Compressor Tech2 May2016

8/17/2019 Compressor Tech2 May2016

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n Customer: Vertically integrated global

petrochemical company, Texas.

n Challenge: Build a world-scale olefin plant to

process plentiful, low-cost shale gas.

n Result: Three trains of reliable, efficient

Elliott steam turbines and compressorsensure the customer’s competitive

advantage in world markets.

They turned to Elliottfor a long-term partnership and long-term service.

World-scale olefin processors turn to Elliott for steam turbines and compressorsthat deliver unmatched reliability, efficiency and value over the life of their investment.Who will you turn to?

C O M P R E S S O R S n T U R B I N E S n G L O B A L S E R V I C E

www.elliott-turbo.com

The world turns to Elliott.


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Featured Articles

12 GE Completes Metem Acquisition

14 Test Facilities Improve Compressor Reliability, Performance Predictability

24 Active Magnetic Bearing System For Large Machines

30 GE Tested, REP Approved

34 RMS Expands Its Footprint

42 Analysis: Valve Performance On Booster Primary Compressor For LDPE

48 Inlet Cooling For Gas Turbines Driving Gas-Gathering Compressors

Departments

4 Page 4 — Australia Leads The LNG Export Race

6 Global Perspective — Emerging Markets Eye LNG

8 About The Business — Domestic Oil & Gas Downturn Continues

While Political Stances Threaten Its Survival

10 Events & Meetings

26 Featured Products

41 Literature

46 Prime Movers

52 Scheduled Downtime

53 Marketplace

54 Advertisers’ Index

56 Cornerstones Of Compression — Sullair Rotary Screw Compressors

May 2016

COMPRESSORtech 2 is the premier resource for gas compression news and information.

Cover Designed By

Alyssa Loope

COMPRESSORtech 2 ( ISSN 1085-2468)

Volume 21, No. 4 — Published 10 issues/yearJanuary-February, March, April, May, June,uly, August-September, October, November,

December) by Diesel & Gas Turbine Publications,0855 Watertown Road, Waukesha, WI 53186-873, USA Subscription rates are $85.00 perear/$10.00 per copy worldwide. Periodicalsostage paid at Waukesha, WI 53186 and at addi-onal mailing offices. Copyright © 2016 Diesel &

Gas Turbine Publications. All Rights Reserved.Materials protected by U.S. and internationalopyright laws and treaties. Unauthorized dupli-ation and publication is expressly prohibited.rinted in the USA.

Canadian Publication Mail Agreement # 40035419.

Return Undeliverable Canadian Addresses to:

.O. Box 456, Niagara Falls, ON L2E 6V2, Canada.

mail: [email protected]. POSTMASTER:

end address changes to: Circulation Manager,

COMPRESSORtech2, 20855 Watertown Road, Suite

20, Waukesha, WI 53186-1873 USA.

www.compressortech2.com

ollow @COMPRESSORtech2 on:

MEMBER OF …


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NEUMAN & ESSERAmérica do Sul LtdaLocated in Belo Horizonte, Brazilwww.neuman-esser.com

Contact me for Central and South America:

Marcos RihanSales [email protected] line: +55 (31) 2126-9503

NEA GROUP Headquarters in Germany

THINK GERMAN,ACT LOCAL.LOOKING FOR AN ALL-IN-ONECOMPRESSION PROVIDER?

OVER 30 YEARS OF EXPERIENCE IN BRAZIL -FROM CONCEPT TO SERVICE, ANY APPLICATION.

NEUMAN & ESSER América do Sul is the expert forany compression needs in Central and South America.Located in Brazil, NEA's team works as the single-contactprovider for: Sales, Engineering, Packaging and Service.This includes care for the entire reciprocating compressorsystem - from the initial drawings to complete life-cycleservice. Hydrogen, technical and natural gases, LNG, airand more, we are here to serve you.

COMPRESSORSYSTEMS


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Page4CT2 Founder .......................... Joseph M. Kane

PUBLICATION STAFFAssociate Publisher ...................Mark Thayer

Associate Publisher ..............Roberto Chellini

Senior Editor ................................... DJ Slater

Senior Editor ................. Michael J. Brezonick

Associate Editor ...............................Jack Burke

Associate Editor ............................Chad Elmore

Associate Editor ...................................Art Aiello

Copy Editor ............................... Jerry Karpowicz

Digital Content Manager ...............Catrina Carne

Advertising Manager .................. Katie Bivens

Circulation Manager ............. Margaret Pieper

Production Manager ................Marisa Roberts

Graphic Artist ...........................Brenda Burbach

Graphic Artist .................................Carla Lemke

Graphic Artist ...............................Alyssa Loope

PUBLICATION HEADQUARTERS

20855 Watertown Road, Suite 220

Waukesha, Wisconsin 53186-1873

Telephone: (262) 754-4100 Fax: (262) 754-4175

CONTRIBUTING EDITORS

Norm Shade – Cambridge, Ohio

Mauro Belo Schneider – Rio Grande du Sul, Brazil

HOUSTON, USA

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12777 Jones Road, Suite 225

Houston, Texas 77070

Telephone: (281) 890-5310

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73760 Ostfildern, Germany

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40 Premier Avenue

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DIESEL & GAS TURBINE PUBLICATIONSPresident & CEO ....................Michael J. Osenga

Executive Vice President ....Michael J. Brezonick

COMPRESSORA Member of the Diesel & Gas Turbine Publications Group

Australia Leads TheLNG Export Race

The country that introduced latex

gloves, vegemite and Crocodile

Dundee is now home to one

the largest LNG projects in the world.

Australia’s Gorgon project, located on

Barrow Island off the coast of north-

western Australia, shipped its first

cargo this spring, strengthening the

lead of the Land Down Under in the

global LNG export race.The U.S. made headlines in February

when Cheniere Energy dispatched the

first shipment of LNG from its facility

at Sabine Pass, Louisiana, bound for

Brazil. But the sheer size and scope

of the Gorgon Project quickly negated

any strides gained by Sabine Pass.

The Gorgon project includes a do-

mestic natural gas plant, a carbon

dioxide injection project and an LNG

export facility. Its three liquefaction

trains have a combined capacity of2.1 Bcfd (59 x 106 m3 /d). The first train

was commissioned in March, with

the second and third trains to follow

at six- to nine-month intervals. The

Gorgon project, taking more than six

years to develop at a cost of US$54

billion, is the world’s most expensive

LNG project to date.

Ultimately, Asia is the LNG prize.

The U.S. will benefit from the US$5.3

billion Panama Canal expansion set

to open this year, cutting costs andtravel time from the U.S. Gulf Coast to

Asia by 11 days (See November 2014

CT, LNG Vessels Will Run Through It ,

p. 38). But the infrastructure required

to meet Asia’s thirst for LNG is lacking

in the U.S.

Including the first train from Gorgon,

Australia’s LNG export capacity current-

ly stands at 6.2 Bcfd (157 x 106 m3 /d).

If the additional LNG capacity currently

under development is fully operational

as planned by 2019, the country’s LNG

exports capacity would likely increase

to the largest in the world, at 11.5 Bcfd

(325 x 106 m3 /d), equivalent of one-third

of global LNG trade in 2014.

Three projects in eastern Australia

have been fully or partially commis-

sioned since 2014. Queensland Curtis

commissioned its two trains in 2014-

15, Gladstone commissioned its first

train in October 2015 and AustraliaPacific sent its first cargo in January

of this year. All three projects process

coal bed methane into LNG and have

a current combined capacity of 2.3 Bcfd

(65 x 106 m3 /d). Once fully completed,

they will have a combined capacity of

3.4 Bcfd (96 x 106 m3 /d).

Gorgon LNG is the first of the four

new projects off the northern coast of

Western Australia to be partially com-

missioned. Three other projects in the

northwest — Prelude, Wheatstone andIchthys — are still under construction.

These three projects have a combined

capacity of 2.8 Bcfd (79 x 106 m3 /d)

and are expected to come online be-

tween 2016 and 2018.

Most new Australian liquefaction

capacity is already contracted on a

long-term basis to countries in the Asia

Pacific region. Among destinations for

Australian LNG, Japan accounts for the

largest share of contracted liquefaction

output, with contracts for 79% of outputfrom the existing liquefaction projects

(in operation prior to 2014) and 35%

from the new projects, according to the

U.S. Energy Information Administration

(EIA). China is the second-largest des-

tination, with 15% of contracted LNG

from the existing liquefaction projects

and 23% from the new projects.

The U.S., mired in red tape and fa-

cility delays, is quickly losing ground

to Australia in the race to become a

global LNG supplier. CT2


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8/60MAY 2016 6 COMPRESSORtech2

Proliferation of innovative and cost-competitive lique-

fied natural gas (LNG) terminal solutions within the

Asia-Pacific region will facilitate more-efficient LNG

deliveries to its emerging markets. Many of those markets

are forecast to see substantial growth in LNG import re-

quirements over the coming years.

Singapore’s marine and offshore engineering firm SembCorp

Marine has increased its stake in near-shore LNG terminal

specialist Gravifloat AS to 56%, or US$27.5 million. In ad-

dition, it secured the right to raise its share by an additional

44% to take full ownership through an equity purchase atthe same price.

The acquisition places SembCorp in a good position to

capitalize on the growing need for flexible LNG solutions

in the Asia-Pacific region. Many of the emerging markets

are projected to see considerable growth in gas demand

and have proposed plans to increase LNG imports over the

coming years.

Nontraditional LNG import markets in Asia — such as

Bangladesh, Myanmar, Pakistan, the Philippines, Thailand

and Vietnam — could add in excess of 15 new LNG re-

gasification facilities, or at least 1.3 Tcf (36.8 x 109 m3) of an-

nual import capacity. Weak LNG prices for at least the nextfive years and robust demand for gas will support long-term

investments in LNG, which in turn will create opportunities

for suppliers to sell into these markets. Given that many of

these projects are either in the proposed phase or pend-

ing final investment decision, BMI Research (BMI) believes

there are opportunities for Gravifloat to offer a cost-efficient

alternative to procuring LNG.

Gravifloat’s near-shore terminal can be situated at water

depths as shallow as 50 to 65 ft. (15 to 20 m), and be

constructed in two to three years. The design utilizes a

modular concept, which allows for flexible adjustment of

capacity, as well as stepwise expansion of storage, power

generation module and berthing platforms, based on need

and investment plans.

Its lower cost structure increases its attractiveness rela-

tive to a conventional onshore import terminal, especially

as firms operate with smaller capex budgets amid the cur-

rent low oil price environment. Furthermore, Gravifloat’s

flexibility to cater to a wide range of market sizes offers it a

competitive edge over standard floating facilities, as over-

supply in the regional LNG market drives investors away

from large-scale LNG projects.

Some countries have already moved to explore the possi-bility of installing Gravifloat terminals to meet rising demand

from the power sector. For instance, Thailand is currently

mulling over plans for a US$45 million LNG-based power

plant in Ben Dam Bay, Con Dao, which will include an LNG

depot, a port and an 18 MW LNG power plant. Myanmar is

also reviewing a proposal from Gravifloat to construct a 127

MW LNG-fueled power plant offshore the Thilawa Special

Economic Zone.

A sustained period of weak LNG prices will create an envi-

ronment whereby countries and companies that perhaps did

not have sufficient financial resources are able to consider

investing in LNG for the long term. BMI forecasts the priceof Asian benchmark Japan Korea Marker (JKM) to remain

below US$5/MMBtu over the period from 2016 to 2020,

lower than the US$13/MMBtu average over 2013 to 2015.

The low prices will place buyers in a strong bargain-

ing position to secure favorable long-term contracts.

Furthermore, floating storage regasification units will

be cheap as shipyards are looking for business amid

a slowdown in the shipbuilding industry. Lower costs of

LNG supply and infrastructure support the view that more

regasification projects will move forward on top of those

under construction, benefitting LNG suppliers who are

looking for export markets. CT2

Emerging MarketsEye LNG >BY ROBERTO CHELLINIASSOCIATE PUBLISHER

Global Perspective

Flexible and cost-competitive LNGterminals provide regasification toemerging Asia-Pacific markets


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U.S. oil production is falling as low prices have stifled

new development. In the first week of April, Baker

Hughes reported that U.S. rigs drilling for oil and nat-

ural gas reached a new low of 443 (354 oil and 89 gas). U.S.

Energy Information Administration (EIA) data shows that

after a 23% decline from 2010 to 2014, crude oil imports ac-tually started increasing again in late 2015. Total 2015 imports

were slightly higher than 2014, and January 2016 imports

soared to 20% higher than the same period last year.

But natural gas production continues to climb due to the

large inventory of drilled wells yet to enter production and to

the amazing productivity of new Marcellus and Utica Shale

wells. The EIA reports that gas storage at the traditional end

of the heating season was 54% higher than the five-year

average, highest ever for that point in the season. This has

kept the Henry Hub price below $1.90/MMBtu.

In the midst of the worst U.S. oil and gas downturn in

decades, environmental advocates, government agenciesand politicians continue to push agendas that endanger the

very survival of the industry that drives the gas compres-

sion market. Uninformed, misinformed or misguided presi-

dential candidates are proposing severe restrictions, and

even bans, on fracking.

In March, an EIA report said that over half of the energy

production in the U.S. comes from fracking, pointing out

that the industry “has allowed the United States to increase

its oil production faster than at any time in its history.” Yet,

some politicians and environmental activists ignore this

fact and push to essentially destroy the U.S. oil and gas

industry. Although green energy development should notbe discouraged, the practical matter is that it cannot meet

demand for decades. And even green energy has environ-

mental consequences, a fact rarely reported by the press

and ignored by the anti-hydrocarbon lobby.

Speaking at the Gas Compressor Association’s Expo

in March, Dr. Ken Morgan, director of the TCU Energy

Institute, explained that solar and winds aren’t as green

and strategically friendly as generally portrayed. Solar cells,

batteries, and turbine generators rely on components that

contain rare earth metals found outside North America. Not

only is that a strategic concern, significant environmental

issues have been reported from mining and manufacturing

them, especially in China.For example, solar, thought to be the greenest of energy

sources, has some serious baggage. A November 2014

National Geographic article, “How Green Are Those Solar

Panels, Really?” pointed out that the fabrication of solar pan-

els requires toxic chemicals and uses large amounts of water

and electricity. The Silicon Valley Toxics Coalition (SVTC),

a San Francisco-based nonprofit that has tracked the envi-

ronmental impact of the high-tech industry since 1982, re-

ported that the solar industry is focused more on survival and

growth than on tackling the dirtier side of an otherwise clean

energy source. These problems undercut solar’s benefits.

Well-organized opponents of oil and gas are energetic,passionate and increasingly effective at influencing public

opinion and politicians. Yet we, as individuals in the oil and

gas industry, do little to counter their messaging and make

our story heard. Talking only among our business associ-

ates is not enough. And, although some of the nastier en-

vironmental facts associated with green energy should be

more widely publicized, negative messaging risks turning

most of the public off from listening to us.

Instead, we should concentrate on constantly educating

the public on the positives of fracking and domestic oil and

gas production to sustain the U.S. and North America en-

ergy needs for the foreseeable future. The benefits — jobs,low costs and security — are obvious to all of us, but the

average citizen rarely hears that message except in some

paid advertisements.

As this column has advocated, it’s up to us to direct

our friends, relatives and neighbors to factual information

that favors our industry, encouraging positive conversa-

tion. There are many good information sources including

the American Petroleum Institute’s (API) Energy Nation

(www.energynation.org) and the Interstate Natural Gas

Association of America’s (INGAA) new Energy Link (www.

ingaa.org/energylink). Make yourself — and your extended

network — familiar with them! CT2

Domestic Oil & Gas

Downturn Continues While

Political Stances ThreatenIts Survival > BY NORM SHADE

About The Business

Informative grass roots conversation isneeded to counter the negative oil & gasmessaging from environmental advocates

BY NORM SHADE

Norm Shade is senior consultant and president emeritus of ACI

Services Inc. of Cambridge, Ohio. A 46-year veteran of the

gas compression industry, he has written numerous papers

and is active in the major industry associations.


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Events & MeetingsBoldface indicates shows and conferences in which COMPRESSORtech 2 is participating

MAY 2016 10 COMPRESSORtech2

JULYJuly 25-27

SGA Operating ConferenceHouston+1 (972) 620-8505www.southerngas.org

AUGUSTAug. 23-25Power-Gen Natural Gas

Columbus, Ohio+1 (918) 831-9160www.power-gennaturalgas.com

SEPTEMBERSept. 12-15Turbomachinery Symposium/Pump Users Symposium

Houston+1 (979) 845-7417http://turbolab.tamu.edu

Sept. 13-15Gas Compressor ShortCourse ConferenceNorman, Oklahoma+1 (405) 325-3136www.ou.edu/outreach/engr/

gascompressor_home.html

MAYMay 24-26Eastern Gas CompressionRoundtablePittsburgh+1 (412) 372-4301www.egcr.org

May 31-June 1Gas AfricaSandton, Gauteng, South Africa+27 11 234 1196www.ingadaevents.co.za

JUNEJune 1-4Caspian Oil & GasBaku, Azerbaijan+44 207 596 5147www.caspianoil-gas.com

June 7-9Global Petroleum ShowCalgary, Alberta, Canada+1 (403) 209-3555www.globalpetroleumshow.com

June 13-16

Nigeria Oil & Gas Conference

Abuja, Nigeria

+234 706 911 7347

www.cwcnog.com

June 13-17

ASME Turbo Expo

Seoul, South Korea

+1 (800) 843-2763

www.asme.org/events/turbo-expo

June 21-23

Power-Gen Europe

Milan, Italy

+44 1992 656 637www.powergeneurope.com

June 21-23

Sensors Expo & Conference

San Jose, California

+1 (617) 219-8300

www.sensorsmag.com/sensors-expo

June 21-23

Developing Unconventional Gas (DUG)

East Conference & Exhibition

Pittsburgh

+1 (713) 260-6492

www.dugeast.com

Don’t replace.

i i ll



Sept. 13-15

Wyoming Natural Gas Fair

Casper, Wyoming

+1 (307) 258-4708

https://wyogasfair.org

Sept. 14-15

International Rotating Equipment

Conference

Duesseldorf, Germany

+49 69 66 03 12 82

www.introequipcon.com

Sept. 14-15

European Forum for Reciprocating

Compressors (EFRC)

Hofburg, Vienna, Austria

+49 69 6603 1286

www.recip.org

Sept. 20-22

Power-Gen Asia

Seoul, South Korea

+44 1992 656 656

www.powergenasia.com

Sept. 20-23

InnoTrans 2016

Berlin

+49 30 30 38 2376

www.innotrans.de

OCTOBER

Oct. 2-5

Gas Machinery Conference

Denver

+1 (972) 620-4026

www.gmrc.org

Oct. 10-13

International Seminar Rotor Dynamics

& Bearings

Cologne, Germany

+ 49 2267 6585-0

www.arla-online.com

Oct. 11-13

HHP Summit 2016

Chicago

+1 (888) 993-0302

www.hhpsummit.com

Oct. 17-19

Saudi Arabia International Oil & Gas

Exhibition (SAOGE)

Dammam, Saudi Arabia

+39 06 3088 3030

www.saoge.org

Oct. 24-27

Rio Oil & Gas

Rio de Janeiro

+55 21 2112 9079

www.ibp.org.br

NOVEMBER

Nov. 2-4

EP Shanghai 2016

Shanghai

+ 852 2811 8897

www.epchinashow.com

Nov. 7-10

ADIPEC

Abu Dhabi, United Arab Emirates

+971 2 6970 518

www.adipec.com

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

HOERBIGER Engine Solutions

Find a distributor near you at www.altronic-llc.com

Rebuild.ncorporating custom Teon extensions, including special

extensions for the Caterpillar 3300 and 3400 engines, multiple

wire styles, a range of primary and secondary connections, and

an assortment of lead accessories, you can cost-effectively

specify a lead for manufacture by your local Distributor, or

ocally by your own personnel. In either case, leads can be

serviced/rebuilt when necessary with moderately priced, easily

nstalled replacement components, including new O-rings, wires,

The Altronic Flashguard 2.0 Secondary Spark Plug Lead Systemgives you the ability to fully rebuild spark plug leads in the field.

boots, or grommets/terminal pins acquired directly from your

Distributor’s inventory or your own.

This system offers accessibility, reliability, and the performance

that are critical to minimize downtime, while driving the

necessary cost-control and serviceability that are so crucial to

twenty-rst century operation.

Contact your Altronic Distributor for all the details.


14/60


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16/60

Since the introduction of its first centrifugal compres-

sor in the early 1960s, Solar Turbines has steadily

developed its compressor product line that now

covers a wide range. The compressors are optimized to

match the speed and power ratings of its Saturn, Cen-

taur, Taurus, Mars, Titan (all registered names of Solar

Turbines) gas turbines. They can be matched with electric

motor drives as well.

Solar continues to invest in its product development ef-

forts through its two ISO 9001:2008 certified campuses in

San Diego. Its gas compressor test facility (GCTF), which

began operation in 2009, is part of a substantial invest-

ment in new product development, as well as providing

customers with expanded options for shop testing.

The three-bay GCTF facility at Solar’s Kearny Mesa

Test Facilities Improve Compressor

Reliability, PerformancePredictability > Solar Turbines investment in extensive test

facilities advances compressor developmentBY NORM SHADE


n This closed-loop at Solar’s gas compressor test facility is powered by a dedicated

Titan 130 gas turbine driver on a universal driven-equipment skid that enables full load

testing in a hydrocarbon or inert gas closed-loop.

continued on page 16


17/60

INNOVATION IS STANDARD

Contact us for solutions and services.

Phone: 918-317-2641 www.fwmurphy.com/newstandard

FIND OUT HOW WE CAN HELP YOU GROW YOUR BUSINESS

T H E T R U S T E D L E A D E R I N

N AT U R A L G A S C O M P R E S S I O N C O N T R O L S

Murphy by Enovation Controls continues toinvest in products that help you get themost our of your business and reduceunscheduled downtime.

By continuing to add diagnostic capability, performance

improvements and unrivaled support, we will work diligently

to make the Murphy choice the easy choice. With more than

75 years in the industry, Murphy is the smart choice, too.

We are creating new waysto help you grow by:

Continuing

to innovate

Developing

fit-for-purpose

products

Bundling end devices that you need

to save you more


18/60

complex is used for research, devel-

opment and production, including new

and aftermarket testing of compres-

sors in accordance with ASME PTC-

10 Type I and II.

In the first two bays, a dedicated

Titan 130 gas turbine engine and an

8 MW variable speed electric motor

drive (VFD) — equipped with univer-sal driven-equipment skids — enable

full load testing in a hydrocarbon or

inert gas closed-loop up to 3500 psig

(241 bar).

The third test bay can accommo-

date full compressor package closed-

loop string testing up to 30,000 hp

(22.3 MW). Testing of Solar compres-

sors at the GCTF facility provides

mechanical integrity, accurate mea-

surements and aerodynamic perfor-

mance. It also ensures rotordynamicstability and low vibration that meet

or exceed API requirements.

In addition to testing new compres-

sors, the GCTF facility is available to

test customers’ gas compressors af-

ter overhaul or restage. At its Harbor

Drive complex, Solar has an addi-

tional closed-loop test facility, which

is also used for Type II compressor

testing, with a dedicated Centaur 40

gas turbine driver.

In the closed-loop facilities, produc-tion or aftermarket compressors can

be shop tested under load to repro-

duce the aerodynamic design point.

Field gas properties can be simulated

through a variety of gas mixtures. Per-

formance verification with shop tests

before site commissioning is critical

to many customers.

Solar is aware of customer require-

ments for availability and durability of

compression equipment, which is why

the company emphasizes significantdevelopment testing prior to compres-

sor qualification.

At development, the compressors

are run on natural gas to their speed

and pressure limits, pushing beyond

their normal operation in the field. A

magnetic exciter is used to directly

measure damping in the rotor-bearing

system. This allows verification of ro-

tordynamic stability under actual op-

erating conditions at high speeds and


n A significant amount of development and production compressor testing has taken

place at Solar’s closed-loop test facilities, which accommodate ASME PTC-10 Type I and

II testing. One of the closed-loop facilities is driven by a dedicated 8 MW variable speed

electric motor (top). The extensive data gathered during these tests (bottom) is fed into

the company’s prediction database to improve analytical models and to improve compres-

sor durability and reliability.



19/60

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operate the unit being tested, while measuring and evaluating its performance.

The system establishes specified test conditions, constants and operating

limits. Test data are monitored by video displays as instructed by the test

agenda, selecting various parameters for display, checking values and limits,

and generating reports as needed. When acceptable performance levels are

achieved, the test technician initiates a command to a computerized real-

time data acquisition system that captures all instrumented points, initiates

automatic performance computations and prints the results for review for a

permanent test record.Closed-loop testing is used for development purposes and is often specified by

customers of mission-critical compressor applications. These applications justify the

higher cost of more extensive closed-loop factory validation of compressor aero-

dynamic and mechanical performance.

Product development advances from

equipment tested in Solar Turbines’

production test facilities.

In addition to the closed-loop fa-cilities, two open-loop test facilities

are used to test every Solar Turbines

compressor prior to shipment to eval-

uate mechanical and aerodynamic

performance in accordance with test

procedures and acceptance criteria as

outlined in applicable test specifica-

tions. The suction and discharge noz-

zles are connected to an open-loop

configuration that uses atmospheric

air. The two open-loop test facilities

have dedicated drivers — a Centaur50 and a Saturn 20 gas turbine.

Mechanical testing is performed first.

The dry gas seals are tested statically

with nitrogen. After preliminary checks

and static seal testing, the unit is operat-

ed at break-in speed, then at maximum

continuous speed. Key mechanical pa-

rameters such as seal gas leakage and

separation seal air flow, oil flow, and vi-

bration levels are measured and evalu-

ated against established limits.

1.800.722.0250

[email protected]

SloanLubrication.com

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PROBLEMS

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fawless compressor operation.

Let our certied lubrication technicians visit

your location and conduct a survey of all your

lubrication systems. It’s a simple, time-saving

evaluation that will give you peace-of-mind,

and a well-running compressor.

COMPRESSOR LUBRICATION SYSTEMS





i i

n Every gas compressor that Solar builds is tested at one of its open-loop test

facilities, which have dedicated drivers — a Centaur 50 and a Saturn 20 (right)

gas turbine. Larger compressors can also be tested open-loop on a (normally)

closed-loop test facility driven by a Titan 130 gas turbine (left).


24/60

After the mechanical tests, aerodynamic testing on air oc-

curs. The primary objective of the test is to confirm the accu-

racy of the individual stage characteristics used for predicting

compressor aerodynamic performance at the air-equivalent

design speed.

Accuracy is determined by comparing the overall head

vs. flow speed line from choke to surge and the surge line

position against prediction when operating at a speedequivalent to the specified site design speed. Surge points

are determined at various speed points to validate the

surge flow estimate for the entire operating speed range.

Extensive instrumentation, together with the facility data

acquisition and reduction system, validates mechanical

and aerodynamic performance.

A separate aero test facility (ATF) allows for testing

scaled single stages while making detailed measurements

in order to improve prediction capability and help under-

stand component performance. In this facility, exclusively

dedicated to development testing, Solar’s engineers can

test entire compressor stage impellers, diffusers, returnvanes and volutes.

Many different types of compressor stage components

can be tested in the ATF. These stages can either be

scales of existing production stages or experimental stag-

es. For each test article, flange-to-flange performance is

determined. Static and total pressures are measured at

various locations throughout the stage to determine over-

all stage performance as well as the performance of each

individual component.

“This process extends our aerodynamic design knowl-

edge,” Schor said, adding that the ATF tests are used to

validate and establish limits of 1-D and 3-D design codes,

evaluate and understand stage component (impeller, return

vane, etc.) losses, establish guidelines for aerodynamic pa-

rameters, and gather data to help design the next generation

of compressors.

“The objective of the facility is not only to design and test

stages with the best efficiency for direct application to a pro-

duction stage, but also to extend our knowledge of critical

parameters,” Schor said. “For example, a stage can be de-signed deliberately with a sub-optimal surge margin and, by

analyzing test data and predicted data, correlations can be

derived as to what critical parameters, such as diffusion or

flow angle, are responsible for the adverse effect on com-

ponent stability.

“This extends the prediction capabilities of the design

software and improves the ability to design stages with the

best compromise between head, efficiency and flow range.”

Throughout its compressor line, Solar Turbines makes use

of pre-designed, pre-engineered and pretested components

rather than customized stages. Since standardized aero

components are used in Solar compressors rather than acompletely customized design, far more effort can be spent

in careful optimization. The impellers for Solar pipeline com-

pressors have complex 3-D blades with inducer inlet sec-

tions. The optimization process makes extensive use of 3-D

modeling components, using computational fluid dynamics

(CFD) tools, scaled model testing at Solar ’s ATF, and full size

testing in its closed-loop test facilities.

“These modern computational tools, together with the

expanded test capabilities, have been used to design

compressor stages with high efficiency and a wide oper-

ating range,” said Manoj X. Dutt, manager, marketing &

product strategy. CT2


n Solar’s aero test facility (ATF) enables

testing of scaled single centrifigal com-

pressor stages while making detailed

measurements in order to improve pre-

diction capability and help understand

component performance.


25/60

2016 EDITION XX WWW.CTSSNET.NET CTSS


26/60

In order to limit the wear of moving components, covering

their surfaces with an oil film is a conventional practice.

For more than a century, this has been the only way to

avoid friction between moving metal components. Oil con-

sumption can be expensive and, in some cases, pollute the

environment or the fluid used by the machine.

An alternative system, applicable to all rotating machines

(specifically high-speed and large-dimension machinery) is

active magnetic bearings. While not new, this system’s big-

gest drawback was its control system. The analog tuning

procedure could take several weeks, sometimes months.

With the advent of digital control systems, this procedurehas been reduced to a few hours and has created new op-

portunities in the design and implementation of all types of

rotating equipment, such as compressors, electric motors/

generators, gas and steam turbines.

With its Simotics Active Magnetic Bearing (AMB) tech-

nology, Siemens has introduced an AMB system for large

machines, such as high-speed, high-voltage motors or in-

dustrial turbines and compressors. The rotors for such ap-

plications are held suspended in the center of the bearing

without any friction or wear. To achieve this, sensors record

the position of the shaft 16,000 times a second and a regu-

lator adjusts the magnetic field to keep the rotor hovering

precisely in the bearing center. Even rotors weighing sev-

eral tons, spinning at maximum speed, can be held in a

position window that has the diameter of a human hair.

The Simotics AMB technology allows the use of standard

components from the Siemens portfolio, such as Sinamics

and Simotion control and converter units. In the context of

Totally Integrated Automation (TIA) and Integrated Drive

Systems (IDS), Simotics AMB technology is a highly effi-

cient and matched solution for large machine applications,

the company said. Simotics AMB technology seamlessly

integrates into the Siemens TIA concept, as all compo-

nents in it are mutually compatible and system tested. TheSinamics standard control components are used both in

the IDS in the drive train to control the magnetic bearings

as well as in the main converter. The PC-based Simotion

P320-4 controller forms a customer-specific, configurable

human machine interface for system monitoring, communi-

cation with the higher-level plant controller and for auxiliary

commissioning functionalities.

Simotics AMB technology is already in use. At NAM/Shell,

two 23 MW high-speed compressor drive trains running at

6300 rpm in the Netherlands’ Groningen gas field utilize Si-

motics AMBs; as well as at Germany’s Jänschwalde power

plant in a 10 MW steam turbine running at 5700 rpm. CT2

Active MagneticBearing System ForLarge Machines > Siemens Introduces Simotics Active Magnetic

Bearing technology for wear-free operation inlarge-machine applications

BY ROBERTO CHELLIN


n Simotics Active Magnetic Bearing (AMB) tech-

nology for wear-free operation in large-machine

applications. The system is built around standard

controller and converter units from the Sinamics

family of products from Siemens. The illustration

shows a special split bearing as used in a feed-

pump drive turbine at the Jänschwalde power

plant in Germany.


27/60

From here, you see greater uptime.

PROGNOST is your portal to the world’s most comprehensive and effective machinery

diagnostics expertise.

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of the leader in online monitoring at your disposal.

[email protected] www.prognost.com


28/60

Protection Relays

Woodward’s new HighPROTEC-2 protection relays are

designed to protect electrical buses and equipment. These

medium-voltage protection relays for generators and

power distribution applications monitor the electrical con-

dition of equipment and discon-nect the power source quickly

when a problem or potential prob-

lem is detected.

Nine separate HighPROTEC-2

products target different electrical

applications, including electrical

feeders, mains decoupling and

line protection, as well as electri-

cal generators, transformers and

motors. Users can configure each

product to address the specific

aspects of a given application.This flexibility reduces the num-

ber of product variations that oc-

curs when matching a solution to

unique application requirements. Broad voltage and cur-

rent inputs (0-800V ac and 1A/5A), wide range input power,

parameter configuration, and communication protocols

(DNP3.0, IEC 61850, Modbus, Profibus) provide application

flexibility. Using the expanded communications capabilities,

the HighPROTEC-2 interfaces with Woodward’s engine

and turbine controls and generator set controllers to form

a complete control and protection solution for generator

systems. Programming and operation menus, available in

seven different languages,reside in each unit.

A graphic display shows

the HighPROTEC-2 con-

nection architecture along

with real-time operating val-

ues and messages, alarms,

and fault data. A PC-based

service tool simplifies con-

figuration and includes pa-

rameter plausibility checks

and an ANSI menu struc-

ture. It includes a displayscreen editor and event,

trends, and disturbance re-

corders and counters to aid

operation and troubleshooting. The HighPROTEC-2 has

worldwide certifications including CE, UL, CSA, EAC and

marine certifications.

www.woodward.com/hpt-2

PRODUCTSFEATURED

Catalyst elements work hard under extreme condions, and even with regular maintenance

a failure is always possible. And a plant operaon shutdown is never a good thing.

A quick replacement with top quality DCL Meta cor products is the key to geng you out o

trouble. We stock a wide range of products in our Houston facility, ready for rush deliver

anywhere in the U.S.

So you won’t be on the spot – we will.

1-877-965-8989 www. c -inc.com

WHEN CATALYST ELEMENTFAILURE PUTS YOU IN A BIND,

DCL WILL BE ON THE SPOT.

O K L A H O M A C I T Y • D A L L A S • G I L L E T T E • H O U S T O N • L O S A N G E L E S • T O R O N T O • D E N V E R


29/60


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32/60

At its Florence, Italy, facilities last September, GE Oil

& Gas completed the full-load engine test of its 16

MW industrial gas turbine for mechanical drive com-

pressors and power generation.

The test confirmed turbine efficiency, power output and

emissions levels, GE said. Efficiency and power were high-

er than analytical forecasts, while emissions came in lower

than expected, according to the test results.

GE Tested, REP Approved > 16 MW gas turbine slated forRussian installation

BY ROBERTO CHELLINI


Russian licensee REP Holding assisted with the engine

development, which involved validating the engine require-

ments and main design parameters. REP Holding also con-

tributed to the preliminary and detail design, as well as the

crafting the low-pressure turbine, and designing the engine

package for the Russian market.

A gas generator full-load test also took place before GE

shipped the module to REP Holding’s Nevsky facility in

n GE Oil & Gas completed a full-load engine test

of its 16 MW industrial gas turbine last September.


33/60

(800) 375-2347

WWW.TULCO.COM

Tulco’s Lubsoil® Synthetic LPG-WS and LPG-WI

Lubricants provide optimal performance and better

equipment protection compared to any other lubricant

on the market. Our eld tested and formulated

products are proven to save downtime and money, all

while increasing your compressor’s productivity. Tulco’s

synthetic lubricants offer:

Reduced gas solubility leading to extended lubricant life

Improved compressor efciency and wear protection

Superior performance in vapor recovery compressors

Excellent performance in H2S and CO

2 rich or “heavy”

gas compression

Tulco Oils has been a top-rated global marketer for

decades, and manufactures petroleum, semi-synthetic

and full synthetic Lubsoil® brand lubricants. We

offer quality products with high-tech support

and comprehensive service. Nomatter the challenge you have

with your compressor, the Tulco

team will have a solution.

DESIGNEDLUBRICANTS.

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St. Petersburg, Russia. At the facility,the licensee performed further joint

testing on the gas turbine as well as

subsequent field installation at a com-

bined heat and power plant.

Two months later in Florence, GE

Oil & Gas finished the assembly of

a fully instrumented unit, which went

through its validation and character-

ization test campaign. The engine was

heavily instrumented with research

and development strain gauges, tem-

perature probes and pressure probes

(among other equipment) in order to map performance, temperatures and

secondary flows.

The measurements will be used to finalize the digital engine model, as well

as fully characterize the performance of each machine component and define a

baseline thermodynamic cycle. The latter will constitute the starting point to further

increase the turbine power output and efficiency, while also improving emissions.

In order to test the complete GE train configuration, a dedicated test stand was

constructed with a gearbox from GE Lufkin and an electric generator from GE

Power Conversion.The instrumented unit will remain on its test stand in Florence for research and

development purposes throughout 2016, the company said.



34/60

GE Oil & Gas is working on the pro-

duction of three gas generators for

REP Holding, which will be used in

St. Petersburg. REP Holding will com-

plete the manufacturing of the low-

pressure turbine modules and engine

packages to create the T16 gas tur-

bine engine; it is called the NovaLT16

for the Russian oil and gas market.

The three units will be used to drive

REP Holding centrifugal compressorsas part of the modernization of Rus-

sian pipeline infrastructure. The job,

which will see industrial gas turbines

replacing aged turbo-compressors,

requires more than 4000 GT units.

The modernization is expected

to improve transportation efficiency

(amount of natural gas consumed vs.

transported gas and availability) with

longer maintenance intervals and a

smaller environmental impact, GE Oil

& Gas said.In 2014, GE Oil & Gas announced

an all-GE pipeline configuration of

its 16 MW unit, with a dedicated GE

Oil & Gas designed package and

BOP, developed in collaboration with

TransCanada Corp. and launched as

NovaLT16.

GE Oil & Gas is working to produce

one complete turbo compression train

for installation along a Canadian pipe-

line in Alberta. CT2

Intuitive: Simple navigation and “Site” setup

Flexible: Calibrate, test, review, or print anywhere

Efcient: Save testing values into analyzer

- download to PC anytime

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softTEC Testing & EmissionsCompliance Softwarefor the testo 350 Emissions Analyzer

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• Improved calibration screens

• New template with gm/bhp calculations


n GE’s 16 MW industrial gas turbine was

heavily instrumented with research and

development strain gauges, temperature

probes and pressure probes (among

other equipment) to map performance,

temperatures and secondary flows.


35/60

repaired motors prior to their installation. Split rings come in mating halves that

simplify field installation around the shafts of in-service/coupled motors.The Aegis Pro SLR Ring is specially designed with O-ring barriers that prevent

the ingress of dust, debris, and excessive contamination that could lessen con-

tact of the ring’s conductive microfibers with the motor shaft. The Aegis Pro-MR

combines a PRO Bearing Protection Ring with a shaft voltage-monitoring ring in

a single unit.

Specially designed universal mounting brackets allow installation of Aegis Pro

Series Rings on large motors. These brackets attach to Pro Series Rings with

screws and have slotted legs that allow mounting to the motor with a bolt circle

of 2.64 to 7.79 in. (67.05 to 197.8 mm) greater than the shaft diameter. They are

provided with 0.5, 1.0 and 1.5 in. (12.7, 25.4 and 38.1 mm) standoff spacers to

provide sufficient clearance for shaft shoulders, slingers, or other end bell protru-

sions. Mounting bolts, flat washers and lock washers are also included.www.est-aegis.com

The Sensor Connection

The Sensor Connection, a division of Harold G. Schaevitz Industries LLC,

has expanded its line of measure-

ment and control instrumentation

with the addition of the model TCA-

MS-K-1. This Single Channel Type K

Thermocouple Amplifier Module con-

verts the low output voltage signalfrom a Type K thermocouple probe

to a single independent linearized 0

to 5 Vdc output voltage. According to

the company, this output is ideal for

interfacing to instrumentation equip-

ment including data loggers, tem-

perature indicators, chart recorders

and controllers.

Product features include a Type K

thermocouple input; temperature

measuring range from 32 to 2282°F

(0 to 1250°C); analog output of 0 to5 Vdc; and a response time of 1 ms.

http://thesensorconnection.com

PRODUCTSFEATURED


36/60

In 1998, a group of experienced turbomachinery engi-

neers with a strong aftermarket engineering background

founded Rotating Machinery Services Inc. (RMS) in

Bethlehem, Pennsylvania. Now in its 18th year, the compa-

ny has steadily grown its business, becoming a major force

in providing turbomachinery aftermarket engineering and

repair services to the refining, chemical, gas transmission,

power generation and steel industries. Earlier this year,

RMS opened a satellite engineering office in Appleton,

Wisconsin, specializing in the support of the former A-C

Compressor line of centrifugal compressors.RMS performs a wide range of services on turbomachin-

ery, including reliability improvements, performance optimi-

zation, repair, component replacement and the supply of

upgraded/overhauled surplus equipment. The company

has experience with repowering turbomachinery pack-

ages and has also supplied new custom-designed equip-

ment skids and lube oil systems. Its experience includes

axial and centrifugal compressors, fluid catalytic converter

(FCC) and nitric acid expanders, gas turbines, aeroderiva-

tive power turbines and steam turbines.

“RMS provides a full range of turbomachinery services,

giving users a complete alternative to the OEM (original

equipment manufacturer),” said Jerry Hallman, company

president and co-founder. “We have a total focus on existing

compressor equipment, as opposed to OEMs, which have

their resources focused on new equipment. We can provide

superior engineered solutions to long-standing problems

that the OEM is unwilling or unable to solve. We also focus

on ‘orphaned’ equipment that is no longer fully supported

by an OEM. And we provide customers with open access

to RMS’ experts.”

Types of projects include rerates for improved performance;

engineered overhauls of rotors and complete machines;mechanical redesigns and upgrades; reapplication of sur-

plus equipment trains; component repairs; new parts sup-

ply including rotor blading, disks, shafts, stators, casings,

bearings and seals; and field service that ranges from in-

spection and turnaround support to providing supervisors

to full turnkey responsibility.

“We take pride in our ability to refurbish turbomachinery

to a condition that ensures long-term trouble-free operation

for our customers,” Hallman said. “Our assemblers, inspec-

tors, machinists and field service supervisors have an aver-

age of 25 years of experience in their respective fields and

RMS Expands

Its Footprint > Rotating Machinery Services Inc. provides full rangeof turbomachinery repair and upgrade services

BY NORM SHADE


n The RMS service facility consists of three 10,000 sq.ft. (929 m2) bays that include a rotor assembly shop (left), large-capacity machine

shop with quality control room, and an assembly shop (right) with a full range of lifting, moving and storage equipment.



37/60

We are where you need us.

Providing solutions for oil and gas applications upstream, downstream and in-between.

Everywhere.

dresser-rand.com

Welcome to a new era of innovation and technology.

As you have come to expect, Dresser-Rand prov ides

safe, reliable and efficient rotating equipment for nearly

every application in the oil and gas market.

But there’s more.

The new Dresser-Rand business now has expanded

resources and more experience as a member of the

global Siemens family. The Dresser-Rand business

combines one of the industry’s most extensive

portfolios of rotating equipment with a universe of intelligent

solutions and one of the world’s largest technical support

and service center networks. We offer more choices—where

you need us—all from a single supplier.

So what can you expect from us? High-quality products

and services, combined with local suppor t around the

clock, wherever you are, for the applications that matter

to you.


38/60

take great pride in our facility and our

ability to handle our customer’s prop-

erty with the greatest efficiency and

attention to detail.”

Hallman said that RMS is affiliated

with respected millwright service orga-

nizations throughout the country, andRMS supplies field supervision for

each crew to ensure proper execution

of every project.

“Our organization is made up of

uniquely experienced engineers and

technicians,” said Robert J. Klova, PE,

vice president, chief engineer and co-

founder. “We leverage our experience

with the latest engineering technology.

Experience in all types of custom-en-

gineered turbomachinery separates

the optimum solution from the run-of-the mill. Strong design and analytical

engineering form the backbone of ev-

erything we do. Engineering makes

the difference, and we focus on con-

tinuous development of the next gen-

eration of turbomachinery engineers

to serve customers’ future needs.”

RMS has analytical capabilities in

structural analysis, aerodynamics,

rotor dynamics and metallurgy using

the latest analytical tools.

The RMS service facility consists

(918) 283-9200 Fax (918) 283-9229 www.axh.com

Experience, Reliability, Integrity...

The AXH manufacturing complex consists ofsix plants, totaling 559,100 SF on 67 acres.



39/60

of three 10,000 sq.ft. (929 m2) bays that

include a rotor assembly shop, machine

shop with quality control room, and an

assembly shop. The rotor shop, which

is serviced by a 25 ton (22.5 tonnes)

overhead crane, houses multiple in-

dicating stands and stacking pits, twoSchenck balancing machines with

respective capacities of 40,000 and

17,000 lb. (18,140 and 7710 kg), an

electrical runout (glitch) system, a va-

riety of hydraulic coupling and tie-bolt

stretching equipment, and a Bracker

hydraulic rotor tenon peening system.

The machine shop houses multiple

large machine tools including a 5 in.

(127 mm) bar CNC horizontal boring

mill, a 60 in. (1524 mm) swing CNC

vertical boring mill, a Mazak 300MCNC turning-milling center, a 52 in.

(1321 mm) swing by 236 in. (5994

mm) between centers engine lathe,

and a 90 in. (2286 mm) swing vertical

boring mill, as well as a variety of small

manual lathes, knee mills and grind-

ers. The temperature-controlled, qual-

ity control room houses a number of

granite tables, coordinate measuring

equipment with scanning capabilities,

positive material identification equip-

ment and two precision air bearing

rotary table inspection stations. The

machine shop is equipped with 25

and 15 ton (22.5 and 13.5 tonnes)

overhead cranes.

The assembly shop has six large

assembly cells, a weld shop, nonde-

structive test (NDT) area with mag-netic particle and wet magnetic particle

booths, an abrasive blast room and

multiple abrasive blast cleaning cabi-

nets. This shop is supported by a 35/15

ton (31.5/13.5 tonnes) crane with 27

ft. (8.2 m) hook height and multiple jib

cranes. Also in this area, RMS’ field ser-

vice operations maintain a 20 ft. (6.1 m)

fully equipped sea container/shop and

gang boxes, ready for immediate dis-

patch to customer sites.

RMS’ capabilities are evidencedby its list of successful turbomachin-

ery projects. A recent major project

was an ammonia/water turbine gen-

erator set, developed from a surplus

steam turbine for a process cus-

tomer in Pakistan. RMS provided the

complete train of equipment, with

new controls and auxiliaries, includ-

ing the application of dry gas seals

for ammonia containment. To sup-

port the project, RMS had to develop

MAY 2016 37


l o w - r a t i n g . h o e r b i g e r . c

o m

L O

W . . .

. . . R

A T I N G

. . .

n

The capabilities of RMS’ experienced en-gineering staff include expertise in all major

types of custom-engineered turbomachinery

and a full range of analytical expertise with the

latest analytical tools in rotordynamics, struc-

tural analysis (e.g., turbine disk, left), aero-

dynamics (e.g., centrifugal stage flow path,

center) and performance (e.g., steam turbine

blade erosion, right).


40/60

performance analysis capability for

ammonia and steam mixtures.

The company has special expertise

in fluid catalytic cracker (FCC) and ni-

tric acid expanders. Nitric acid is the

basic material for the production of

fertilizers, explosives and chemicals.

In 2014, an I-R E520 nitric acid tail

gas expander experienced a high-

pressure seal failure. RMS engineer-ing supervised the change-out of the

damaged expander with a spare unit

that had been sitting idle following a

multiyear run. The spare expander

had experienced high of 2 to 3 mils

(51 to 76 µm) and unstable shaft vi-

brations during its prior run. Improved

cold alignment, bearing changes, and

careful setup resulted in low and

stable vibration of less than 1.06 mils

(27 µm), the lowest historical level for

this expander.


n RMS provided this complete machinery

train for a nitric acid plant in 2008. Start-

ing with a surplus train, RMS completely

designed the axial compressor and rerated

the turbine, providing a new lube oil con-

sole as well. It also rerated the customer’s

existing expander during a turnaround.

n RMS provided this complete ammonia/water turbine gen-set for a process customer in Pakistan. Developed from a surplus steam

turbine, it provided the complete train of equipment, including controls and auxiliaries and the application of dry gas seals for ammonia

containment. To support the project, RMS had to develop performance analysis capability for ammonia and steam mixtures.


41/60

In 2008, RMS provided a complete

machinery train for a nitric acid plant.

Starting with a surplus train, RMS

completely designed the axial com-

pressor and rerated the turbine, pro-

viding a new lube oil console as well.

It also rerated the customer’s existing

expander during a turnaround.

In 2012, RMS was contracted tosupport the emergency breakdown

of a European refinery’s FCC power

recovery train. A failed Elliott hot gas

expander was at the heart of the

breakdown. RMS was able to restore

the main axial compressor to service

on motor only within a 10-day period.

The company then received another

contract for a root cause analysis

of the failure and for rebuilding the

damaged expander using an existing

spare rotor. During the inspection pro-cess, RMS determined that the entire

intake casing assembly was no longer

suitable for service. It was able to de-

liver a new intake casing assembly, in-

cluding first- and second-stage stator

housings in an expedited 16 weeks

from date of order. RMS’ field service

team travelled to Europe to support

the installation of the intake casing

and expander assemblies, enabling

an early startup.

Last year, RMS was offered a

unique challenge to urgently replace a

Cooper-Bessemer RC20 compressor

rotor that suffered a heavy rub failure

caused by impellers contacting the

diaphragms. The impellers were re-

verse engineered through mechanicaland FaroArm inspection methods in

four weeks. RMS engineers analyzed

the inspection information, and new

CAD models were created. Utilizing

forged material from in-house stock,

RMS was able to complete five-axis

machining of the impellers and a fin-

ished product, including overspeed

testing, in less than eight weeks. The

engineering and manufacture of a

new shaft, balance piston and shaft

sleeves were completed in 12 weeks,so that the entire replacement rotor

assembly was assembled, balanced

and shipped in 13 weeks, one week

ahead of the agreed-upon 14 weeks.

RMS also performed a rotordynamics

analysis and developed performance

curves for the design.

In addition to service and repair,

MAY 2016 39

n RMS provides engineering and support to users

with older power turbines, such as Cooper RT65, I-R

GT51 and GT61, Dresser-Rand DR61 and Dresser-

Clark DJ125. Projects have included remaining life

predictions for rotors and stationary components,

casing redesigns, replacement of major stationary

and rotating parts including outer casings and rotor

disks, field service, and rotor and complete power

turbine overhauls.


n An axial compressor rotor is ready for

return to a customer after an engineered

overhaul in RMS’ shop.


42/60

solving turbomachinery problems with engineering analyses and improved designs

has always been an RMS focus. For example, a 1968 vintage GHH horizontallysplit centrifugal compressor in a toxic gas service had experienced chronic joint

leakage over many years. The end user tried various fixes including purchasing

a spare compressor with a thicker casing; yet the sealing problem could not be

consistently eliminated. Finally, the end user was faced with the need to replace the

machines entirely. However new compressors would not match the existing layout

and pipe locations, and lead time was

over 30 months. RMS custom designedand manufactured two new 300 series

stainless-steel “drop-in” replacement

compressors with upgraded barrel type

casings to solve the split line leakage

problem. The complete units utilized

new RMS casings and diaphragms with

the customer’s existing rotors, bear-

ings and inner seals. Dry gas seals and

a new common oil system were also

included as part of the upgrade. The

new compressors were installed in the

spring of 2014, completely eliminatingthe chronic leakage problems.

FCC expanders can experience sig-

nificant erosive wear due to catalyst

particles entrained in the flue gas.

Using computer fluid dynamics (CFD)-

aided state-of-the-art aerodynamic

design, RMS developed a number of

unique features that have significantly

improved blade and disk lives. These

include low-erosion rotor and stator

airfoils, blade platform seals, and a

unique overlapping platform designupgrade that shields the rotor disk

from the harmful effects of catalyst

laden flue gas. The low erosion design

doubled the life of the rotor disk and

blades to six years at one customer

site. “RMS’ significant experience in all

aspects of FCC expander design, ser-

vice and support has earned it a strong

and growing place in the FCC expand-

er aftermarket, where numerous refin-

eries rely on us to support their FCC

power recovery trains,” Klova said. CT2


n RMS refurbishes and upgrades process (left) and pipeline centrifugal compressors including new custom-engineered

aerodynamic assemblies (right).


43/60

CompressedTechnical Services

Stark Industries’ brochure

outlines its Compressed

Technical Services offering.

CTS designs and manu-

factures compresor system

packages for industrial gas.Compressors, oil-removal

systems and air-storage

solutions are enumerated

along side the company’s

services offering.

www.starkindustries.com

CoolingSolutions

The Fuzzy’s Radiator bro-

chure lays out the products,

services and technologies

used by the Texas panhan-

dle company. Fuzzy’s cool-

ing solutions include radiatorpackages, heat exchangers,

fin fan packages, radiator

cores, charge air coolers,

gaskets, cooling coils, hydro

blasting, soda blasting and

repair services.

www.fuzzysradiator.com

GeminiUpgrade Parts

TrueRock released bro-

chures to highlight the fea-

tures and benefits of its line

replacement/upgrade parts

for Gemini compressors.

The brochures feature theH Series aluminum pis-

ton rod (pictured) and the

M/H Series variable volume

clearance pockets.

www.truerocksupply.com

PreservationCoatings

A-76 Technologies supplies

the A-76 line of preserva-

tion coatings and lubricants,

offering corrosion prevention

and lubrication in high-

humidity, high-salinity envi-ronments. A green variation

contains no volatile organic

compounds, helping custom-

ers reduce emissions.

www.a76tech.com

LITERATURE

Stop by Booth 301/400 at the EGCR for more informatio


44/60

The production of low-density polyethylene (LDPE)requires special compressors to obtain the pres-

sure necessary for the product.

The booster primary compressor brings the pressure

from low value up to the suction of the hyper compressor

that feeds the reactor.

Great attention is paid to all details of the plant in order to

achieve maximum operating time. The valves represent an

important component that strongly influences the reliability

of compressors and the plant.

The booster primary compressor requires stringent ca-

pacity control, further increasing its complexity.

An analysis of the design, production and performanceaspects of the booster primary compressor follow.

Plant features

The booster primary machine is a six-cylinder, mul-

tiservice compressor, which combines the function of

the booster and primary on one frame manufactured by

Nuovo Pignone (now GE Oil & Gas). The motor oper-

ates at 4000 hp (2983 kW) at 327 rpm. The machine has

Analysis: Valve Performance On Booster

Primary Compressor For LDPE > Production of critical parts, maintenance strategieshelp to optimize availability, minimize costs

BY JIMMY SALMON AND ENZO GIACOMELLI


a capacity of 16,000 lb./hr (7000 kg/hr) for the booster and56,000 lb./hr (25,000 kg/hr) for the primary.

The booster’s suction pressure is slightly above the at-

mospheric one, collecting the gas from the plant recovery

system. The discharge of the primary reaches 3600 psi

(25 MPa) to feed the hyper compressor. The hyper com-

pressor, designed and manufactured by GE Oil & Gas, is

an eight-cylinder machine that raises the pressure to full

reactor pressure. The three cylinders are double acting on

the booster, which reaches a pressure of 3278 psi (22.6

MPa). The compressor has 24 Nuovo Pignone-designed

valves manufactured by Cozzani.

The primary compressor operates up to 3771 psi (26 MPa)and has two cylinders with a tandem arrangement (second-

stage inboard and third-stage outboard). Additionally, the pri-

mary’s first stage is double acting with 2+2 valves, while the

two second and third stages are single acting and positioned

on the same cylinder with a tandem arrangement. The sec-

ond stages have one suction valve and one discharge valve

per cylinder, while the third stages have one combined suc-

tion and discharge valve per cylinder. All the cylinders are

equipped with plastic piston and packing rings.

The cylinder lubrication is made with a mineral oil with

lubricity additives. It is the same one that is applied for the

booster/primary and hyper compressor.

n Booster primary compressor.

Jimmy Salmon i s a senior principal engineer with 40 years of con-

tinuous service in LDPE maintenance, reliability and production.

Enzo Giacomelli is a consultant for Dott.Ing.Mario Cozzani Srl.



Valve applications

The set of 30 valves is equipped

with metal rings in all stages of boost-

er and primary. The capacity control

requires the use of finger-type, one-

step unloading systems as well as

continuous bypass control. Because

the gas involved is not corrosive, the

material of the seat and guards isalloy steel AISI 4140.

The valve bolts for the seat/guard

system were provided with a threaded

connection, including a surface treat-

ment for longer life. Castle-type lock-

nuts were used to prevent the assembly

from loosening in service. These nuts

also include an anti-friction surface layer

to reduce damage during maintenance.

Simulation programs have real-

ized the design on the full operat-

ing range. The machines have beenmanufactured to meet quality control

procedures. The critical parts, such

as springs and rings, are designed to

withstand fatigue stress.

Maintenance strategies

In the years following the 1983 com-

missioning, the decision was made to

use predictive maintenance for de-

termining when the valves should be

changed. Changes in gas tempera-

ture and interstage pressure were thesignals to indicate failing valves. In

the first 13 years, however, there were

no issues.

A lengthy turnaround in 1996 pro-

vided an opportunity to change out all

valves on a proactive basis. A detailed

inspection showed no problems. After

this shutdown, a preventative, time-

based maintenance program was de-

veloped for the valves, which followed

the standards elsewhere on site.

Today, bearings and valves are re-placed on a time-based schedule.

During the scheduled shutdowns,

we also check bearing clearances

and rider band wear. We crack de-

tect critical bolts by ultrasonic means.

One throw per shutdown is checked

for web deflection. These inspections

(nearly every two years) also include

a rider band wear check. Other work

includes oil and filter change, lubricator

box inspection, and functional checks

on compressor alarms and shutdowns

(temperatures, pressures and vibra-

tion). In operation, we monitor process

and oil temperature and pressure, as

well as machine vibration.

Valve performance

The valves are critical compressor

components. Their performance has

been checked by pressure and tem-perature analysis. The attention to any

deviation from the design parameters

and homogeneity of the valves of the

same cylinder is essential to assess

performance and keep operations run-

ning until a failure can be predicted.

Following the 1996 valve change,

the next change occurred in 2002 for

all of the valves. In 2006, the primary

third-stage valves were changed dur-

ing re-ringing of the third-stage cylin-

ders, as the cylinders were alreadylargely dismantled. All other valves

remained in service.




Most valves have lives of six to 13

years. The primary third-stage valves

were removed with lives of four to 13

years. The last valves placed in ser-

vice now have nine years and are

still operating. The valves were

in good condition during each

inspection. While slight wear oc-

curred to some seating surfaces,it wasn’t enough to cause per-

formance issues. There was also

slight wear in the bottom of some

spring recesses.

The rings were in good condition, with

no cracks or broken pieces. The springs

were intact, with none of them broken or mis-

shaped. Every reconditioning was made accord-

ing to the recommended procedure.

Conclusions

The original valves installed in a booster primary com-pressor have performed well from one proactive switch to

the next during the 32-year window. All replacement parts

have been designed to the original more than 30-year-old

design. Although potential design improvements could be

made, such as plastic rings, the original work suited this

application. CT2

In 2013, as part of the proactive replacement plan, the

booster and first-stage primary valves were reconditioned.

The final reconditioning efforts took place in Cozzani’s

service center in Magnolia, Texas, with the coordination

of the compressor manufacturer and supervision from the

valve manufacturer.

n Ring valves after disassembly.

l i l i


47/60

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MOVERSPRIME


Gasmet Technologies

Gasmet Technologies has acquired Quantitech Ltd.

Headquartered in Finland, Gasmet Technologies is a

global manufacturer of gas monitoring instruments and

systems for industrial and environmental applications in-cluding continuous emissions monitoring, process control,

engine exhaust gas, greenhouse gas monitoring and car-

bon capture.

Quantitech Ltd. provides advanced environmental and

process monitoring instrumentation in the U.K. and Ireland.

Following the acquisition, Quantitech will remain at its

Milton Keynes, U.K., location, trading under the same name

and continuing to supply the same range of products.

Burckhardt Compression

Burckhardt Compression will acquire a 60% stake in

Shenyang Yuanda Compressor Co. Ltd., a Chinese recip-rocating compressor manufacturer. Shenyang Yuanda re-

portedly had sales of about US$111 million in 2015 with

650 employees.

Shenyang Yuanda, established in 1997, is focused on

the development, manufacturing and service of recipro-

cating compressors. Burckhardt said the acquisition helps

them gain local market reach in new market segments,

expands its product portfolio to cover market requirements

and gives them direct access to a well-established local

supply chain.

BP

BP and China National Petroleum Corp. (CNPC) have

signed a production sharing contract for shale gas explo-

ration, development and production in the Neijiang-Dazublock in the Sichuan Basin, China. The contract is BP’s first

shale gas production sharing contract in China and covers

an area of approximately 579 sq.mi. (1500 km2). CNPC will

be the operator for this project.

This production-sharing contract is the first achievement

from BP and CNPC’s framework agreement on strategic

cooperation that was signed last October during the visit

to the U.K. by Xi Jinping, president of The People’s Re-

public of China. In addition to unconventional resources,

the framework agreement covers possible future fuel re-

tailing ventures in China, exploration of oil and LNG trad-

ing opportunities globally, and carbon emissions tradingas well as sharing of knowledge around low carbon energy

and management practices.

Wasco Engineering Services Singapore

Wasco Engineering Services Singapore (WESS) has

signed an agreement to serve as LeROI Gas Compressors’

authorized packager and distributor.

As a LeROI packager and distributor, WESS will have

product and service offerings that include vapor recovery,

well unloading, fuel gas compression, flare gas capture and

wellhead compression.

WESS’ network includes the Middle East, South EastAsia and Australia. LeROI controls more than 60% of the

U.S. compression market, the company said.

Enerflex Ltd.

Enerflex Ltd., a supplier of products and services to the

global energy industry, opened its new service facility in

Adelaide, Australia. The facility is the latest addition to

Enerflex’s global branch network and the seventh loca-

tion in Australia.

The 21,528 sq.ft. (2000 m2) facility, located at Gilman, will

provide Enerflex’s complete product and service offerings

including compression, process and electric power equip-ment sales, aftermarket service and support, and integrated

asset management for the Southern Australia region.

The facility includes a workshop focused on equipment

overhauls, project optimization, upgrades, retrofits, and

general asset management, as well as a regional training

facility and a parts warehouse.

Correction

The minimum suction pressure for MAN Diesel & Turbo bar-

rel compressors was incorrectly stated in “Standardized Refin-

ery Compressor Packages” in the March 2016 issue (page

75). The correct minimum pressure is 50 psig (3.5 bara).


49/60

Exclusive Sealings

Exclusive MaterialsExclusively OEM

Now established and manufacturingin the US – German Experts in SealingTechnology for ReciprocatingCompressors, Rotary Systems andRenewable Energies

We proudly present theSD50 Sealing Ring – a contactingsegmented ring for rotating equipment,such as blowers, dryers, mixers and otherrotating applications.

This ring provides a high sealing efficiencyagainst the rotating shaft throughoverlapping se

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