas is a
Tel: +49 711 3416 74 71 major player in that. Compressor stations aren’t going away,
gabriele.dinsel@khl.com
Roberta Prandi and they are not the monstrosities that many in the public
Tel: +39 0464 014421 believe them to be.
roberta.prandi@khl.com
The only way to solve that conflict between protesters
Chief Executive Officer
James King and pipeline companies is the same way you combat
Chief Financial Officer misinformation – with education and the ability to listen and
Paul Baker consider perspectives that might differ from your own.
President & Chief Operating Officer Speaking of new perspectives, we hope you enjoy the
Trevor Pease
new look of COMPRESSORTECH2. CT2

© Copyright KHL Group, 2018

KHL GROUP AMERICAS LLC


3726 E. Ember Glow Way,
Phoenix, AZ 85050 USA DJ Slater
e-mail: americas@khl.com Senior Editor dj.slater@khl.com
GTRS
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GOVERNMENT

Trump team tries to protect


coal from cheap gas
Interest lacking in protecting pipelines from cyberattacks. By Patrick Crow

C
oal miners were good to candidate compressor stations, it was a tocsin. FERC’s commissioners scoffed at the
Donald Trump. Coal was a centerpiece It also provided the DOE with a new angle DOE’s latest proposal during a Senate
of his campaign and he won in the to bail out struggling coal-fired generation. Energy and Natural Resources Committee
coal-mining states. And as president, Donald The DOE cited a National Security Council hearing in June. They saw no current national
Trump has tried to be good to the coal (NSC) memo that claimed gas pipelines were security emergency that could justify federal
industry. increasingly vulnerable to cyber and physical intervention in wholesale power markets.
His administration rolled back several attacks. Therefore, it said, the nation should Commissioners Neil Chatterjee and
anti-coal regulations last year. Also, Energy increase its reliance on coal and nuclear Richard Glick also have commented on the
Sec. Rick Perry requested the Federal Energy power to generate electricity for critical fragmentation of federal functions designed
Regulatory Commission (FERC) to consider a infrastructure and military operations. to protect the pipeline network. FERC
“Grid Resiliency Pricing Rule.” It was suggested that President Trump oversees cybersecurity for the electric grid,
Coal- and nuclear-fired electricity could use his national security powers to but not for gas pipelines. The Transportation
generators, if they met criteria showing they order power grid operators to buy electricity Department’s Pipeline and Hazardous
were resilient to disruptions, would have from a list of struggling coal and nuclear Materials Safety Administration has some
received subsidies to maintain baseloads. plants for two years “to forestall any further powers. The DOE has entered the arena by
The proposal clearly was designed to shrinkage of capacity at those facilities” and creating an Office of Cybersecurity, Energy
ameliorate the plight of coal-based prevent their “premature retirement.” Security and Emergency Response.
generation under pressure from a surplus of
shale gas. Protection for pipelines Addressing future threats
Although FERC is within the U.S. Dept. of The Interstate Natural Gas Association of The principal oversight agency is the
Energy (DOE) umbrella, it is an independent America (INGAA), which represents the long Department of Homeland Security’s
agency. In January, its commissioners (four lines, saw the proposal as another ploy to Transportation Security Administration (TSA).
of them Trump appointees) unanimously “prop up uneconomic coal.” It added, “There It has worked with pipelines to develop
rejected the administration’s proposal. is absolutely no justification for the extreme voluntary cybersecurity guidelines.
intervention in energy markets suggested Chatterjee and Glick said that, as of May
Keeping coal relevant in the draft NSC memo. Such a move would 2017, TSA had only six full-time employees
Fast forward to March, when a foreign be bad public policy, costly to American to oversee the security of more than 2.7
cyberattack against a third-party electronic consumers and the economy, and legally million miles (4.3 million km) of gas, oil and
communications firm forced at least five questionable.” hazardous liquid pipelines.
gas pipelines to suspend communications The INGAA said although the NSC thinks The two commissioners urged
with their customers. Although the incident the expanse of the U.S. gas pipeline network Congress to consolidate within the DOE
did not interrupt gas flows or shut down makes it vulnerable to disruptions, it actually the responsibilities of protecting pipelines
sserves as a benefit. In the event of a mishap, from cyberattacks. They reasoned that the
tthe network could draw gas from diverse DOE best understands the energy sector and
THE AUTHOR

PATRICK CROW is an Austin, ssupplies and storage sites and reroute has the most resources to address
Texas, writer and a former sshipments where necessary. the threat.
COMPRESSORtech2 editor. He has “It’s also important to point out that, “Natural gas pipelines have a long history
reported for oil and gas publications unlike the power grid, pipeline incidents
u of providing reliable service. But given our
since 1967 and has written extensively about do not result in cascading outages and growing dependence on natural gas in
energy issues before Congress, federal widespread losses of service. There is no conjunction with the escalating potential for
agencies and the courts. natural gas equivalent to a rolling blackout,” cyberattacks, we cannot simply hope for the
INGAA said. best,” the pair said. CT2

AUGUST-SEPTEMBER 2018 | COMPRESSORTECH2 | 9


GAS LINES
U.S. ELECTRICITY GENERATION

Share of gas-fired power generation near record


T
he U.S. Energy Information a result of sustained low natural gas prices, capacity since 2004. More than 10 GW of coal-
Administration (EIA) expects natural increases in natural gas-fired capacity and fired capacity was retired over the 12-month
gas-fired power plants to supply 37% of retirements of coal-fired generating capacity. period ending April 2018.
U.S. electricity generation this summer, near Over the three-year period from 2015 to EIA forecasts the delivered cost of natural
the record-high natural gas-fired generation 2017, the cost of natural gas delivered to gas will average US$3.16/MMBtu this summer.
share in summer 2016. EIA forecasts the electric generators averaged US$3.16/MMBtu, In contrast, the cost of coal delivered to
share of generation from coal-fired power compared with US$7.69/MMBtu between electric generators is forecast to rise slightly
plants will drop slightly to 30% in summer 2006 and 2008. this summer. The continued low cost of
2018, continuing a multi-year trend of lower Power plant operators added 5.4 GW of natural gas, along with the recent additions of
coal-fired electricity generation. new natural gas-fired generating capacity natural gas-fired capacity and retirements of
The share of electricity generation during the first four months of 2018 with an coal power plants, drive EIA’s expectation that
supplied by natural gas-fired power plants additional 15 GW scheduled to come online natural gas will contribute a growing share
has increased over the past decade, while the through the end of the year. This addition of electricity generation this summer, while
share supplied by coal has fallen, primarily as would be the largest increase in natural gas coal’s share will fall. CT2

BAKER HUGHES RIG COUNT US NATURAL GAS STORAGE (Bcf)


Source: Baker Hughes Source: EIA
1400 5000
1200
4000
1000
800 3000

600 2000
400
1000
200
0 0
July-16 July-17 July-18 January December
North America International 2018 Five-Year High Five-Year Low

HENRY HUB NATURAL GAS SPOT PRICE (US$/MMBtu) BRENT CRUDE OIL PRICE (US$/Barrel)
Source: EIA Source: EIA
$5.00 $85.00

$4.00 $75.00

$3.00 $65.00

$2.00 $55.00

$1.00 $45.00
May-16 May-17 May-18 Aug-16 Aug-17 Aug-18

AUGUST-SEPTEMBER 2018 | COMPRESSORTECH2 | 11


Don’t replace.

EVENTS & MEETINGS


Altronic_Rev_Flashguard.indd All Pages

DIARY DATES

2018 Barcelona, Spain Sept. 24-27 +44 845 868 8234


SEPTEMBER +44 (0) 203 615 5914 Rio Oil & Gas globuc.com/blackseaoilgas
Sept. 11-13 gastechevent.com Rio de Janeiro, Brazil
Southwest Energy Institute +55 21 2112 9000 Oct. 28–30
Short Course Industry Training Sept. 18-20 riooilgas.com Syngas Technologies
Liberal, Kansas Turbomachinery and Pump Conference
+1 (620) 417-1170 Symposium Sept. 30–Oct. 3 Colorado Springs, Colorado
swenergyinstitute.org Houston, Texas Gas Machinery Conference +1 (703) 276-0110
+1 (979) 845-7417 Kansas City, Missouri globalsyngas.org
Sept. 12-13 tps.tamu.edu +1 (972) 620-4026
Wyoming Oil & Gas Fair gmrc.org NOVEMBER
Casper, Wyoming Sept. 18–20 Nov. 12–15
+1 (307) 258-4708 Gas Compressor Short Course OCTOBER ADIPEC
https://wyogasfair.org University of Oklahoma Oct. 15-17 Abu Dhabi, U.A.E.
+1 (405) 325-0673 EP Shanghai 2018 +971 2 444 4909
Sept. 12–14 pacs.ou.edu/gas-compressor Shanghai, China adipec.com
11th EFRC Conference + 852 2811 8897
Madrid, Spain Sept. 18–20 epchinashow.com Nov. 14–16
recip.org Power-Gen Asia 20th Korea Rotating Machinery
Jakarta, Indonesia Oct. 23-24 Symposium
Sept. 17–20 +1 (918) 831-9160 Black Sea Oil & Gas Seoul, South Korea
Gastech Exhibition & Conference asiapowerweek.com Bucharest, Romania +82-2-579-6271

12 | COMPRESSORTECH2 | AUGUST-SEPTEMBER 2018


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EVENTS & MEETINGS 7/25/18 4:10 PM

DIARY DATES

krmea.or.kr/engmain/main.php 2019 March 13-15 Ravenna, Italy


+1 (918) 831-9160 FEBRUARY Australasian Oil & Gas Exhibition +39 0544 219418
asiapowerweek.com Feb. 11-13 & Conference omc2019.it
Egypt Petroleum Show Perth, Australia
DECEMBER Cairo, Egypt +61 3 9261 4500 APRIL
Dec. 4-6 +971 4 445 3781 aogexpo.com.au April 14-17
Power-Gen International egyps.com GPA Midstream Convention
Orlando, Florida March 19-22 San Antonio, Texas
+1-888-299-8016 Feb. 25-28 GCA Expo & Conference +1 (918) 493-3872
power-gen.com Laurance Reid Gas Conditioning Galveston, Texas https://gpaconvention.org
Conference +1 (972) 518-0019
Dec. 5-7 Norman, Oklahoma gascompressor.org
Iraq Oil & Gas Show +1 (405) 325-4414 Boldface indicates shows
Basrah, Iraq https://pacs.ou.edu/lrgcc March 26-28 and conferences in which
+ 90 21 23 56 0056 International Petroleum COMPRESSORTECH2 is
basraoilgas.com MARCH Technology Conference participating
March 5-7 Beijing, China
Southwest Energy Institute +60 3 2182 3030 For a complete listing of
Short Course Industry Training iptcnet.org upcoming events, please
Liberal, Kansas visit our website at www.
+1 (620) 417-1170 March 27-29 compressortech2.com/events/
swenergyinstitute.org OMC 2019

AUGUST-SEPTEMBER 2018 | COMPRESSORTECH2 | 13


SHALE
NEWS

BAKKEN

PERMIAN

EAGLE
FORD
MARELLUS/
UTICA

Shale
play-by-play
In this first installment of a new
feature in COMPRESSORTech2,
James Willis highlights the latest news from the major North American shale plays.

PERMIAN open season for the


Concho/RSP megamerger Western Energy Storage
Concho Resources Inc. completed a US$9.5 billion all-stock and Transportation
purchase of RSP Permian, Inc., creating the largest unconventional (WEST) Header Project, a
shale producer in the Permian Basin. The newly expanded Concho new 650 mile (1046 km),
controls 640,000 acres (258,999 ha) of leases and operates a fleet large-diameter interstate natural
of 27 rigs — the largest drilling program in the basin. Concho CEO gas pipeline designed to move gas
Tim Leach said the combined companies will compete globally and bidirectionally between multiple receipt
tackle large-scale projects. and delivery points throughout states located
in the Western Energy Corridor. The WEST Header Project
KM plans pipeline is designed to leverage 40 Bcf (1.13 X 109 m3) of salt cavern
Kinder Morgan and partners EagleClaw Midstream Ventures and storage currently under development near Delta, Utah. The
Apache Corp. have signed a letter of intent to develop the Permian project will provide access to prolific natural gas supplies at or
Highway Pipeline Project. The US$2 billion, 2 Bcfd (56.6 X 106 m3/d) near the Opal Hub in Wyoming, Goshen Hub near Salt Lake City and
pipeline will provide an outlet for increased natural gas production Permian Basin supplies flowing westbound to locations at or near
from the Permian to growing market areas along the Texas Gulf Ehrenberg, Arizona. Open season is until Aug. 31.
Coast. The 42 in. (1067 mm) pipeline will stretch 430 miles (692 km)
from Waha, Texas, to the U.S. Gulf Coast and Mexico markets. Natural Cryo plant ordered
gas supply will be sourced from multiple locations, including Kinder Honeywell’s UOP Russell business will build a gas processing plant
Morgan, EagleClaw and Apache’s existing systems in the Permian, for Navitas Midstream Partners. The 200 MMcfd (5.6 X 106 m3/d) plant
with additional interconnections to both intrastate and interstate will remove natural gas liquids (NGLs) from natural gas produced from
pipeline systems in the Waha area. several counties in the Midland Basin. Honeywell’s solution includes
design and supply of a UOP Russell modular cryogenic plant with
New WEST pipeline refrigeration and dehydration units. The plant includes a Honeywell
Magnum Energy Midstream Holdings launched a non-binding UOP MolSiv unit, which is designed to remove impurities and water.

MARCELLUS/UTICA
THE AUTHOR

JAMES WILLIS is the editor of the m3/d to 13.3 X 106 m3/d). The boost in capacity
Marcellus Drilling News, a daily Pipeline capacity to rise does not require construction. TGP can now
newsletter covering the Marcellus The Federal Energy Regulatory Commission increase exports along its 24 in. (610 mm)
and Utica plays. has approved a request by Tennessee Gas pipeline from Hidalgo, Texas to Reynosa,
■ For more information, go to: Pipeline (TGP) to boost capacity on the Mexico. TGP runs from Boston to the Mexico
www.marcellusdrillling.com pipeline where it crosses the border into border and sources natural gas from the
Mexico from 185 to 468 MMcfd (5.2 X 106 Marcellus/Utica region, as well as other >
AUGUST-SEPTEMBER 2018 | COMPRESSORTECH2 | 15
SHALE
NEWS

regions. Several northeast gas suppliers, a Notice of Violation in mid-July with FERC
including Range Resources-Appalachia LLC, claiming Rover improperly disposed of spent
filed motions to intervene on behalf of TGP. drilling mud containing trichloroethylene
(TCE), a charge Rover disputes.
FERC delays laterals
Energy Transfer’s Rover Pipeline – traveling Dominion pulls plan
from Pennsylvania, West Virginia and eastern As part of the Eastern Market Access Project
Ohio through Ohio and into Michigan – is to deliver natural gas to a new electric power
built and ready to flow Appalachian gas plant being built in Maryland, Dominion
to Midwest and Canadian markets. The Energy planned to build a compressor station
mainline is up and running, but several feeder in Maryland, just across the Potomac River the compressor could not be seen from Mt.
laterals that reach into Pennsylvania and from Mount Vernon, Virginia, the historic Vernon. Ultimately, Dominion said it would
West Virginia have not yet been certified home of George Washington. Mount Vernon find a new location for the station.
to begin operation. The Federal Energy is a National Historic Landmark and part of
Regulatory Commission (FERC) has refused the National Park Service’s National Register Diversified’s Appalachia buy
to allow startup for several laterals following of Historic Places. Those operating Mount Diversified Gas & Oil signed an agreement to
Rover’s lack of restoration work at other Vernon took exception to the compressor buy EQT’s Huron Shale assets in Kentucky,
locations. Adding to Rover’s woes, the Ohio station, fearing it would clutter the panoramic Virginia and West Virginia for US$575
Environmental Protection Agency (EPA) filed view. Dominion initially fought back claiming million. The deal includes nearly 12,000

EAGLE FORD BAKKEN


Venado/KKR buy more A billion for Bakken
Privately owned Venado Oil and Gas and At the fourth annual Bakken Conference
investment firm KKR recently announced & Expo in Watford City, North Dakota,
they have closed on buying more acreage Jason Swaren, vice president of
and wells in the South Texas Eagle Ford. operations with Oasis Petroleum, said the
Assets include 22 producing wells and significant future drilling company plans to spend US$1 billion in
potential across 23,000 net acres (9308 ha) immediately the Bakken this year. Among the projects
adjacent to existing operating assets held by Venado/KKR in on tap for Oasis is a new gas processing
Atascosa and Frio counties. During the second quarter of 2018, the assets plant north of Watford City. The plant,
produced 4500 net barrels of oil equivalent per day (74% oil, 11% natural gas and 15% NGLs). due to go online later this year, will boost
With this new acquisition, the Venado/KKR partnership now owns 136,000 net acres (55,037 North Dakota’s processing capacity an
ha) producing 43,000 barrels of oil equivalent per day from the Eagle Ford. additional 10% and reduce the need for
flaring. The company is also evaluating
ConocoPhillips dials down the use of drones, which, Swaren said,
ConocoPhillips, headquartered in Houston, Texas, has been focusing more on the Eagle can accomplish survey jobs in hours
Ford and been drilling less in the Permian in 2018. According to CEO Ryan Lance, the rush instead of weeks.
to drill in the Permian has created bottlenecks for pipelines and labor shortages, making it
more expensive. Speaking after the company’s recent annual shareholder meeting, Lance “Permania” over?
said, “We’ll take our time [in the Permian], and we’ll do it right.” ConocoPhillips owns acreage Pablo Prudencio, upstream analyst for
in the Austin Chalk in Louisiana. The Eagle Ford overlaps the Austin Chalk and extends into Wood Mackenzie, said that “Permania”
Louisiana. ConocoPhillips’ strategy is to use its experience in South Texas on the Louisiana – the phenomenon where E&Ps are
acreage. During the first quarter of 2018, ConocoPhillips pumped 163,000 b/d of oil equivalent flocking to, and paying high prices for,
from the Eagle Ford, and just 19,000 b/d equivalent in the Permian. Permian acreage – is over. Addressing
the fourth annual Bakken Conference
Sumitomo buys acreage & Expo, Prudencio said deals in the
Japan’s Sumitomo Corp. subsidiary Summit Discovery Resources II is buying 624 acres Permian have slowed. He said the
(253 ha) in Karnes County, Texas, from IOG Capital. The acreage currently produces 3000 b/d average Permian deal has been around
of oil equivalent. Summit will become the 100% owner of the property and plans to develop US$25,000 per acre, while the average
more wells. deal in the Bakken has been around

16 | COMPRESSORTECH2 | AUGUST-SEPTEMBER 2018


SHALE
NEWS

wells with 200 MMcfd (5.6 X 106 m3/d) of ha) and catapults the company into one of headquartered in Greenwich, Connecticut,
natural gas production connected by 6400 the largest privately owned exploration and and EMG), and a fourth, unnamed seller. The
miles (10,300 km) of gathering pipelines production companies in the United States. CNX/Hess acreage, which is 78,000 net acres
using 59 compressor stations. Most of the The selling companies are CNX Resources (31,565 ha), is located in the wet gas window
wells are conventional. Before the sales and Hess (selling a joint venture it co-owned), of Belmont, Guernsey, Harrison and Noble
were announced, former EQT CEO Steve Utica Minerals Development (a subsidiary counties. This sale marks Hess’ exit from the
Schlotterbeck said that Huron was where EQT of First Reserve, a private equity firm Utica Shale. CT2
first experimented with shale drilling before it
was “a thing,” and that, “the Huron play was
like prep school for us.”

Quality www.klsummit.com
Acreage for Ascent
Ascent Resources, founded by Aubrey Products
McClendon after he left Chesapeake Energy,
announced it is buying 113,400 Utica Shale You Can Trust
acres (45,891 ha) along with 93 operating
wells located in eastern Ohio for US$1.5
billion. The new acreage brings Ascent’s total
to over the 300,000 Utica acres (121,406

US$2500 per acre. For comparison, the


Permian has stacked plays and is up to
2500 ft. (762 m) thick, while the Bakken
is around 300 ft. (91.4 m) thick. The game
changer for the Bakken has been the
Dakota Access Pipeline, providing cheaper
transportation costs to move Bakken oil to
other markets.

Stateline back online


A utility building at Oneok’s Stateline facility
in Williams County, North Dakota caught
fire on July 8. The facility includes a 200
MMcfd (5.6 X 106 m3/d) gas processing
plant and a 26,000 b/d dethanizer. There
were no injuries and the plant, which has
served Bakken operators since 2013,
returned to service a few days later. The
cause of the fire is under investigation. Protect your Equipment with
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AUGUST-SEPTEMBER 2018 | COMPRESSORTECH2 | 17


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COMPANY
NEWS

GE Power facility in Schenectady, New York.


In an effort to streamline its operations, GE
said it will “pursue an orderly separation” from
Baker Hughes a little more than a year after
finalizing the purchase of the company. GE also
announced the sale of its Distributed Power
business, which produces the company’s
Jenbacher and Waukesha engines.

The changing face of GE


Company seeks to find a financial way forward after managing director of First Reserve. “We
believe Dresser NGS has a resilient business
major structural moves. By Jack Burke model, a leading brand and a global footprint
which position the company well for the

W
hen GE announced it would doesn’t fit GE’s newest strategy to right itself. future.”
purchase 62.5% of Baker The plan includes spinning off GE healthcare Flannery said that separating GE
Hughes to create a US$23 billion and concentrating on aviation, power and Healthcare and BHGE will allow the two to
behemoth, the company saw the move as a renewable energy, Flannery said. invest in innovation and pursue their own
“compelling combination” that would produce Soon after, First Reserve, a Greenwich, growth strategies.
a leading equipment, technology and Connecticut, U.S.-based global private equity “I think the big message here for our
services provider in the oil and gas industry. firm focused on energy, said it would buy owners is Baker Hughes is a strong,
“The combination of our complementary Dresser Natural Gas Solutions (NSG) from improving asset,” Flannery said. “We had an
assets will create a platform capable of Baker Hughes. First Reserve previously upstream business, we made a strategic
seamless integration while we enhance our owned the business for about 10 years when decision to combine it with a downstream
ability to deliver optimized and integrated it was part of Dresser Inc., a former First business – that’s been very well received
solutions and increase touch points with Reserve portfolio company sold to GE in 2011. by customers, a full stream offering. We’re
our customers,” said Martin Craighead, really right in the middle of executing the
then chairman and CEO at Baker Hughes. Part of the “grand scheme” merger and making sure we realize all the
The companies said that the “new” Baker Dresser NGS manufactures Dresser benefits that both parties saw at the time of
Hughes would be a leading equipment, products including natural gas meters and the merger.”
technology and services provider in the oil instruments and gas pipeline solutions, as Those include the transfer of technology
and gas industry with operations in more well as chemical injection pumps and electric between the companies, best practice ideas,
than 120 countries. actuators. Dresser NGS’ equipment serves digital platforms and other synergies.
But only a few months after the diverse energy end-markets, including “That process is going very well, but we
blockbuster deal was finalized, GE CEO the gas distribution utility, midstream, and want to let that process run its course,”
John Flannery was publicly discussing “exit petrochemical industries. Flannery said. “Our core objective is
options” for Baker Hughes. Then at the end of “Our investment in Dresser NGS maximizing the value of BHGE and therefore
June – less than a year after the merger – GE represents a continuation of First Reserve’s in turn for GE. So when that process is
said it would “pursue an orderly separation” thematic approach to investments targeting completed, BHGE is going to be a very strong,
from Baker Hughes because the company the asset integrity sector,” said Jeff Quake, robust standalone company. >
AUGUST-SEPTEMBER 2018 | COMPRESSORTECH2 | 19
COMPANY
NEWS

“We like the company a lot, but in the


grand scheme of our portfolio analysis, we
did not think it made as much sense for us
to own that directly over time as to have it
outside GE.”

Distributed Power
That isn’t the only change announced by A Baker Hughes BCL compressor. Only a few months after the blockbuster deal that brought Baker
GE. The company also said it will sell its Hughes and GE together was finalized, GE CEO John Flannery was publicly discussing “exit options.”
Distributed Power business to private equity Less than a year after the merger, GE said it would “pursue an orderly separation” from Baker
firm Advent International for US$3.25 billion. Hughes because the company doesn’t fit GE’s newest strategy to right itself.
The transaction includes Distributed
Power’s Jenbacher and Waukesha engines,
as well as manufacturing sites in Austria, Boston, Massachusetts. According to its International. “We plan to invest substantially
Canada and the U.S. Distributed Power offers website, over the last 10 years, the company in critical areas such as the product
a product portfolio that includes industrial has invested in a wide variety of companies, portfolio, service network and digitization
gas engines generating 200 kW to 10 MW. including Concardis Payment Group, a to support Distributed Power in sustainably
With approximately 3000 employees and provider of digital payment solutions; MEDIAN strengthening its market position.”
three main facilities located in Austria, the Kliniken, a post-acute clinic operator in The transaction is expected to close by
U.S. and Canada, Distributed Power has Germany; Casa Reha, a German nursing the fourth quarter of 2018.
delivered more than 48 000 Jenbacher and home group; Addiko Bank (formerly Hypo
Waukesha reciprocating gas engines to Group Alpe Adria), which operates a banking Power Business
customers around the world. The Distributed network in southeast Europe; allnex, a Even with the divestiture of Baker Hughes
Power business had sales of US$1.317 billion global producer of industrial coating resins; and Distributed Power, GE will remain a player
in 2017. Douglas Holding, a European beauty retailer; in the power markets. The company’s Power
GE said that, with over 100 transactions GFKL, a provider of receivables management Division produces gas and steam turbines,
successfully completed in the Industrials, services in Germany; and Oxea, a producer of boilers and other products used in power
Energy and Business Services sectors, oxo-alcohols and derivatives. generation.
Advent is one of the most experienced “In Advent, we have a partner that shares Flannery noted that the power industry is
global investors in these sectors. GE said the our team’s passion for delivering outstanding “going through a deep turnaround” now, but
firm invests in well-positioned companies customer outcomes,” said Carlos Lange, has a bright future.
with significant operational and strategic president of Distributed Power. “Advent will “Our overall strategy as we look forward
potential and partners with management help accelerate our growth as we continue to – two years, five years, 20 years – the
teams to create value by driving revenue and execute on our priorities.” industry’s not going away,” Flannery said.
earnings growth. Advent has a strong global “Distributed Power is a terrific asset with “Gas stays in the mix, the big picture is
network as well as extensive experience in highly regarded engines that are the go-to renewables are up, coal, nuclear down, and
carve-outs of large industrial companies to OEM for the efficient generation of electrical gas remains an important part of the global
significantly support the Distributed Power power and heat as well as gas compression,” energy mix.”
business in expanding its market position said Ranjan Sen, managing partner at Advent He noted a recent Bloomberg report that
and establishing a strong standalone entity. found that the segment of electricity
Advent beat out other suitors, including produced by gas will increase by
Kohler and Cummins, for the GE portfolio. 20% by 2050.
Advent, founded in 1984, is based in “We’re a leader in that
business and we’re playing a
GE’s change strategy also includes long-term game there,” he said.
selling its Distributed Power business to “It’s going to be choppy in the
private equity firm Advent International next one to two years as we go
for US$3.25 billion. The transaction through this, but it’s a valuable asset
includes Distributed Power’s Jenbacher and I have a lot of confidence in
and Waukesha engines, as well as Russell (Stokes, CEO of GE Power)
manufacturing sites in Austria, and the team to execute the plan we
Canada and the U.S. have.” CT2

20 | COMPRESSORTECH2 | AUGUST-SEPTEMBER 2018


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FORECAST
2019

Global natural gas outlook:


Optimism and opportunity through 2025
Global gas demand continues to grow; innovation, policy incentivizing further production. In oil plays,
such as the Permian, high oil prices are
key to strengthening market. By Uday Turaga driving drilling and completions activity,
thereby increasing the production of

I
n the summer of 1988, the 17th World 2017 and continues to be led by the Middle associated gas. Collectively, North American
Gas Conference was held in Washington, East and the CIS states (including Russia), shale production is expected to continue
D.C., and President Ronald Reagan followed by Asia-Pacific, Africa and North growing at a steady pace.
began his address by describing natural America. Comparatively, North America leads
gas as a resource that would help reduce in gas production and diversity, followed by Global gas demand growth is
U.S. oil imports. Thirty years later, when the CIS states, Middle East and Asia-Pacific. accelerating
the 27th World Gas Conference returned to In 2017, Russian gas production grew the Natural gas demand grew much faster
Washington, D.C., this past June, the U.S. was most in terms of volume relative to all other in 2017 at 3.7% over the previous year,
firmly established as a growing natural gas producers, which include Australia, China, which was more than twice the rate in the
exporter. In fact, Sempra and Venture Global Egypt and the U.S. Mexican gas production current decade. Demand growth was robust
signed long-term LNG supply contracts to declined substantially while Latin American virtually in all regions of the world. Chinese
a Polish utility during the 2018 World Gas supply was stagnant. demand for natural gas grew by 15%, driven
Conference. These deals are one of many Unconventional resources, which by weather as well as strong policies to
that exemplify the growing role of U.S. as an accounted for more than 85% of production replace coal-fired power generation with
exporter in the global gas industry. growth during 2010-16, is anticipated to natural gas in China’s urban areas. Other
Supply growth has continued globally, lead natural gas supply growth in the emerging economies, such as South Korea,
and the availability of gas is not a concern near and medium term. In North America, India, Taiwan and other south and southeast
these days. Demand grew in 2017 at the unconventional shale plays, such as Asian countries, drove demand growth in
fastest pace it has in a decade. Marcellus and Utica, continue to be active Asia-Pacific.
New technology and innovation and competitive in terms of breakeven While gas-fired power drove a significant
continue to support both gas demand costs despite low natural gas prices. The amount of demand growth in Asia-Pacific,
and supply trends. However, the growing
competitiveness of renewables for power
generation, and the lack of a consistent and
development of new pipelines has reduced
natural gas price discounts in the Marcellus,
the restart of several nuclear power plants
led to a significant decline in gas use in >
supportive policy and regulatory framework
3.7 1.6 0.96 89.2
pose challenges for the gas industry going
6.5 1.7 0.5
forward. Even so, the global gas market
74.4
offers numerous opportunities for industrial
equipment and service providers across the
value chain.

Resource and supply continue to


grow globally
There is plenty of gas around the world. The
resource base changed little in
AUTHOR

UDAY TURAGA is the founder 2017: Exports: Exports: Exports: Industrial Power Res., 2020:
Demand LNG Pipeline- Pipeline- comm., Demand
and CEO of ADI Analytics. inc. Mexico Canada and inc.
Contact him at: exports transport exports
turaga@adi-analytics.com
EXHIBIT 1 U.S. Natural Gas Utilization Growth in Bcfd

AUGUST-SEPTEMBER 2018 | COMPRESSORTECH2 | 23


FORECAST
2019

Japan. Although European gas demand underscoring the threat to gas-fired power terminals will drive demand growth in the U.S.
grew robustly at more than 6% over 2016, from increasingly competitive renewables. as detailed in Exhibit 1.
the trends were mixed within the various This was also reflected in the U.S. market The U.S. has benefited from a faster
countries. Displacement of coal-fired power where renewables coupled with higher gas turnaround observed in the global LNG
was a key driver of demand growth. Higher prices led to a demand decline in 2017. Going market, where oversupply has depressed
adoption of wind generation led to demand forward, natural gas exports via pipeline to prices and driven spot buying among
declines in Norway and the United Kingdom, Mexico and as LNG from the various export emerging economies led by China. Exhibit 2
shows that U.S. LNG export projects will all
continue to be competitive.

Innovation accelerates, but policy


support is mixed
Innovation continues to accelerate steadily
in natural gas markets globally across supply
and demand segments. On the supply
side, North American operators continue to
innovate drilling, completions and production
technologies for shale and unconventional
resources, although reductions in breakeven
costs of natural gas production are slowing
down. Even so, nearly 1500 Tcf (42.5 X 1012
m3) of natural gas in North America continues
to be accessible with a competitive return at
less than US$4 per million Btu.
Similarly, new technologies and
innovation are accelerating even faster
in LNG markets with an emphasis on
regasification. Numerous floating storage
and regasification units (FSRUs), which has
been planned for several years, are now
coming onstream dramatically reducing the

2
EXHIBIT Cost competitiveness of
PROCESS U.S. LNG export projects.
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24 | COMPRESSORTECH2 | AUGUST-SEPTEMBER 2018


FORECAST
2019

cost of new countries joining the LNG buyers of natural gas are significant for industrial at the same time.
club. In the case of liquefaction, Petronas equipment and service providers serving Finally, innovation will drive new supply
and Shell have commercialized floating these markets. Further, end user preferences models and demand applications that require
LNG vessels, and several new small- and are also changing. For example, larger industrial players to adjust their product
mid-scale liquefaction technologies are emerging economies are moving from small development strategies, sales and marketing
also moving forward. Even so, innovation capacity power generation systems to larger programs, and operational and business
in distributed gas-fired generation, gas use units, while distributed generation is growing models. CT2
for high-horsepower equipment, and new
storage technologies is sorely needed.
Finally, several policy reforms have been
enacted in various countries that should
collectively support the growth of natural gas
markets. Even so, policy support is mixed
and inconsistent in other regions and areas
such as climate change, where government
policies can significantly accelerate natural GENUINELY
RELIABLE.
gas demand.

Industrial equipment manufacturers


and service providers should be
optimistic across the gas value
chain Day in, day out performance. Year
Collectively, the global gas market is after year. That’s what matters in a
positioned for optimism and opportunities pump. And that’s why we engineer
through 2025, but replete with many every Gorman-Rupp rotary gear pump
changes across the value chain. Natural
to be the most reliable, durable, and
gas production is concentrated among a
smaller number of large players and plays, easy-to-service pump on the market.
such as the Permian. As a result, well pads,
production facilities, gas processing and
fractionation plants, and pipelines will likely
get larger than before, impacting equipment
and service needs.
Specifically, the changes in end users

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TURBOMACHINERY
L.A. TURBINE

L.A. Turbine declares


war against wires
Ares turboexpander L.A. Turbine’s Ares AMB
turboexpander-compressor features
features skid-mounted a skid-mounted AMB control system
and PLC control panel.
control system, PLC.
By DJ Slater

L
.A. Turbine’s new turboexpander-
compressor doesn’t have any strings
to hold it down, an intentional move on
the company’s part to keep all the necessary
connections and wires closer to the skid.
Instead of running wires from the
turboexpander to its controllers in a separate
building several paces away, the Ares active
magnetic bearing (AMB) turboexpander-
compressor features a skid-mounted control
system and programmable logic control (PLC)
panel. By placing these components on the
skid, gas processing operators can have
their turboexpander packages preconfigured applications, especially with the lure of fewer on the skid within the shop, and when it goes
ahead of time and ready to go once it lands wires and components. to the customer, they are able to just push
onsite. “We thought, ‘Let’s put the control panel the start button.”
It’s all part of L.A. Turbine’s plan to make on the skid and make the box safe for Class I/ The genesis of the Ares AMB dates to July
AMB-equipped turboexpanders popular and Div. 2 areas,’” said Troy O’ Steen, L.A. Turbine’s 2017. John Maskaluk, L.A. Turbine’s owner,
less costly for gas processing midstream director of sales. “We can do the tuning right wanted to level the playing field for magnetic
bearing technology in turboexpanders.
L.A. Turbine While magnetic bearings in turboexpanders
collaborated are not a new concept, the upfront costs
with Waukesha overshadow the perks. Lack of operational
Magnetic knowledge across the industry, as well
Bearings as longer delivery times, also made AMB
to create a turboexpanders less attractive against the
turboexpander- same machines using oil-lubricated bearings.
compressor
with the Cutting wires
controls Bringing the price down, however, required
mounted design changes and L.A. Turbine’s staff
on the skid. focused on one area that inflated the
expense of AMB turboexpanders – cables
and wires.
“Previously, from the turboexpander, you >
AUGUST-SEPTEMBER 2018 | COMPRESSORTECH2 | 29
TURBOMACHINERY
L.A. TURBINE

had to run some expensive cables that go all


the way to the control room,” O’Steen said.
“Those cables can run hundreds of yards and
are very difficult to install.”
Removing the cables negates the
expense and complications that come from
on-site installations, leaving customers with
a simple piece of machinery designed for gas
processing plant capacities ranging from 60
to 300 MMcfd (1.7 to 8.5 X 106 m3/d).
“We spent a lot of time designing these
AMB military connectors for quick connection
and disconnection while eliminating the
potential for human error for all processes,” “Waukesha Magnetic Bearings has a stand next to this one, they realize how
said Tadeh Avetian, L.A. Turbine’s director different approach in how they design their simple it is,” Mascari said. “They realize how
of engineering. “We took 50 plus wires that control system,” said Danny Mascari, L.A. many points of failure have been eliminated
had to land on the terminal block and we’ve Turbine’s president. “They have superior and how many future maintenance costs
consolidated that down to six plug-and-play control system technology with the (oil changes, filter changes) have been
connectors.” compact design, hazardous area installation eliminated.
compliance, temperature operating range “Operators have known about the
More flexibility and open-source application that worked advantages of using magnetic bearings, but
L.A. Turbine didn’t craft this new AMB well for a skid installation.” price was a barrier. Customers overlooked
turboexpander offering alone. The company The control system and panel also the total lifecycle cost of an AMB unit and
turned to Waukesha Magnetic Bearings doesn’t require Waukesha Magnetic Bearings focused on the initial investment costs,”
to assist. The company provides custom- to have someone on-site for troubleshooting, he said. “We can offer the Ares AMB at
engineered magnetic bearing systems Avetian said. Instead, technicians can virtually the same investment price, and
for turbomachinery and similar rotating remote inspect the machine to ensure that operators see future costs diminish due to
equipment. everything is running smoothly. the elimination of ongoing auxiliary system
Waukesha Magnetic Bearings supplied If the lack of wires and a price point on maintenance and operations. Operators can
the Ares turboexpander-compressor with par with oil machines isn’t enough for Ares get the AMB advantage without paying a
its AMB hardware, as well as the Zephyr consideration, then the footprint and lack higher price.”
five-axis digital controller. The controller of ongoing maintenance should grab their
features a web-server interface and a built-in attention, Mascari said. Smaller footbrint
condition monitoring system for diagnostics. With magnetic bearings as part of the The Ares turboexpander-compressor also
The controller has the capability for flexible turboexpander-compressor, plant operators takes up less space than the oil variants.
packaging options, along with automated don’t have to worry about future expenses, Because the magnetic bearings don’t require
commissioning and retrofitting options. as there are fewer moving parts to maintain a lubrication system on the skid, the Ares
The controller’s diagnostic capabilities compared to its oil-dependent counterparts. footprint takes up roughly 1/3 less space.
include event logging, trip data logging, “Our customers are very familiar with Additionally, the AMB machine footprint does
automatic clearance check, transfer the lube oil machines, and when they fluctuate in size the same way oil skids do
function measurement, spectra
capability, harmonic capture
and built-in tools that display
compliance with ISO sensitivity ““Operators
O have known about the advantages of
performance criteria, according to
Waukesha Magnetic Bearings. The u
using
s magnetic bearings, but price was a barrier.
typical temperature rating of the Zephyr yr
controller is 32° to 104°F (0° to 40°C). With C
Customers
ustom overlooked the total lifecycle cost of an
the air-conditioned cabinet featured on the
Ares skid, the possible temperature range is AMB unit and focused on the initial investment costs.”
extended from as low as -40° to 110°F (-40°
to 43°C). DANNY MASCARI, president, L.A. Turbine

30 | COMPRESSORTECH2 | AUGUST-SEPTEMBER 2018


TURBOMACHINERY
L.A. TURBINE

The Ares AMB variant (left) takes up


1/3 less space than its oil-dependent
counterpart (right).

said Ares has the potential to fit well within


large downstream applications.
“A compact piece of equipment can make
more sense from an operational and capital
standpoint,” he said. “The Ares AMB is a big
return on investment for EPCs (engineering,
procurement and construction) and end
users on larger projects.”
based on gas processing requirements, AMB skid remain the same, O’Steen said. And with a name like Ares – the Greek god
ambient temperatures or elevations. “It simplifies and standardizes the of war – L.A. Turbine hopes its message to
For example, an oil-based turboexpander process from a design standpoint,” he said. the industry is clear: cables and wires won’t
skid will differ in size depending on the So far, L.A. Turbine has two Ares AMB hold back its latest product, and neither will
specific needs of a gas processing plant, turboexpander-compressors committed to larger competitors.
which extends the lead time needed to a customer at two different 200 MMcfd (5.7 “We’re a privately held business
build it. The AMB skid size remains relatively X 106 m3/d) gas processing plants. More are competing against the titans,” Mascari said.
consistent for gas plants. The only difference expected in the coming months, and the “We’re always willing to take a risk and build
comes from the size of the turboexpander company expects to see the Ares apparatus a product that makes sense for the market.
itself, but all the other components on the not only in midstream applications. O’Steen We’re willing to go to war.” CT2

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AUGUST-SEPTEMBER 2018 | COMPRESSORTECH2 | 31


Information for Reliability and Instrumentation Engineers

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RECIPROCATING
COMPRESSORS

A Mayekawa mechanic performs


maintenance on one of the company’s
reciprocating compressors. Mayekawa
recips are a popular commodity among
Canadian gas plants that opt for
reciprocating compressors over screw
compressors.

Overhaul variations key to


equipment longevity.
By DJ Slater

Mayekawa keeps
legacy recips running
M
ayekawa Canada doesn’t been running for three to four decades. the most damage,” Smith said. “If a customer
worry about the longevity of “There’s no reason that our recips can’t just needs the top-end service, it can get
its reciprocating compressors, continue to run (after 40 years).” their machine up to factory efficiency.”
which are used in propane refrigeration Mayekawa offers two main maintenance The second package is a complete
applications. packages designed to keep its reciprocating overhaul. Unlike the first option, the service
When the compressor itself is known compressors in pristine condition. The first is centered on the bottom end of the
to outlast the building around it, its safe option is the most common – a top-end compressor. Affected areas include the
to assume this equipment has a knack for overhaul. This package focuses on the top main bearing, thrust bearing and shaft seal
survival. portion of the compressor, such as the assembly. The crankshaft may also be
“We see it often – the gas plant around valves, springs and top end of the piston. removed for inspection and reconditioning.
the compressor becomes economically “The top end of the piston is where we see
unfeasible,” said Curtis Smith, service sales Maintenance schedule key
manager, Mayekawa Canada. “They will shut For recip owners, Mayekawa recommends
down a gas plant around our compressor its top-end service annually and its complete
before they sell off the compressor.” overhaul every two years. Mayekawa
A Mayekawa reciprocating compressor’s technicians handle the maintenance work,
longevity, however, isn’t strictly determined providing a direct service line from the OEM
by its build quality. Without proper to the customers. Following the company’s
maintenance, the machine could suffer maintenance schedule will keep a Mayekawa
a severe problem or catastrophic failure reciprocating compressor running into the
within a five-year window. With proper half-century mark, Smith said.
maintenance, though, it’s not uncommon The oil and gas sector, however, doesn’t
to see Mayekawa recips with 1977 Mayekawa’s reciprocating compressors can always put the same value on maintenance,
manufacturing nameplates. last for decades as long as operators follow often times opting to defer it. Smith said he
“Our recips can last a long time,” Smith Mayekawa’s suggested maintenance schedule. sees this practice often and urges owners to
said, referring to recips he’s seen that have follow the appropriate maintenance schedule >
AUGUST-SEPTEMBER 2018 | COMPRESSORTECH2 | 33
RECIPROCATING
COMPRESSORS

to avoid costly repairs down the road.


“The machines we’re dealing with are
running constantly,” Smith said. “They may
be able to get three or four years out of them Mayekawa
without an overhaul. If you get past a certain recips with 1977
point, you’re flying blind and we get nervous. manufacturing
“The annual inspections are there to avoid nameplates are
a catastrophic failure,” he said. “With these not uncommon
oil and gas plants, they might be looking at sites at gas
US$20,000 to US$25,000 a day if they are plants in Canada.
not processing their gas liquids.”

Intuitive maintenance older nameplated machines still in service. Mayekawa has a worldwide presence,
Though maintenance plays a major role, it’s Camron Chicoine, a service manager for but its reciprocating compressors are
not the only reason Mayekawa still has its the company in Western Canada, said the immensely popular in Canada, specifically for
company’s compressors are designed recreational ice and gas plants. According
specifically to make maintenance easier and to Mayekawa, the company has sold 8319
intuitive. reciprocating compressors in Canada, which
Mayekawa’s reciprocating compressors is roughly 208 recips a year. Of that amount,
consist of sturdy, wearable parts that can 3744 were sold between 1970 and 1988,
be swapped out seamlessly and are also meaning those machines are 30 to 40
easy to source regardless of a customer’s years old.
location, Chicoine said. The company estimates that about
Mayekawa’s reciprocating compressors 2500 Mayekawa recip compressors with
are mostly commonly used in refrigeration 30 to 40 years of life are still in operation
applications, Smith said. On the oil and gas today in various applications. Drilling down
side, those compressors are designated for into the numbers, roughly 375 legacy
small and medium-sized gas plants. In those compressors are a part of oil and gas
Parts for Mayekawa’s reciprocating applications, the compressors are used to applications.
compressors can be easily sourced and extract hydrocarbons out of the natural gas “Our recips can really take a beating,”
swapped out to ensure the machine’s longevity. stream using the chilling effects of propane Smith said. “Even with a failure, our guys can
refrigeration skids. get it up and running again.” CT2

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CATALYTIC ENGINE SOLUTIONS • ENGINE & PROCESS SILENCERS • HEAT RECOVERY • GAS TURBINE • FIELD SERVICE • TESTING
TURBOMACHINERY
BUSHINGS

Tri-Bushing
flexes when
the heat is on
New disc technology from Altra
improves coupling reliability

1
A
meridrives and Bibby Turboflex, two the coupling statically. Generally, a good FIGURE
Altra Industrial Motion brands, have practice consists of designing a coupling Blade failures where
developed a new turbomachinery with enough flexibility to handle thermal the disc material bent
bushing – Tri-Bushing. The flex element/ growth, especially if that growth exceeds the around the traditional
blade triangular bushing is designed coupling’s capacity by 25%, the company round bushings.
to increase the axial capability of high- said. Where possible, couplings are
performance flexible disc couplings used in designed to grow into their neutral, Traditional round
turbomachinery applications. relaxed position. bushings installed on a
Flexible couplings used in these In many cases, however, couplings scalloped flex element/
applications must accommodate angular must operate in a compressed or disc pack.
and axial movement due to thermal growth. stretched mode to accommodate
In steam and gas turbines, the machinery this movement. Extensive testing When selecting
shafts, casings and piping expand as their reveals that when approaching turbomachinery
temperature rises, according to Altra. the axial limit of a disc coupling – couplings, some
When axial deflection is significant, while accommodating for angular operators prioritize axial
spacers are purposely made short to stretch misalignment – the disc packs thermal growth rather than
become highly stressed in the area the torque requirement.
Altra coupling brands have developed the around the traditional round bushings, A larger coupling may be
Tri-Bushing, a flex element/blade triangular according to Altra. needed to handle the axial
bushing design that increases the axial growth.
capability of flexible Retrofit solution Mark O’Neil, chief principal engineer for
disc couplings used The API 671 standard for “Special-Purpose Altra’s coupling brands, said the Tri-Bushing
in turbomachinery Couplings for Petroleum, Chemical, design came from his team of engineers
applications. and Gas Industry Services” requires from Ameridrives and Bibby Turboflex. Those
couplings to accommodate 0.20 degree engineers dealt with a variety of issues
of angular misalignment. In most cases, during Tri-Bushing’s development.
turbomachinery drivetrain components “The focus of our team’s attention was
are laser-aligned for maximum on the coupling’s blade/flex elements.
precision but, at 1/5 of a degree, the While developing coupling solutions for
impingement of the flex element the turbomachinery market, we needed to
around the bushings does not ensure that our legacy disc coupling design
typically result in failures due to the could be retrofitted with a new flex element,”
radius and low angle, the company said. O’Neil said. “This meant that the flex element

36 | COMPRESSORTECH2 | AUGUST-SEPTEMBER 2018


TURBOMACHINERY
BUSHINGS

damaging impact on the disc coupling


blades as they bent around the apex of
the bushings at the tangents,” O’Neil said.
“Ultimately, this led to the development of the
Tri-Bushing design.”
The design profile features two straight
sides that reduce and redistribute the
stresses that typically occur around the disc
pack bushings. The FEA results shown in
Figure 2 provide a comparison of the stress
reductions.
“Utilizing the new Tri-Bushing design
can increase a coupling’s axial capability by
more than 33%,” said Oliver Doidge, Altra’s
turbomachinery business development
manager. “Given this significant increase in
axial growth capability, in many applications,
coupling designers no longer need to upsize
their coupling to accommodate this growth.
bolt circle was locked in from the start, which In addition lateral vibration problems may
limited many of the design options we could FIGURE2 be avoided with a smaller coupling. A higher
explore.” Stress comparison of a typical round bushing safety factor results regardless of the
With this constraint, the design process and a Tri-Bushing. misalignment required.”
began, which included finite element The new Tri-Bushing design from Altra
analysis and prototype testing. Historically, solve the problem by varying the thickness is available for use in all new Ameridrives,
dynamic testing for new coupling designs of the blade/flex elements, but the failures Bibby Turboflex, TB Wood’s and Lamiflex disc
is performed for 100 million cycles. continued. The blade failures were all in the couplings. New disc packs with Tri-Bushing
Unfortunately, during the early prototype areas where the disc material bent around stress reduction technology can also be
testing, coupling failures were consistently the traditional round bushings positioned at retrofitted into existing couplings as part
occurring between 40 million and 50 million the bolt holes (see Figure 1). of repair or rebuild services performed at
cycles, the company said. “Based on these findings, we looked various Altra coupling facilities around the
The engineering team attempted to at how we could eliminate or reduce the world. CT2

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Cartridge bearings with


EPP technology
Designed to offer the performance of magnetic
bearings with the simplicity of oil bearings.
By Drew Devitt

E
xternally pressurized gas bearings and headaches by avoiding
have not been the first choice of turbo maintenance and cooling issues es associated
equipment designers. Aerodynamic with oil lubrication.
bearings, like foil bearings or dry gas seals, Externally Pressurized Porousus (EPP) gas
are much more popular in use. Externally bearings use the natural porosity of a carbon
Pressurized Aerostatic bearings do have or graphite face material to restrict and damp
advantages though, especially with porous the flow of gas into the gap between the
compensation. face and the rotor. All the porous surfaces
New Way Air Bearings now offers a are sealed except the bearing face and so
cartridge type bearing assembly employing pressurized gas introduced through the FIGURE 1
Externally Pressurized Porous (EPP) gas face acts as oil in a hydraulic cylinder, with
bearing technology. Cartridge assemblies pressure times area, forcing the rotor away would be 1000 lbs. (454 kg) of aerostatic
allow for direct replacement of oil-based from the bearing face, shown in Figure 2. pressure exerted on the shaft, with 1000 lbs.
journal or tilt pad bearing cartridges. Available With 10 sq.in. (6452 mm2) of bearing area (454 kg) of load on the bearing. At this point,
with thrust bearings, flanged or unflanged, and 100 psi (6.9 bar) input pressure there theoretically there would be zero lift and so
both radial and axial bearings may be split zero flow but still near zero friction as
at 180 degrees for ease of assembly. The FIGURE 2 the air pressure unweights the load from
bearing pads mount compliantly, providing the face. We call this the “balanced force”
for self-alignment and adjustable stiffness, point. Unless you’re using this principle to
see Figure 1. reduce wear or heat from a contact brush
The key is the Externally Pressurized or exciter, you want your gas bearings to
Porous (EPP) gas bearing technology, fly on a pressurized film of gas. This means
offering the performance of magnetic there will be flow, and so less than the
bearings with the simplicity of oil bearings. source pressure in the gap. With 100 psi
The technology represents a relatively new (6.9 bar) input pressure 50 to 60 psi (3.4 to
way for the rotating equipment industry 4.1 bar) may be generated as an average
to increase efficiencies by reducing pressure in the gap, in this case resulting in
shear losses as well as reducing costs 50 to 60 psi (3.4 to 4.1 bar) unit loading and
500 to 600 lbs. (227 to 272 kg) of load with a
fly height of about 0.0002 in. (0.00508 mm),
THE AUTHOR

DREW DEVITT is the founder, see Chart 1.


chairman and chief technology Unit loading of 900 psi (62 bar) has been
officer at New Way Air Bearings demonstrated with 1000 psi (68.9 bar) input
and former president of the pressure. The current cartridge bearings
American Society for Precision Engineering shown accept 300 psi (21 bar) input pressure
(ASPE). He can be reached at ddevitt@ giving about 200 psi (13.8 bar) unit loading
newwayairbearings.com capacity although most operate at less than
100 psi (6.9 bar) input. >
AUGUST-SEPTEMBER 2018 | COMPRESSORTECH2 | 41
PRODUCT
   
 
FOCUS
www.norwalkcompressor.com

GENUINE SPARE PARTS 3


Compliantly mounted FIGURE
MADE IN THE USA
O-ring mounting technology, typically used in
mounting a bearing cartridge, is used directly
on the bearing segments. New Way has 20
years of experience with O-ring mounted allows for fitting the bearings into tight
air bushings. These O-rings allow for self- spaces.
alignment and adjustability in stiffness, The low friction of gas bearings is also a
Figure 3. major advantage. In the continuing drive for
The 360o “journal-like” gas bearings system efficiencies, bearing losses are a low
are made with gas bearing clearances hanging fruit. Anytime there is a need to cool
between the rotor and journal. Since lubrication oil, there are losses. There is the
steels expand more than carbons with original loss from shear then the loss is more
temperature, temperature change is a than doubled to remove the heat.
practical limitation, significantly changing or See Chart 2 for examples of losses at
As horizontal, single throw, single or multi- even eliminating bearing clearance. These different gaps for oil and gas bearings
stage compressors, which are designed for new cartridges bearing assemblies employ relative to surface speed. Machines with
intermittent/continuous duty applications, “bushing segments”. Segmentation provides such dramatically lower power losses would
and with frame power capabilities up to 400 HP, “expansion joints” as the O-rings distribute have a lower cost of ownership through the
package configurations are available as high as the load, while still providing self-alignment efficiencies and reduced costs from not
25,000 PSIG for oil-lubricated configurations and damping. This low-profile mounting providing and maintaining oil systems.
and 6,000 PSIG for non-lubricated.
Several options designed and engineered
to suit the most rigorous specs.
• Continuous Service with Minimum
Maintenance
• Standard V-Belt Drive – Gear or Direct
Coupled Drive trains
• Splash Lubricated Frame and Running
Gear – Force Feed Optional
• Crosshead with Adjustable Shoes
• Single or Double Compartment
Distance Pieces
• Water Cooled Cylinders
• Lubricated or Non-Lubricated Gas End
Configurations
• Piston/Cylinder Configurations: Single
Acting, Double Acting, Step, Tandem
• Available Fully Factory Packaged or
Customer Packaging

Have confidence in Norwalk’s services.


Maintaining your equipment at optimum
performance is always in your best interest.
Equipment that is well taken care of
provides decades of reliable service. With
a Norwalk-certified technician, you know
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CHART 1
This is a lift vs. load chart for EPP gas bearings. The slope of the curve is representative of the
http://www.norwalkcompressor.com/products/
reciprocating/slimline/ gas film stiffness. Typical operating ranges for DGS and foil bearings are super imposed to help
conceptualized gas bearing technology in turbo equipment.
Norwalk Compressor Company
1650 Stratford Avenue
Stratford, CT 06615 USA
Tel: (203) 386-1234 • Fax: (203) 386-1300
PRODUCT
FOCUS

GE, he founded Bently Pressurized


Bearings in an effort to solve many
Monitor your engine’s
of the rotordynamic problems he had
identified with his probes. Don did a
health like a
great job describing the advantages of
gas bearings in numerous articles and
Real-Time Expert
his textbook. We use his theories and
analysis and have named the bearings See what’s happening
“Bently Bearings” after Don. inside your cylinders
Gas bearings also go well when
integrated with high speed motors.
with best-in-class tools.
There is a trend in the general industry
Continuous Pressure Monitoring
with motors getting closer to the work
being done. We see this in machine tools, software is the most advanced
heavy earth moving equipment, and continuous cylinder combustion
marine propulsion to name a few. Multiple monitoring tool available, with
Low friction high-speed motors, each with a single or an interface simple enough to
This low friction is also an advantage for double stage would afford more freedom of use on the shop oor.
maintaining rotordynamic stability. Oil shear design than internally geared compressors.
friction is responsible for the cross coupled The stages could be run at varying speeds • Engine Balancing
stiffness terms in stability calculations. and located more rationally for intercooling. • Advanced Combustion Analysis
This friction is the traction the rotor gets Additionally, by not needing to reach through
• Ion Sense and Pressure Ratio
trying to climb up the side of the journal and oil seals and having the thrust constraint
is responsible for whirl motion inside the close to the work, the impeller clearance • Trapped Equivalence Ratio
bearing. Don Bently, founder of Bently Nevada between the impeller and stator can • Combined fault detection logic
Corp., was a pioneer using eddy current be reduced. This is especially important • Continuous data logging
probes to “see” rotordynamic instability for smaller higher speed impellers and or • Capture, play back recordings
problems. After selling Bently Nevada to impellers working on dense gases. CT2
Kistler sensors used exclusively with CPM

CPM
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Comparison of shear power losses in Fluid Films.
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PRODUCT
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On the hunt for


relevant data
Brüel & Kjær Vibro offer options for condition
monitoring in industrial applications

P
racticing efficient condition inspections are an oxymoron given all
monitoring on critical machinery the permits and supplementary activity
enables operators to gather valuable that must occur before a machine can be Setpoint Machinery Protection
information to plan an effective maintenance even partially disassembled. As a result, System (MPS) offers full API 670
schedule. With the power to identify potential the ability to know whether a problem is compliance, an integral touchscreen display
problems before they arise, operators are major or minor – or even a problem at all – is and 56 channels. Pictured is the VC-8000 model.
better armed to mitigate the issue before it extremely beneficial in planning scheduled
becomes a catastrophic machine failure. maintenance and in confirming whether hour. In contrast, a typical power generation
The case and economic payback for unscheduled maintenance is necessary. plant may have multiple steam turbines
condition monitoring has become well and/or gas turbines. If one goes down, plant
established in every sector where large The perils of downtime output will be affected, but rarely will the
rotating or reciprocating machinery is In many oil and gas facilities, the largest and entire plant output be at risk.
applied. For example, consider the thermal most critical machines are often un-spared However, process interruptions are not
power generation sector. The loss of just and can thus inhibit the entire production the only considerations: there are also the
one gas-fired turbine generating unit could process when they do not run. Downtime for costs of the machine repair itself. As would
cost the operator up to 500 MW of generated one machine means downtime for the entire be expected, large, expensive machines
power – representing a significant impact on process, and can be millions of dollars per represent large, expensive parts (often with
production. In a nuclear plant, very long lead times) and
the stakes are even higher with require expensive, highly-
a single turbine-generator often specialized service personnel
accounting for 1000 MW of to install those parts. Then
output or more. there are the human and
Outages to address environmental consequences
problems typically entail of failure. Because machine
months – not days – and “quick” speeds are high and the
amount of entrained energy
Setpoint condition monitoring enormous, failures can
software (CMS) connects directly progress quickly and adjacent
to the Setpoint MPS without the plant equipment and personnel
need of any additional intervening can be at risk. Further, the
hardware. It provides visualization process itself often involves
tools such as timebase, orbit, substances that are fire
spectrum, bode, polar, shaft hazards, toxic to human and
centerline, multi-variable trend, environmental health, or
and other plot types specific both. For all of these reasons,
to rotating and reciprocating the stakes are exceedingly
machinery, allowing online high and risk mitigation is of
condition monitoring analysis and
machinery diagnostics.
paramount concern.
While most operators protect their critical >
AUGUST-SEPTEMBER 2018 | COMPRESSORTECH2 | 45
PRODUCT
FOCUS

machinery through systems that detect Thus, with this background, and recognizing move beyond machinery protection and
severe violations of bearing vibration and that condition monitoring is of benefit economically justify condition monitoring.
temperature limits, tripping the machine on most types of machines and in most
under such circumstances, these systems industries – not just compressors in the oil Condition monitoring for all
do little to allow proactive intervention and and gas sector – we now turn our attention In the last two decades, the percentage
detect problems before they reach the to technologies that are enabling a larger of operators utilizing machine protection
levels at which automatic trips are initiated. percentage of machines and operators to systems connected to an online condition
monitoring software has been steadily
increasing from around 10% 20 years ago to
around 30% today. However, the use of these
systems is still very much consigned to large
COMPRESSOR LUBRICATION SYSTEMS plants where operators have the benefits of
economies of scale.
Typically, condition monitoring was
performed by installing purpose-built online
systems dedicated exclusively to vibration
data. Thus, an entire ecosystem of single-
purpose networks, servers, software,
and interfaces to other data types had

WHEN to be installed and maintained. This was,


understandably, a huge cost hurdle for many

MACHINES operators and explains why the percentage


of operators choosing to adopt the combined

STOP,
machine protection/condition monitoring
measures has remained relatively low.
Beginning in 2012, Brüel & Kjær Vibro

PROBLEMS began investigating ways it could overcome


some of these difficulties and allow a larger

START.
percentage of customers to begin realizing
the benefits of condition monitoring –
regardless of the underlying protection
system they might be using. It arrived at two
key conclusions: first, for many customers, a
B[jekhY[hj_Ó[ZbkXh_YWj_edj[Y^d_Y_Wdil_i_j
software system (the process data historian)
oekhbeYWj_edWdZYedZkYjWikhl[oe\Wbboekh was already in place that could enable
bkXh_YWj_edioij[ci$?jÊiWi_cfb["j_c[#iWl_d] condition monitoring. All that was needed
[lWbkWj_edj^Wjm_bb]_l[oekf[WY[#e\#c_dZ" was a way to introduce vibration data into
this system instead of just limiting it to
WdZWm[bb#hkdd_d]Yecfh[iieh$
slower-changing process data.
Second, for many customers the value
of condition monitoring was not primarily
found in their ability to access data over
Sloan’s Service is the key to a network, but instead to ensure that the
ÔWmb[iiYecfh[iiehef[hWj_ed$ data the needed to make high-quality, data
driven decisions regarding their machinery
was actually being captured at the times
they needed it. The company found that the
1.800.722.0250 imposition of retrieving the data manually
Sales@SloanLubrication.com was a much smaller problem in most cases
SloanLubrication.com than the fact that no (or insufficient) data
was often available following a machine
event.

46 | COMPRESSORTECH2 | AUGUST-SEPTEMBER 2018


SloanLub_WhenMachinesStop.indd 1 7/20/18 12:06 PM
PRODUCT
FOCUS

A different approach of data solves one significant challenge: in tools for alerting plant personnel to changing
All plants have process control systems one, dedicated tool, it becomes far easier to conditions in machine health, they are rarely
which process tens or hundreds of correlate process data and vibration data, enough for isolating root cause. For this,
thousands of measurements relating to with time stamps representing one version the vibration analyst needs the ability to
pressures, temperatures, flows, levels, etc. of the ‘truth’ and a range of uncertainties view actual waveform data and a variety of
Originally, these readings were archived on
strip chart recorders consisting of literal
paper and ink.
eliminated.
But while correlated trends are powerful
specialized data presentation formats, such
as spectra, orbit, time base, bode, polar, >
In the 1980s, computers began replacing
strip chart recorders and generically became
known as “operational data historians.”
F
TOP O
Today, the most widely adopted historian
!
CLASS
in the power generation and hydrocarbon
processing industries is the OSIsoft PI
System, with a market share exceeding 60%.
Brüel & Kjær Vibro observed that virtually
all operational data in the plant was being
entrusted to this system with one very
notable exception: real-time, high-speed
vibration data – which instead remained
confined to a special-purpose infrastructure
intended only for vibration data. The logical
place for vibration data to reside was in this
operations data historian, provided that
the technical hurdles could be overcome. It
would allow far easier correlation because
both vibration and process data would
reside in a common place with common
timestamps, and it would eliminate the need
for a separate computing infrastructure and
software just for vibration data.
Fortunately, these hurdles were overcome
through a combination of technology that
stores data only when it changes and
dramatic increases in speed of the PI System
itself over the last decade. The eventual
Brüel & Kjær Vibro product that emerged from #1 in Emissions Testing & Tuning
these efforts was called Setpoint and was
introduced to the market in late 2012. To date, • Most dependable
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Emission Testing
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Correlated trends of vibration and process
data are extremely powerful tools for • Best network / combustion
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identifying whether machinery condition has • State and Federal compliance testing
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conditions resulted in changing mechanical for Compliance Reporting
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the machinery itself is to blame. Because Fi d out more at www.testo350.com
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multiple systems are notoriously difficult to
correlate, use of the PI System for both types

AUGUST-SEPTEMBER 2018 | COMPRESSORTECH2 | 47


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and shaft centerline. Setpoint CMS works


together with the PI System to seamlessly
move from viewing trends to viewing these
specialized plots. The resulting combination
of visualization environments allows all the
diagnostic capabilities routinely employed by
vibration analysists.

Embedded intelligence
Increasingly, users are looking for ways
to move beyond manual diagnostics and
data review just to spot problems. They are
looking for systems that can flag developing
problems through automated analytics.
Where possible, the system will automatically
identify a problem and either isolate the type
of problem, or provide a range of possibilities A screenshot of the Setpoint CMS software, which offers a variety of visual measurements.
and corresponding probabilities based on
the indicators present and their correlation
to particular machinery malfunctions or even systems is they do not have the data a condition monitoring system is possible. In
process conditions (such as cavitation in a available when they need it. Because of order to make it available to non-adopters,
pump or surge in a compressor). the way most systems store data, they look Brüel & Kjær Vibro has eliminated the need for
Fortunately, the PI System has a standard for dramatic changes rather than subtle software use altogether.
suite of tools (AF Analytics) that can be used changes before storing high-resolution Known as a Flight Recorder, a half-
to embed such intelligence. In addition, data. Events of interest are often not terabyte solid-state drive can be supplied
PI has a very large network of more than captured. integral to the machine protection system,
400 partner companies that provide highly The opposite problem can also occur: which will easily handle more than a year
specialized solutions, such as bolt-on systems that try to store and stream of high-speed vibration data. The data can
capabilities for machinery learning (ML) and almost everything to a server, creating a then be retrieved and events leading up to an
artificial intelligence (AI). morass of data to wade through and filling alarm or even unexpected machine trip can
even the largest hard drive in a matter be reliably identified.
Knowing when and when not to of weeks. Another issue comes when While use of a flight recorder by
store systems are configured to respond to itself is primarily reactive, it is still a step
To ensure the PI System does not become subtle changes in the data instead of being forward for customers that don’t have a
flooded with useless data (waveforms able to automatically detect it. The user condition monitoring option and no ability to
and other values that represent little or no must build and maintain a daunting set of understand why an alarm or trip occurred.
change from prior stored data), sophisticated supplementary alarm levels to trigger data The Flight Recorder approach is appealing
change detection algorithms are embedded collection. to those averse to, or unable to, install and
in Bruel & Kjaer Vibro’s hardware. These Such systems are “overly configurable” maintain larger system networks, such as
algorithms decide when data needs to be in the sense that they must be configured to those working in remote locations without
stored and when it can be reliably discarded. store data properly instead of allowing the networks, where the data can be retrieved as
This ‘embedded intelligence’ flags changes user to have good results by default, and to little as once a year for archiving.
and never omits anything of importance. be able to tailor the system for even better
When something changes, it is stored; results to improve it. Conclusion
when something isn’t changing, it needs Too little or too much data, mandatory In a perfect world, every industry would
only to be stored once, not repetitively. This versus optional tailoring, and ensuring that operate in a very proactive fashion, fully
concept is what allows an operational data events are never missed without flooding online, with dedicated resources and
historian, such as the PI System, to be used the system with useless data are all design surveillance in place on all machines.
so effectively for storing and visualizing criteria that the Setpoint system overcomes. However, this is not reality, but Brüel & Kjær
vibration data. Vibro aims to give customers the ability
A significant problem in the industry Adopting condition monitoring to accurately record data in an effective
for operators using condition monitoring Making it less expensive and simpler to adopt way. CT2

AUGUST-SEPTEMBER 2018 | COMPRESSORTECH2 | 49


Exline_Partner.indd 1 7/26/18 3:25 PM

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23 | ISSUE 7
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s-At-A-Glance
Turbine Spec
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Upgrading general
purpose steam turbines
Replacing select components leads to better machine STEAM GLAND

life, cost savings. By Heinz Bloch and Richard Smith

I
t is not unusual for large oil refineries to are adjacent to each other (Figure 2).
have 160 general purpose (GP) steam Fortunately, modern bearing protector seals
turbines installed at a major site. As are readily available for GP steam turbines.
long as these machines are connected If well-designed, these protector seals can
to a steam supply, preventing the often virtually eliminate premature bearing failure.
TURBINE WHEEL BEARING HOUSING
steam-inundated environment (Figure 1) Upgrading to an advanced bearing housing
from entering the bearing housing is of great seal retrofit arrangement (Figure 3) is, FIGURE2
importance to reliability-focused refineries, therefore, well worth considering. Thoroughly The unavoidably close proximity of a steam
fertilizer producers and petrochemical engineered bearing housing protector seals gland to the bearing housing promotes
plants. Steam intrusion often occurs simply achieve effective moisture intrusion into the lubricating
because steam gland and bearing housing oil. Contaminant and vapor exclusion
Return-on-investment and are achieved by bearing protectors that
projected payback incorporate an axially-moving O-ring. These
Return-on-investment (ROI) studies and bearing protectors are cost-justified and
related cost assessments indicate that contribute to run length extensions; they
major refineries may have opportunities to are the subject of this article.
capture steam turbine-related corporate-
wide maintenance savings in excess of data; alternatively, they are encouraged
US$3 million annually. These experience- to study and use our projected savings.
backed savings projections can be examined Note that we have occasionally been asked
more closely and deserve to be compared where oil refineries have published their
to what it costs to maintain small steam failure details and related maintenance cost
turbines with their “as originally supplied” records. History provides the answer; it
FIGURE1 components. If available, readers can draw shows that entities that perform below par
Steam leakage surrounds this typical GP on their own in-plant experience and cost will not broadcast their poor performance to
(General Purpose) Steam Turbine tthe rest of the world. Similarly, the few who
sstand out and excel will claim Competitive
AUTHORS CORNER

HEINZ BLOCH’s professional career began in 1962 and included long-term assignments Advantage and are thus equally reluctant
A
as Exxon Chemical’s Regional Machinery Specialist for the United States. He has authored tto communicate useful details on how they
or co-written close to 700 publications, among them 20 comprehensive books on practical became Best-of-Class (BoC) performers.
b
machinery management, failure analysis, failure avoidance, compressors, steam turbines, TThis is why we are ready to offer our own
pumps, oil mist lubrication and practical lubrication for industry. experience-backed numbers.
Contact him at heinzpbloch@gmail.com.
Where savings come from
W
RICHARD SMITH is a product manager with international responsibilities for AESSEAL, M
Maintenance savings and steam turbine run
Inc., located in Rotherham, UK, and Rockford, Tenn. His 35-year experience is largely llength extension are in great part attributable
concentrated in the development of advanced sealing products for fluid machinery in the tto advanced bearing housing protection
petrochemical and petroleum refining industries. Contact him at Richard.Smith@aesseal.com. components, Figure 3. We have simplified
c
our study results by expressing savings in >
AUGUST-SEPTEMBER 2018 | COMPRESSORTECH2 | 51
TECH CORNER
TURBINES

different ways. Among these are time elapsed for benefits to equal
investment, often called “payback.” Another study examines the
benefit-to-cost ratio for advanced bearing protector components
that can be fitted to new and also to existing steam turbines. In
particular, plants will find it easy to pursue such retrofitting as
part of a structured plant-wide maintenance cost reduction and
equipment availability improvement program.
Working with a reasonably accurate total investment of
US$1500 per GP steam turbine (which includes installing protective
seals at the three locations identified in Figure 3), we often obtain
breakeven or payback within less than 6 months.
We found that, although usually aimed at preventing bearing
distress, upgrading to advanced bearing housing protector seals
also captures safety benefits. Steam turbine fires can result
from steam leaking into the bearing housing. As the steam then
condenses, some of the oil is forced out as leakage. Because the
upgrade prevents steam leaking into the bearing housing, the
imputed value of fire avoidance is a cost saving that deserves to
be included in cost justification calculations. Some closely-guarded
“company confidential”, albeit pessimistic, reports assume one
US$3 million fire per 200 repair interventions on small steam
turbines in low-performing oil refineries. True optimists assume one
High Performance Disc Coupling fire per 2000 distress or repair events—the number we will actually
use later.
• Scalloped profile disc pack optimized for A large corporation with 10 or 12 oil refineries may have a fleet of
high speed compressor applications 1600 small steam turbines installed. For an individual facility with
160 small steam turbines, 16 repair interventions per year would
• Cost reduced, economical solution for
today’s turbomachinery market represent an MTBF of 160/16 = 10 years, which is a slightly above
industry-average mean-time-between-failure.
• Fully compliant to API-671/ISO10441
• Disc material – 300 series stainless, Understanding and estimating the cost of current
Inconel option practices
• Coated or uncoated discs Before discussing cost savings achieved with advanced
• Phosphate coating standard on components bearing protection in GP steam turbines, recall that bearing
failure avoidance through the conscientious implementation of
• Shrouded fasteners for reduced windage
precautionary maintenance routines is possible, but will cost
• Optional fail-safe designs
money. “Saving” such monetary outlays by doing nothing will be
even more risky. “Doing nothing” causes frequent failures; it incurs
www.Ameridrives.com/CT high repair expenditures, reduces equipment unavailability and
causes safety incidents. We can be certain that “doing nothing”
neither enhances employee morale nor company image.
Scan to watch the Turboflex Plus High Not unexpectedly, a few facilities that report high steam
Performance Disc Couplings video turbine reliability have achieved low failure rates by spending more
money for preventive maintenance. Recall that lubricating oil is
contaminated by steam blowing past the carbon rings in the shaft
Visit us at the Turbomachinery & glands (Figure 2). The contaminated oil requires periodic discarding
Pump Symposium, Booth 2517 and must be replaced by fresh, clean, oil. As a precautionary
Sept. 18-20, 2018 in Houston, TX activity, water must be drained off in an effort to extend bearing
life and machine reliability. However, by the time free water collects
and is visible in a sampling line or sight glass, dissolved water
will exist and often cause additives depletion through a process
called partitioning. The additives partition themselves between
TECH CORNER
TURBINES

FIGURE3
Location and configurational details of a well-proven steam turbine
bearing housing protector seal. Note the large cross-section O-ring
which seals against a static seat if the shaft is stopped and provides
an axial micro-gap with shaft operating.

the oil and water phase in proportions that largely depend on their
relative solubilities. When free water is removed from the oil by
gravity, coalescing or centrifuging, these additives are lost. The loss
deprives the oil of the protection normally given by anti-rust and
anti-oxidant inhibitors. Moreover, water will combine with airborne
dust to form sludge.
Straightflo Innovation
It follows that scenarios whereby free water is periodically The revolutionary Straightflo™ valve is based on the
removed manually are technically inferior; merely draining off
free water is not found among the practices of reliability-focused
simple principle of moving gas from point A to point
Best-of-Class facilities. Sound water removal strategies involve B in the most efficient way possible. At the heart of
mechanical equipment and include vacuum dehydration,
coalescing, and air sparging. All of these strategies cost more
the every valve is the patented module design which
money than preventing water intrusion through the use of modern provides a direct flow path and more effective flow
bearing housing protector seals.
Taking into account the above, some facilities schedule and
area. The result is a high efficiency valve which
carry out monthly precautionary lubrication interventions. As a increases compressor performance,
result, labor costs are incurred to visit the machine for regular oil
sampling, oil replacement, and waste oil disposal. Corrective action
and your bottom line.
work orders are then required for the work activities to be initiated
and carried out. Disposal costs of US$ 4.00 (or more) are generally
associated with each gallon of contaminated oil. Writing and
processing a work order is typically assumed to cost US$400.
It goes without saying that high reliability is also essential for
machines in hot standby service, or serving as “cold” (blocked-
in, fully installed) spares. In all cases steam turbine repairs can
consume considerable workshop man-hours and associated
money outlays. To re-state the obvious: Taking chances by simply
doing nothing is a risky alternative to precautionary intervention; > WWW.ZAHROOFVALVES.COM
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the “Do Nothing” alternative is, therefore, with the requirements spelled out above in Throughout the world these seals
never considered by reliability-focused API-611, paragraph 6.10.4.2.1. are installed in a wide range of steam
and responsible Best-of-Class (BoC) users. Lubrication protection must be effective turbine sizes. The lube application details
Reliability-focused users are thus left with when the equipment is running and also in these machines often differ. Returns-
either a precautionary intervention option when it is not in operation. With low-cost on-investment can differ as well, as
that costs money over the life of the plant, and traditional labyrinth seals moisture comprehensive and detailed payback studies
or upgrade steps that are limited to the one- aspiration occurs while running and also will illustrate. We will therefore distinguish
time cost of bearing housing protector seals during the shut-down phase. The underlying between Situation “a” and Situation “b”.
with a demonstrated life that averages in basics are simple: As the equipment cools, Situation “a” is a non-pressurized splash
excess of 10 years. the surrounding ambient air is drawn into lubrication system, also described as a
That said, BoCs take note that the the bearing housing. In order to prevent turbine bearing housing with an oil sump.
component technology in current use has moisture ingress during this condition, Situation “b” exists if oil is continuously
changed little in 100 years. But a measure a vapor shut-off device is needed. This supplied to the bearing housing by a
of uniformity and reliability upgrading exist shut-off feature is overlooked in many OEM pressurized feed system, generally known
in certain industry standards. The machines (original equipment manufacturers’) labyrinth as a circulating oil system. This distinction
at issue are almost always purchased type seals. Figure 3 again helps to explain is worthy of emphasis by merely restating
by invoking the provisions of API-611, the how a thoroughly well-engineered bearing that payback periods will differ from as
American Petroleum Institute’s Standard housing seal prevents moisture ingress little as three weeks to perhaps twelve
for General Purpose Steam Turbines in the when the turbine is operating and also months. One study involved Situation “a” at
Petroleum, Chemical and Gas Industries. In when it is not operating. Temperature a world-scale facility in one of the Southern
this instance, clauses that apply to bearing resistance is achieved by using graphite United States. In this case study competent
housing seals are of interest to us. The foil secondary shaft seals; it should also reliability professionals published their actual
applicable API-611 standard states: be noted that several design options are experience and in-plant statistics. They
6.10.4.2.1 Bearing housings shall be available to fully accommodate the thermal included a bearing replacement event to
equipped with replaceable labyrinth-style growths encountered in larger multistage the tune of US$14,000 and a steam turbine
end seals and deflectors where the shaft GP, or even special purpose (SP) steam rebuild event costing US$35,000; both are
passes through the housing; lip-type seals turbines. meaningful numbers to keep in mind.
shall not be used. The seals and deflectors
shall be made of non-sparking materials. Return on investment for a Payback for non-pressurized oil
The design of the seals and deflectors shall conversion and upgrading splash or sump lubrication systems
effectively retain oil in the housing and program (Situation “a”)
prevent entry of steam, condensation and The advanced bearing housing protector Here we are dealing with oil sumps with
foreign material into the housing. upgrade should be incorporated into the capacities typically ranging from 1/2 to 11/2
6.10.4.2.1 (Option): <> If specified, bearing normal steam turbine maintenance cycle gallons. There is no provision for oil filtration
isolation seals providing a positive tight rather than a pre-planned removal cycle. and, to achieve an MTBR of 10 years with
seal to prevent the ingress of atmospheric Planned removal would make the upgrade only the traditional labyrinth seals, one
contaminants shall be supplied. project unnecessarily expensive. It’s again would probably opt for oil changes every
worth mentioning that the approximate total two months. Alternatively, after installing
The advantage of new investment required is a relatively negligible modern bearing housing protector seals
technologies US$1500 per turbine and that payback, as (Figure 3) one might reasonably change the
As was shown in the insert on Figure 3, indicated later in our sample comparison oil once per year or perhaps only once every
modern replaceable rotating labyrinth studies, are often as short as three or four three years.
devices are readily available that can be months. While not universally applicable to The vulnerabilities of allowing water and
installed in existing machines without every conceivable product make or design, solid contaminants to enter into bearing
bearing housing modifications. Unlike this payback is not unusual for steam turbine housings were mentioned earlier. In short,
traditional fixed labyrinths, rotating labyrinths bearing housing seals that incorporate the if atmospheric contaminants are allowed
use centrifugal force to expel potential specific design features shown earlier in to enter and long bearing life is desired
contaminants before they reach the oil. Figure 3. In the years leading up to 2017, nevertheless, the lube oil must be frequently
During periods of operational idleness hundreds of these protector seals have been replaced. Cleaning by any of the available
dynamic (axially moving) vapor-blocking operating flawlessly in GP steam turbines on-stream purification methods is highly
O-rings provide a secondary level of
protection and, therefore, full compliance
manufactured by Coppus, Dresser-Rand,
Elliott, Terry, and Worthington.
uneconomical on small sump sizes.
We use oils costing from US$8 per gallon. >
AUGUST-SEPTEMBER 2018 | COMPRESSORTECH2 | 55
TECH CORNER
TURBINES

(straight mineral oil) to US$36 per gallon. nor afford to “do nothing.” In essence, we (occurring every 10 years) and the total
(“synthetic” oil) and assume oil disposal to want to do everything that is reasonable outlay would amount to 60 times US$400=
cost US$4 per gallon. The key labor and oil and cost-effective to ward off the perils US$24,000—US$2400/yr.
contamination cost contributors that can be associated with run-to-failure decisions in
eliminated are given below, but the list could critical machines. Performance expectations for sump
probably be expanded. lubrication systems and advanced bearing
Performance expectations for sump housing protector seals:
Performance expectations for sump lubrication systems and labyrinth seals: Upgrading is done with a set of 3 advanced
lubrication systems and “doing nothing”: Pursuing a US$400-per-oil-change strategy bearing housing protector seals (US$1500
Frequent turbine outages and/or repair includes at least three elements: labor, the for the set) and thereafter changing the oil
events are inevitable if unacceptably high cost of new oil, and the disposal cost of only three times in 10 years. This schedule
oil contamination is invited or tolerated. To used oil. Using traditional labyrinth seals is of three oil changes per 10 years is presently
do nothing is simply unacceptable and, in thought to allow owners to opt for 6 lubricant being followed by a refinery in the UK after
a 10-year period, would probably require at replacements per year (at US$400/ event) conversion to advanced bearing housing
least three complete rebuilds at US$40,000 and to then reasonably expect a 10-year protector seals. In a 10-year period, this
per occurrence. That’s US$120,000, or MTBR for the GP steam turbine. With labyrinth refinery expects to pay three X US$400 =
US$12,000 per turbine per year. It follows seals there would thus be 60 lubricant US$1200 for oil changes. Their 10-year total
that a responsible plant can neither allow replacements between turbine overhauls will amount to US$1200+US$1500 = US$2700.
This is equal to US$270/yr. One way of
calculating the refinery’s payback ratio is
US$2400/US$270 = 9:1.

([SHULHQFH5HOLDELOLW\,QWHJULW\ Payback for pressurized oil feed


systems (Situation “b”)
Many background histories have confirmed
that, as long as steam and other atmospheric
contaminants are prevented from entering
bearing housings, lube oils can remain
serviceable in steam turbines for 10 years
and longer. With suitable on-stream
purification on reservoirs with more than
3000 gallon oil capacity, some U.S. utilities
have used the same charge of oil for 25
years. An ethylene plant in Texas used the
same charge of mineral oil for 14 years in two
large turbomachinery trains. The plant found
it convenient to replace the oil, although oil
analyses consistently certified this on-
stream purified oil in the “as new” condition.
Of course, our Situation “b” relates to much
smaller pressurized systems without on-
stream oil purification.
The vulnerabilities of allowing water
and contaminants to enter into bearing
housings were mentioned earlier. In short,
The AXH manufacturing complex consists of
if atmospheric contaminants are allowed
six plants, totaling 559,100 SF on 67 acres.
to enter and long bearing life is desired
nevertheless, then lube oil must either be
frequently replaced or the lube oil must
be kept clean by on-stream purification.
 )D[  ZZZD[KFRP While entirely feasible, oil changes and/
or on-stream purification incur the cost of

56 | COMPRESSORTECH2 | AUGUST-SEPTEMBER 2018


XH.indd 1 7/25/18 4:11 PM
TECH CORNER
TURBINES

maintenance labor or purification equipment bearing housing protector seals costs


or both.
In the absence of spending maintenance
US$1500 and will last at least 10 years;
the set costs US$1500/10 = US$150/year. Power Cylinder
money, the ultimate cost of reduced
equipment life and/or repair downtime-
For a simple payback calculation we add
US$150+US$1,320 = US$1470 and then Monitoring That’s
Just Right
related related monetary outlays must divide US$1470 by US$3960—less than
be considered. Much of this cost can be 5 months.
eliminated with the advanced bearing A similar calculation pertains to synthetic
housing sealing method described here oils. On a change-each-year-basis (which
and illustrated in Figure 3. Realistic cost might be practiced if serious contamination Easy to use and a nice price.
projections are given here, but readers are occurs), a charge of synthetic oil costs
encouraged to use whatever represents US$36/gallon times 330 gallon = US$11,880. TruTrace is a real-time,
their own local experience for labor and Disposal (at US$4/gallon) will cost US$1320. single-cylinder pressure
materials. A further distinction must be made Adding the two items yields US$13,200 and
monitoring system for
if a circulating oil system serves more than multiplying by 10 equates to US$132,000 over
one steam turbine, in which case a more a 10-year period. Again, assume spending engine balancing and
detailed analysis would be needed. In other US$1500 for a set of bearing protector seals basic combustion analysis.
words, our projected expenditures refer to a and planning three oil replacements in 10
single steam turbine with its own dedicated years. This would cost US$132,000/3 = • Pressure Monitoring
circulating system. US$44,000 in 10 years, or US$4400 per year. • Engine Balancing
Our set of bearing housing protector seals • Basic Combustion Analysis
Performance expectations for pressurized costs US$1500 and, because it will last at • Rugged PC-based platform
oil feed systems least 10 years, the set costs US$1500/10
• No reference signal input needed
We again assume a 330 gallon oil reservoir = US$150/year. For a simple payback
(per Figure D-1 in API-611, 5th Edition, 2008, calculation we look at incremental savings • View, record and play back
containing oils costing from US$8 per gal. by using a set of bearing housing protector real-time pressure-time traces
(straight mineral oil) to US$36 per gal. (3.85 seals: US$13,200-US$4400 = US$ 8800/ Kistler sensors used exclusively with TruTrace
L) of “synthetic” oil. Oil disposal is assumed to year. Our benefit-to-cost ratio is 8800/150 – a
cost US$ 4 per gal. rather staggering 58:1.
With conventional labyrinth seals in a Even a less optimistic alternative
steam turbine equipped with pressurized oil calculation is rather telling: If, for 330 gal
feed system, we could reasonably achieve a of US$36/gallon synthetic oil, we assume
10-year MTBR (mean-time-between-repairs), three precautionary oil change and disposal
but only if we opted for yearly precautionary intervals in 10 years; we will have spent
oil changes. Extending oil change intervals US$3564/yr. With a set of bearing protector
beyond one year would risk an increase in seals, our initial payback would be 1500/3564
costly unscheduled downtime events due to = 5 months.
unacceptable oil contamination. While we have purposely demonstrated
We are now contrasting steam turbines different ways of calculating returns on
with plain labyrinth seals versus steam investment, the results always confirm
turbines with the bearing housing protector that bearing housing protection seals make
seals in Figure 3. On a per-year basis, economic sense.
(mineral) oil costs US$8/gallon times 330
Comparisons re-visited and
gal = US$2640. Disposal (at US$4/gallon) will
cost US$1320. Adding the two items yields summarized TruTrace
US$3960 and multiplying by 10 equates to Any of several approaches can be used for Call or click to learn more.
US$39,600 over a 10-year period. But now comparisons and examination of payback.
assume spending US$1500 for a set of Suppose we view labyrinth seals and make Advanced Engine
bearing protector seals and thus extending six oil changes per year our basis. In that
Technologies Corporation
oil replacement to only 3 in 10 years. This case, our first-year outlay (per steam
www.aetco.com
would cost US$39,600/3 = US$13,200 in
10 years, or US$1320 per year. Our set of
turbine) with labyrinth seals in place
would be six times US$400 = US$2400. > info@aetco.com
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TECH CORNER
TURBINES

We could also say that our first-year outlay justification or scoping methods. Here, we 30 minutes and cost US$35 per intervention.
with the upgrade seals shown in Figure 3 again start by focusing on the basic labyrinth As we then assume 20 such water drain-
equals US$400 plus US$1500 = US$1900. The seal of years ago. We replace oil every two off events per year, we arrive at a cost of
first-year payback would be 1900/2400 = <10 months—six times per year, US$400 each US$700/year. Adding to this an oil change
months. time = US$2400. However, after retrofitting (oil at US$8/gallon) and a work order which
Perhaps we would also derive confidence a US$1500 set of modern 10-year life bearing costs US$400 to write and process will total
by looking at the incremental savings likely housing protector seals (per year cost roughly US$1100 per year. In contrast, the
realized by the UK refinery. We know that US$1500/10 = US$150/year) we would have three-year cost of a set of bearing housing
they installed many sets of modern bearing only a single oil replacement activity per protector seals is limited to US$1500 and
housing protector seals for US$1500/set year (US$400). As we add US$400+US$150, a US$400 oil change. The cost will be
and, over a three-year period, will have we find the per-year cost to equal US$550. US$1500+US$400 = US$1900/3 years, or
spent US$1500 plus US$500 for the single Therefore, our net savings per turbine per US$633/year. In this instance, we came up
oil change, including labor and synthetic year will amount to US$2400 - US$550 = with the lowest possible benefit-to-cost-
oil. They use replacement intervals of three US$1850. Upon completion of the project we ratio, approximately 2:1. However, we must
years and their three-year total would be can multiply this number by 160 to obtain look at the entire picture and make allowance
US$2000. Staying with labyrinth seals and the potential savings for our sample facility for the fact that the US$1100/year approach
aiming for the same reliability, this refinery which has 160 GP steam turbines. US$1850 allowed water to enter the bearing housing.
would have to replace a mineral oil six times times 160 = US$296,000. Now the cost–to-benefit-ratio will actually be
per year, or 18 times in three years. Their cost It’s good to also put a value on far more favorable that 2:1.
would then be 18 times US$400 = US$7200 reassigning freed-up technical talent to Finally, we chose to be optimistic when
per GP steam turbine per three years. other reliability improvement tasks. Making we earlier considered fire risk, on page
Calculating in this manner, our payback best use of their time and effort will extend 3. Assume that a plant might expect one
would be 2000/3 divided by 7200/3. This the uptime and profitability of an entire turbine-related fire per 2000 repairs or similar
would result in a payback of somewhere plant. Yearly direct savings approaching interventions; this would give an amortised
between three and four months. We could US$500,000 are obviously within reach fire cost of US$1500 per event. Suppose we
also calculate benefit-to-cost-ratios for once all conversions have been fully had 160 turbines and an MTBF of 10 years. In
similarly convincing and equally attractive implemented. that case, the risk is 1 in 125 years. We would
outcomes. We have also seen refineries that don’t obtain a per-year cost of US$3 million/125
One last comparison summary again change oil regularly; some of these send unit = US$24,000. If we use the “do nothing”
demonstrates the general validity of
many different cost assessment or cost
operators or “field persons” into the facility
to drain off water. This activity might take
approach and an MTBF of only three years
for a population of 160 turbines, the risk >
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TABLE 1
PHASED 10-YEAR STEAM TURBINE LABTECTA INVESTMENT PROGRAM FOR A REFINERY WITH 160 MACHINES
WITH INVESTMENT IN BEARING SAVINGS OVER CONVENTIONAL COST COMPARISON “DOING
HOUSING PROTECTION MAINTENANCE EFFORT, Dollars NOTHING” vs. BEARING PROTECTION
Column 11
Column 9 Cumulative
Column 8 Repairs/ Column 10 fire
Column 2 Column 4 Column 6 Cumulative yr US$, Fire loss avoidance
Column 1 M/Cs Column 3 All 16, Column 5 All 16, Column 7 savings for EACH US$ w / 10 / 3 credit 10 vs.
Year per year EACH M/C US$/year EACH M/C US$/year Payback 16 M/Cs, US$ machine. year MTBF 3 years, US$
Year 1 16 1500 24,000 1850 29,600 ~10 mo 29,600 12,000 24k/80k 56,000

Year 2 16 1500 24,000 1850 29,600 ~10 mo 59,200 12,000 24k/80k 112,000

Year 3 16 1500 24,000 1850 29,600 ~10 mo 88,800 12,000 24k/80k 168,000

Year 4 16 1500 24,000 1850 29,600 ~10 mo 118,400 12,000 24k/80k 224,000

Year 5 16 1500 24,000 1850 29,600 ~10 mo 148,000 12,000 24k/80k 280,000

Year 6 16 1500 24,000 1850 29,600 ~10 mo 177,600 12,000 24k/80k 336,000

Year 7 16 1500 24,000 1850 29,600 ~10 mo 207,200 12,000 24k/80k 392,000

Year 8 16 1500 24,000 1850 29,600 ~10 mo 236,800 12,000 24k/80k 448,000

Year 9 16 1500 24,000 1850 29,600 ~10 mo 266,400 12,000 24k/80k 504,000

Year 10 16 1500 24,000 1850 29,600 ~10 mo 296,000 12,000 24k/80k 560,000

TOTAL 160 240,000 296,000 120,000 240k/800k

■ Note that Table 1 is initially divided into the three groupings Investment, obtain the numbers in column 6 by multiplying the numbers in column 5 by 16
Savings, and Cost of Doing Nothing. The groupings are subdivided into a total (i.e., US$1850 X 16 = US$29,600)
of 11 columns containing numbers; we will again explain how we arrived at the COLUMN 8 lists the cumulative dollar savings for 16 machines; the numbers
various numbers. The Investment Group is first; it gives yearly expenditures in are obtained by adding a subsequent year’s savings to the sum of all savings
three of its four columns: realized in preceding years.
COLUMN 1 lists 10 consecutive years; each line in this column will reflect that The last three columns in Table 1 have the heading “doing nothing.” To do
we decided to convert 10% of our 160 turbine population-total each year. In nothing implies a run-to-failure (“RTF”) philosophy. For plants that process
other words, we upgrade 16 machines per year. flammable, toxic or explosive materials, RTF has been thoroughly discredited.
COLUMN 2 repeats (or merely re-states) that 10% of 160 equals 16 machines; Sadly, run to failure philosophies are still occasionally practiced by a few
these 16 are involved in the projected conversion/upgrading work in a given people who will never learn that steam turbine maintenance is far more
year. complex and important than properly maintaining children’s roller skates.
COLUMN 3 shows an outlay of US$1500 (our “Investment in Greater Reliability”) COLUMN 9 is the yearly per machine (M/C = machine) cost of “doing nothing”,
per set of 3 bearing housing protector seals installed in each turbine. i.e., running to failure. Failure would occur after 3 years of operation, at which
COLUMN 4 is obtained by multiplying column 2 times column 3 and the Dollars time it would cost US$36,000 to repair. The per-year portion shown in each
invested per year which, of course, equals US$24,000. The 10-year total of row is 1/3rd of US$36k = US$12,000 per machine
US$240,000 is shown in the last row of column 4. COLUMN 10 was devised to show the cost of steam turbine fires. We expect
Next, there are four columns in the segment labeled “Savings.” We can one fire per 2000 maintenance interventions. For an MTBF of 10 years and 160
demonstrate savings by using monthly and cumulative savings attributable steam turbines, 16 repair interventions will be experienced in each of these 10
to installing Advanced Bearing Housing Protector Seals versus continuing years. However, with an MTBF of only 3 years, there would be 53 repairs per
operation with leakage-allowing conventional labyrinth seals. Recall that our year. Yearly fire-related costs would be US$24,000 (24k) with an MTBF of 10
numbers relate to Situation “a”—which is more prevalent world-wide in small years and US$80,000 (80k) with an MTBF of merely three years.
GP steam turbines than Situation “b”. COLUMN 11 is obtained by observing, from column 9, the yearly fire losses in
COLUMN 5 shows yearly savings (per steam turbine) after performing the the 10-year MTBF and 3-year MTBF cases. The losses equal US$24,000 and
subtraction US$ 2400- US$550 = US$1850 US$80,000, respectively. The yearly difference is US$56,000. Each year,
COLUMN 6 gives the yearly savings for a total population of 160 machines. We another US$56,000 is added to the previous year’s figure.

60 | COMPRESSORTECH2 | AUGUST-SEPTEMBER 2018


TECH CORNER
TURBINES

is 1 in 37.5 years and US$3 million/37.5 = they were originally fitted with labyrinth “old technology” that makes the machines
US$80,000/yr. seals. Suppose the client’s or user’s either maintenance-intensive or, with
company now wanted to follow through with inadequate and deferred maintenance, more
Using a “Phased 10-year a phased upgrade/investment approach. In failure-prone than deemed acceptable by
investment” approach this phased approach we can readily see our risk-averse oil refineries.
Of all these and many other possibilities, yearly outlays and compare these upgrade These and related new technologies
we decided to elaborate on a phased investments to the resulting savings. are of interest to the risk-averse and are
investment approach and constructed We have reason to believe that Table 1 almost always cost-effective in reliability-
explanatory Table 1. We kept it relatively reflects generally accepted investments, focused oil refineries. Check into replacing
simple, letting financial experts aim for savings and costs. Savings exceed segmented carbon rings in small and
greater precision. But beware: While investments every year. medium-size steam turbine glands and
computer software programs exist that can Overall, we see that the population of consider installing vastly superior STS
do the work faster, we adhere to the belief general purpose (GP) steam turbines in High Temperature Mechanical Seals.
that common sense and experience might refineries is aging. In devising Table 1 and Although first tested and cost-justified
be just as valuable as placing seven digits electing to use Situation “a”, we took into in 1985, substantially improved versions
behind the decimal point. account that a majority of bearing frames in were recently introduced. These cartridge-
As an aid to visualization, we constructed these GP machines are still fitted with simple mounted High Temperature Mechanical Seals
Table 1, calling it a “Phased 10-Year Steam stationary labyrinth devices. Experience make extensive use of modern Dry-Running
Turbine Upgrade/Investment” approach. Our shows that these components are quite Compressor Gas Seal technology. They
numbers pertain to Situation “a”, where a ineffective in preventing moisture ingress should be actively considered as a highly
user has 160 steam turbines, all incorporating and contamination of the lube oil. In other effective means of lowering maintenance
small oil sumps. These turbines are aging; words, stationary labyrinth seals represent costs and extending steam turbine life. CT2

We are pleased to announce the addition of the


Power Division into the KHL portfolio...

MAYEKAWA LEGACY RECIPS


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AUGUST-SEPTEMBER 2018 | VOLUME 23 | ISSUE 7 www.compressortech2.com/subscribe www.dieselprogressinternational.com September 2018

Turbine Specs-At-A-Glance
New Power
Progress:
The Launch of
TurboTides www.newpowerprogress.com September 2018 | A KHL Publication

Early Caterpillar AUTONOMOUS


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2018 TURBINE SPECS

3000
2500
2000
2250

2750
1000

1500
1250

1750
450
400

500
350
300
250
200

750
100
150
50
0

Ansaldo Energia 80 to 538 MW


15 to 1000 MW

5 to 130.1 MW
Baker Hughes, 11.3 to 126.1
A GE Company 1 to 100 MW
5 to 135 MW

Capstone Turbine 0.03 to 30 MW

212 to 400 MW
Dongfang Turbine 0.5 to 1035 MW

0.05 to 100 MW
Elliott Group
0.05 to 50 MW

0.5 to 50 MW
Fincantieri 0.5 to 50 MW

GE Marine 4.6 to 52.7 MW


4.6 to 52.7 MW

24 to 145 MW
GE Power 24 to 557 MW
50 to 1900 MW

300 to 2600 MW
Harbin Turbine 25 to 1000 MW

Kawasaki 0 to 30 MW
1.5 to 30 MW

6 to 13 MW
MAN Diesel 6 to 13 MW
& Turbo 1 to 160 MW
1 to 160 MW

62 | COMPRESSORTECH2 | AUGUST-SEPTEMBER 2018


-AT-A-GLANCE
Gas turbine mechanical drive
Gas turbine electric generator drive
Steam turbine mechanical drive
Steam turbine electric generator drive

3000
2500
2000
2250

2750
1000

1500
1250

1750
450
400

500
350
300
250
200

750
100
150
50
0

54 to 115 MW
Mitsubishi Hitachi
28 to 470 MW
Power Systems
1 to 1400 MW
Nanjing Turbine
40 to 125 MW
& Electric
6 to 330 MW
Machinery

Niigata 0.3 to 7.8 MW


0.2 to 14.6 MW

NPO Saturn 4 to 16 MW
2.8 to 114.5 MW

Opra 1 to 2 MW

Power Machines 65 to 160 MW


0 to 1000 MW

5 to 62 MW
Siemens 2 to 567 MW
10 to 250 MW
0.01 to 1900 MW

Solar Turbines 1.2 to 23 MW


1.2 to 23 MW
Ural Turbine
30 to 335 MW
Works

Vericor 3 to 3.5 MW
3 to 3.5 MW

Zorya- 6 to 25 MW
Mashproekt 5 to 25 MW

AUGUST-SEPTEMBER 2018 | COMPRESSORTECH2 | 63


TURBOMACHINERY
TURBOTIDES

Turbomachinery design
software launched
TurboTides developed to
cover all steps in design
process

T
urboTides Inc. said its software
package developed to cover all steps
in the turbomachinery design process
is available to be licensed globally.
The TurboTides software package is a
unified design solution for turbomachinery
that includes all the necessary design
tools in a single software package and user 2-D throughflow and blade-to-blade analysis is used to get nearly immediate feedback on design
environment, according to the Lebanon, changes as the blade rows and other flow path elements for a single component, full stage or multiple
New Hampshire-based company. TurboTides stages are designed, according to TurboTides.
may be used to design centrifugal, mixed-
flow, and axial compressors, turbines as well the process itself. Built to handle single- the 3-D geometry, which the user may then
as several other applications, the company stage or multistage turbomachinery, optimize interactively or automatically. It is
said. TurboTides also offers an integrated TurboTides includes thermodynamic cycle at this stage that flow passage contours,
optimization capability that can be used at design and optimization capabilities that blade angle distributions, or blade thickness
each design step or may be span multiple can be combined with 1-D meanline distributions may be optimized based on the
steps at the same time. performance prediction to make important included 2-D blade-to-blade and throughflow
There are various turbomachinery design decisions. Meanwhile, the TurboTides simulation capabilities, the company said.
design models and methods for different Design Wizard incorporates application- The included optimizer can be used at this
types and applications, the company specific design rules that allow designers to stage, for example, to minimize blade loading.
said. TurboTides enables users to apply obtain a reasonable starting design in three From this step, a complete computational
different customizable design rules and simple steps, the company said. fluid dynamics (CFD) simulation can be
knowledge to different applications. done while a finite element analysis (FEA)
TurboTides said the package is designed Optimizer included calculation for stress, thermal, or vibration
to assist turbomachinery developers in When a meanline design has been finalized, analysis can also be completed.
optimizing not just the stage design but TurboTides provides a starting design for “TurboTides is not a collection of different
software programs that work together but
rather one software package that uses a
TurboTides, Flexware announce collaboration single, shared geometry model for every
TurboTides announced that Flexware Inc., turbomachinery consultants and the distributors of step of the design process,” said Dr. Xuwen
CompAero and TurbAero, will help promote the TurboTides integrated turbomachinery design Qiu, president of TurboTides Inc. and chief
software package to users of the CompAero and TurbAero software codes, which Flexware software architect for the TurboTides
Inc. acquired from Ron Aungier in 2014. software. “This ‘one-stop shop’ serves to
Flexware Inc. will continue to offer CompAero and TurbAero licenses to new and existing standardize the design process and facilitate
clients but will also make them aware of TurboTides if they require a more comprehensive faster design iterations, allowing diverse
solution. As part of the agreement, TurboTides Inc. will become a distributor for Flexware’s teams of designers to produce successful
Flex Live turbomachinery condition monitoring software. designs consistently while reducing overall
design cycle time.” CT2

AUGUST-SEPTEMBER 2018 | COMPRESSORTECH2 | 65


PRODUCT
FOCUS

Three energy forms,


MAN, ABB collaborate to create Electro-Thermal Energy The Electro-Thermal
Energy Storage
Storage (ETES) system. By Roberta Prandi (ETES) system
is able to store

M
AN Diesel & Turbo Schweiz AG and engineering, said MAN and ABB wanted a electricity, heat and
ABB Switzerland are collaborating system that went beyond basic energy cold at the same
on a new three-way energy storage storage. time and distribute
system. The pair signed a cooperation “This is not just a storage system, but an them to different
agreement to develop, produce and energy management system,” he said. “We consumers.
commercialize the Electro-Thermal Energy realized early enough that having a system
Storage system (ETES), which is designed only able to store electricity would have and 2030.5 psi [140 bar]),”
to storage massive quantities of electricity, hardly been commercially viable – at least not Jacquemoud said. “The
heat and cold for customer distribution. in those areas where the price of electricity CO2 is then fed into a
“ETES is the only storage system able to is on the low side. Thus we decided to stop high performing heat
store electricity, heat and cold at the same thinking only in terms of electricity-in and exchanger and heats the
time and also distribute them to consumers, electricity-out and expand the concept to storage medium – water
which makes it unique,” said MAN Energy heat and cold as well.” – which is then stored in
Solutions Schweiz AG‘s Managing Director tanks.”
Hans Gut. Storing energy After the heat transfer
Turbomachinery technology and Technical Project Manager Emmanuel ends, the CO2, which is still at high
thermodynamic cycles are at the core of the Jacquemoud said the ETES can store energy pressure, passes into an expander to lower
system. As dictated by the agreement, MAN from any source, but it is optimized for the pressure, which liquefies and cools
will supply the complete system for the ETES, renewable sources as it can balance their the substance. This cold energy is then
including an HOFIM compressor, an oil-free fluctuating nature. The system is based on transferred through another heat exchanger
barrel type compressor with integrated high- the thermal storage of energy and works to the cold storage side, where water is
speed induction motor, and active magnetic with two basic processes: charging and frozen to 32°F (0°C) and stored in a tank in
bearings. discharging. the form of ice.
ABB will provide its expertise on the “Charging is a typical heat-pump process, Jacquemoud said the hot water on the
electrical side, with the power transmission in which surplus electricity is taken from the heat side can be maintained for several days.
from the grid into the system and the grid to power the oil-free HOFIM compressor “The discharging process actually works
reverse process. MAN will manage the and is there turned into thermal energy by the same way, with thermal energy brought
commercialization of the system. compressing CO2 to its supercritical liquid back into the system, this time not into
The ETES is location independent
dependent and state (typically about 212/248
212/248°FF [100/120
[100/120°C]
C] the compressor but into an e electrically-
able to fit in to a variety off applications. For driven liquid pump,” Jacquem
Jacquemoud said. “The
example, the system could ld provide heat for gaseous CO2 is brought throu
through another heat
the food-processing industry stry or laundry exchanger and condensed thanks th to the
facilities, and cold for data a centers or air cold from the ice tank. The liquid
conditioning for multi-level el pump then increases
incre the CO2
buildings, according to MAN. AN. pressure and feeds
fee it into the
Patrick Meli, MAN Energy gy heat exchanger to be heated
Solutions’ vice president, up again by the h hot water in the
head of compressor hot-side tanks.
tank This thermal
energy can beb fed into a
At the core of the ETES system
em power turbine to generate
is a hermetically-sealed, electricity for the grid
again electrici
ssor.
oil-free HOFIM turbo compressor. supply.
“To complete the
th loop, the

66 | COMPRESSORTECH2 | AUGUST-SEPTEMBER
GUST-SEPTEMBER 2018
PRODUCT
FOCUS

one roof heated CO2 is condensed into its liquid form


The ETES creates an interesting
opportunity for data centers, especially when
most of them are popping up in urban areas,
Meli said.
“Data centers are currently responsible
for 3% of the global CO2 emissions and,
at low temperature and low pressure, so that being located into the cities, they are under
it is ready for another cycle,” he said. a lot of pressure to reduce their emissions
and become CO2 neutral,” he said. “In the
Looking ahead application case of data centers, ETES
The ideal size for the ETES system makes it possible for the customer to get
is about 5 to 15 MW electrical power, rid of engine-powered gen-sets but to keep
Jacquemoud said. The system has a five batteries to guarantee the fast reaction times
times higher energy density compared to for a reliable, uninterrupted power supply.
a conventional steam turbine. The system “In the case of data centers, the system
is also modular and flexible, allowing for can be made more profitable by adopting the
adjustments to fit the customer’s needs. For three-way energy storage and deliver heat to
example, a customer could request an ETES external customers,” Meli said.
system with larger tanks, he said. Asia and Europe are the primary markets
The ETES is optimized for three energy for ETES. MAN Energy Solutions expects to sell
outputs, but can be used in data centers, the first ETES application within 24 months,
which require two outputs for electricity and with MAN associates already discussing the
cold, Jacquemoud said. first project. CT2

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t: 1-800-55-ROOTS (76687) e: compressors@howden.com & Pump Symposia
Houston, TX; Booth 1527
September 18 - 20 © Howden Group Ltd. All rights reserved. 2017
INDUSTRY
NEWS

Siemens hits
100th recip
compressor
milestone Permian Basin customer nabs 11 HOS

S
iemen’s Dresser-Rand business has sold its 100th reciprocating compressors for gas processing operation
compressor to a midstream operator. The operator ordered
11 heavy oilfield separable (HOS) compressors, which will be
used for gas gathering in the Permian Basin. Since 2012, the operator applications, including gas lift, gas gathering, pipeline boosting, gas
has purchased 106 high-speed reciprocating compressors from transmission, underground gas storage (injection and withdrawal),
Dresser-Rand. fuel gas boosting, and landfill gas among other applications. These
The compressors will be installed near a gathering system that compressors are suited for sweet natural gas services, as well as
has 4500 miles (7242 km) of natural gas gathering pipelines that sour natural gas, propane, carbon dioxide, air, nitrogen, and most
span across nine counties within the Permian Basin in West Texas. other gases.
The gathering system has a processing capacity of 875 MMcfd (24.7 It is rated to 7200 hp (5370 kW) at 1500 rpm with design pressures
X 106 m3/d). Two of the 11 HOS compressors will be used in two new up to and exceeding 6600 psig (455.1 bar). HOS compressors are
250 MMcfd (7.1 X 106 m3/d) plants, which will begin operating in 2019. available in two-, four- or six-throw configurations and in cylinder sizes
The HOS compressor is engineered for higher horsepower ranging from 3.75 in. (95.3 mm) to 26.5 in. (673.1 mm). CT2
COMPRESSED NEWS

■ Dover Corp. has formed Dover Precision bearings and seals. machinability due to the addition of silicon,
Components, a provider of performance- These brands were originally brought the company said.
critical solutions for rotating and together in November 2015 to broaden Solution Strengthened Ductile Iron is a
reciprocating machinery. Brands included product offerings, expand global resources metallurgical term that has been adopted
in the renamed operating company are and apply operational efficiencies to better by the producers of ductile iron and is
Cook Compression, which delivers custom- serve customers in the energy and industrial gaining increased interest from numerous
engineered valves, sealing technologies, markets. Since then, synergies between customers for a variety of applications.
pistons and rods, as well as repair and the brands have extended engineering and SSDI, from Dura-Bar, has a minimum
reconditioning services and advanced materials expertise, opened new avenues tensile strength of 75,000 psi (5171 bar),
technical support, for reciprocating for innovation, promoted best practices in a minimum yield strength of 55,000 psi
compressors; Inpro/Seal, which designs and manufacturing, and advanced quality and (3792 bar) and a minimum elongation
manufactures bearing protection and shaft continuous improvement efforts. of 15%. SSDI also boasts a tightened
seals designed to increase the reliability of Brinell Hardness (BHN) for consistency
rotating equipment; Waukesha Bearings, ■ Dura-Bar announces the availability throughout the material compared to other
which does engineered hydrodynamic of a new ductile iron grade—Solution similar ductile iron alloys.
fluid film bearings and brush seals for high- Strengthened Ductile Iron or SSDI. SSDI is designed for rotors used in air
performing turbomachinery and, under With improved strength and ductility, the and natural gas compressors as well as
the Waukesha Magnetic Bearings brand, company said SSDI is an excellent alternative hydraulic manifolds and cylinders used
produces active magnetic bearing systems; to 1045 steel used in a wide variety of oil in fluid power applications. It can also be
and Bearings Plus, which specializes in the and gas and fluid power applications. One used in oil and gas applications such as
repair, replacement, and upgrade of fluid film of the key features of SSDI is the enhanced plug valve inserts and crossheads.

68 | COMPRESSORTECH2 | AUGUST-SEPTEMBER 2018


INDUSTRY
NEWS

Monico brings

PEOPLE NEWS
■ Epic International has named
JJohn Sargent the company’s
mCore to market nnew chief executive officer
effective immediately. In
ef
Monico has introduced mCore, a condition this role, Sargent will lead Epic’s
monitoring platform that also serves as a global growth initiatives for both the
protocol translator and edge device gateway. reciprocating and centrifugal compressor
mCore is designed for remote monitoring, aftermarket businesses.
telematics and edge analytics for heavy Sargent has more than 24 years of
industrial mobile applications. domestic and international experience in
Monico said it made cybersecurity a key the compressor industry. Most recently, he
focal point of the mCore, which contains served as vice president of Energy for Epic
high assurance boot (HAB), serialized X.509 and previously spent the two decades in
certificates for bi-directional authentication various sales and operations roles with
and other forms of hardware encryption. El Paso Corp., Cameron International and
mCore also incorporates a quad core 1 Spitzer Industries.
GHz processor, with each core containing
one Neon math co-processor with the ■ Hicor Technologies, a
capability of handling 1.8 billion floating compression technology
c
point calculations per second. Together, the company, has appointed Rob
c
processor can handle 7 billion calculations Perry as its chief executive
Pe
per second. officer. Perry spent the past eight
offic
The device can withstand years in two different roles at TechnipFMC;
high-vibration and high- global systems engineering director
shock environments. Its and global director of subsea
Freudenberg Filtration Technologies has enclosure is IP66/IP67 processing. Before that, he spent
overhauled its website to make it easier rated and is dust and water more than 22 years at BP in a variety
to navigate. The new homepage, www. resistant, the company said. of technical and commercial roles, his
freudenberg-filter.com, was revamped for user According to Monico, latest as vice president of deepwater
optimization, clear navigational solutions and subsequent versions of the ffacilities technology. He also led BP’s
customized content to the user. device are planned for the research and development division.
re
future. CT2
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AUGUST-SEPTEMBER 2018 | VOLUME 23 | ISSUE 7 www.compressortech2.com/subscribe
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1 CT2 08-092018 Front Cover_DJ.indd 1 17/08/2018 09:56:42


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WHAT IS YOUR COMPANIES PRIMARY BUSINESS?


74  Natural Gas Productions 54  Distributing, Servicing & Overhauling Engines OTHER
77  Gas Gathering Company & Compressors 99  Other: Please Explain
70  Natural Gas Process Plant Operations 63  Manufacturing Compressors
72  Gas Transmission Pipeline Compressor 65  Manufacturing or Packaging
Operations Compression Sets & Systems
75  Natural Gas Storage Company 40  Manufacturing Motors, Natural Gas (LNG) or
Dual-Fuel Engines
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76  Refinery Operations Engines and Gas Expanders
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INDUSTRY
NEWS

Caliche expands NGL storage

MEDIA NEWS
■ The Cryobox Nano
LNG-Station from Galileo
Caliche Development Partners, a Houston, The expansion will include a new five- Natural Gas Technologies
Texas-based company focused on the million-barrel cavern for ethane storage, with is designed to enable
development, construction, and operation of up to 120 000 barrels per day of deliverability, customers to become their
subsurface hydrocarbon storage assets and as well as a 12 mile (19.3 km) ethane header own producer of liquefied natural gas (LNG).
related pipelines in North America, plans to mirroring the path of Caliche’s existing www.galileoar.com
expand its natural gas liquids (NGL) salt dome ethylene system. This header will cross five
cavern storage facility in Beaumont, Texas. ethane pipelines connecting more than 50% ■ Edge said its Gas 3.0
of Gulf Coast ethane consumption with the Solutions offers low-cost
Mont Belvieu NGL complex. Caliche said it and lean energy from
expects its previously announced ethylene regional stranded shale gas.
cavern to be fully subscribed by its Sept. 30 www.edgelng.com
in-service date and continues to respond
to customer interest regarding additional Energoflow AG is a Swiss
cavern development. company specializing in
When fully developed, Caliche’s Coastal flow metering solutions and
Caverns storage facility could provide up to related products.
32 million barrels of purpose-built, salt cavern www.enerflow.com
storage facilities. CT2

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AUGUST-SEPTEMBER 2018 | COMPRESSORTECH2 | 71


47TH TURBOMACHINERY & 33 RD PUMP SYMPOSIA
Petrochemical | Oil Refining | Oil & Gas Production | Utility | Power | Aerospace | Related Industries

Symposia & Exhibition: George R. Brown Convention Center Short Courses:


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CORNERSTONES
OF COMPRESSION

Early Caterpillar
natural gas engines
Diesel engine development became
e
gateway to prime movers for
emerging natural gas applications.
Norm Shade reports.

C
aterpillar has a reputation for its
earth-moving equipment and other
construction machinery, but it also Early Caterpillar gas engines were conversions of diesel models. The gas conversion components for
specializes in natural gas engines used for the D13000 engine are shown in yellow on the left side [left] and right side [right] of the engine.
driving gas compressors. The history of this
development began more than 130 years ago.
Caterpillar’s roots date to 1886 when powered tractor, which a photographer noted Caterpillar engine, a 45 hp (34 kW), 550
Benjamin Holt began building combined “crawls along like a caterpillar.” rpm four-cylinder gasoline engine for his
harvester threshers in Stockton, California. C.L. Best, son of the founder, was track-type tractors. Gasoline engines offered
In 1890, he began building steam-powered displeased with the new Holt arrangement. more power per pound than his steam
tractors, incorporating as the Holt He formed the C.L. Best Gas Traction Co. units. A 75 hp (56 kW) unit followed. The
Manufacturing Co. in 1892. in 1910, manufacturing gasoline-powered first two decades of the 20th century found
Meanwhile, Best Manufacturing Co., tractors including track-type. Both companies both tractor manufacturers using the new
launched in 1871 by Daniel Best, was also enjoyed great success supplying tractors gasoline- and kerosene-fueled power plants.
producing steam-powered tractors and for World War I, but a post-war depression The Caterpillar diesel engine didn’t appear
combines in San Leandro, California by and a price war that included Henry Ford’s overnight. It was the culmination of years of
the 1890s. Fierce competition led to legal Fordson tractor threatened the survival of research and testing, with an element of risk.
battles that Holt won in 1908, with Holt both companies. To endure, Holt and C.L. Best There were those who thought it foolish to
acquiring the Best brand. After moving to East merged their companies in 1925 to form the pour money into technology that, at the time,
Peoria, Illinois, in 1909, Holt Manufacturing Caterpillar Tractor Co. was considered “exotic.” Early diesel engines
Co. registered the “Caterpillar” trademark. were slow speed and extremely heavy in
The name originated in 1904, when Holt The genesis of Cat engines relation to the power they produced. Until the
introduced the first track-type steam The start of Caterpillar engines actually 1920s, diesels were used almost exclusively
began in the late 1800s when Daniel Best in stationary and marine applications. Henry
EDITOR’S NOTE This is the first part of a and Benjamin Holt were experimenting with Kaiser, of Kaiser Industries fame, installed
four-part series on the history of Caterpillar various forms of steam tractors used for Atlas Imperial stationary diesel engines in two
natural gas engines. farming. In 1906, Holt introduced the Holt existing Caterpillar 60 tractors, but the units >

1886 1892 1908 1909 1910 1925


Benjamin Holt begins Incorporated as the After legal battles, Holt Manufacturing C.L. Best Gas Traction Holt and C.L. Best
building combined Holt Manufacturing Holt acquires Co. registered Co. formed by son of merge companies to
harvester threshers in Co. building steam- competitor Best the “Caterpillar” the founder of Best form the Caterpillar
Stockton, California powered tractors Manufacturing Co. trademark Manufacturing Co. Tractor Co.

AUGUST-SEPTEMBER 2018 | COMPRESSORTECH2 | 73


CORNERSTONES
OF COMPRESSION

revolutionized the industry. The four-cycle brochure refers to factory gas engine
D9900 was the first diesel engine with an conversions being offered. Five 1600 rpm
air filter, and the fuel system was designed models, rated from 25 to 54 hp (19 to 40 kW),
to be non-adjustable so no one could try were listed with a factory natural gas option
to “improve” it themselves. The engine by swapping out the pistons.
used a precombustion chamber, because
standard diesel fuel was not yet available. The A wide engine portfolio
An early spark-ignited natural gas version of a petroleum industry sold a variety of various The 1943 Diesel Engine Catalogue indicated
Caterpillar D13000 engine is shown belt-driving octane distillates that were a jumble of that eight sizes of industrial diesel engines
an oil-field plunger pump. The 1000 rpm six- compositions. Operators were forced to use ranging from 34 to 190 hp (24 to 142 kW)
cylinder engine had a continuous power rating whatever was available. were then manufactured by the Caterpillar
of 104 hp (78 kw) and an intermittent rating of The first prototype, nicknamed “Old Tractor Co. It also said that Caterpillar engines
130 hp (97 kW). Betsy”, is on display at the Smithsonian in were available in six sizes to burn natural
Washington, D.C. Four hand-built D9900 gas. The two largest – the 1000 rpm D13000
engines were produced that first year. Full and D17000 – were conversions of diesel
proved too heavy for mobile operations. scale production started in 1932, thrusting engines with continuous ratings of 104 (78
At the beginning of 1928, C. L. Best Caterpillar into the diesel engine business. kW) and 180 (134 kW) hp, respectively. With
approached an outside consulting engineer, New 5.75 in. (146 mm) bore x 8 in. (203 the field conversion kits (heads, magneto and
C.G.A. Rosen, to investigate equipping a mm) stroke diesel engines entered production carburetor), the article said that one of these
production Caterpillar 60 tractor with diesel in 1932: the D6600, D8800 and D13000 with diesels could be converted to natural gas in
power. Rosen looked over other diesel engine three, four, and six cylinders, respectively. about five hours without having to change
designs – Atlas, Buda, Benz and Coho – for Within a few more years, Caterpillar had the pistons.
over a year, but in the final analysis, it was only moving assembly line for diesels and Four sizes of standard 1600 or 1650 rpm
determined that Caterpillar itself could design was among the world’s largest diesel engine natural gas engines were introduced in 1940.
and produce the required unit in-house. producers. In 1935, the D17000 V-8, the first The 800G was a 5.5 hp (4 kW) single-cylinder
Preliminary engineering and design work was Caterpillar diesel not designed for tractor use, model. The 34 hp (25 kW) 3400G was a four-
finalized in January 1930, with the first engine was introduced. Rated at 160 hp (119 kW), 850 cylinder 3.625 x 5 in. (92 x 127 mm) model.
test complete by October 1931, the same time rpm and weighing 7600 lb. (3447 kg), it was The four-cylinder 4400G and six-cylinder
when Caterpillar introduced the D9900. More so successful that it remained in production 4600G were 4.25 in. (108 mm) bore x 5.5 in.
than US$1 million was invested in the project, for 20 years. (140 mm) stroke models rated at 50 and 75 hp
a tremendous sum in those early years of the The diesel line continued to grow to (37 and 56 kW), respectively. These early gas
Great Depression. At the same time, Caterpillar include engines for trucks and all kinds of engines were used for salt water injection,
changed the standard paint color of its industrial applications. Although the date irrigation, cotton gins, and power generation,
machines from gray to the legendary “Hi- of the first Caterpillar natural gas engine with a few also packaged with straight-line
Way Yellow” with black trim. This paint color production is uncertain, an early 1930s reciprocating gas compressors. CT2
prevailed until 1979 when it was replaced with
“Caterpillar Yellow.” Image of the Caterpillar 1600 rpm, 4.25 in. (108
mm) bore x 5.5 in. (140 mm) stroke 4600G from
Rise of the D9900 the 1943 Diesel Engine Catalogue. The 75 hp
The four-cylinder, 6.125 in. (156 mm) (56 kW) six-cylinder 4600G and 50 hp (37 kW)
bore x 9.25 in. (235 mm) stroke D9900 four-cylinder 4400G were among the earliest
weighed 5175 lb. (2347 kg) and produced Caterpillar natural gas engines that were not
87 hp (66 kW) at 700 rpm. Mounted in the simply converted diesel models.
Caterpillar 60 tractor, this engine quickly

1928 1930 1931 1932 1935 1943


C.G.A. Rosen assigned Preliminary First engine test – the Full scale production D17000 V-8, the first Eight sizes of
to equip a production engineering and prototype “Old Betsy” thrusts Caterpillar Caterpillar diesel not industrial diesel
Caterpillar 60 tractor design work finalized – is completed in into the diesel engine designed for tractor engines being
with diesel power in January 1930 October 1931 business use, is introduced manufactured

74 | COMPRESSORTECH2 | AUGUST-SEPTEMBER 2018


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