Novel Method of Detection of Surge- Gas Machinery Journal Q2_13

8/17/2019 Novel Method of Detection of Surge- Gas Machinery Journal Q2_13

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GAS MACHINERY JOURNAL P. 3

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The Gas Machinery Journal is distributed at no charge to 5000 energy industry profession-als and top-level decision makers with responsibility for gas machinery and compressorstation design, installation, operations and maintenance.

The Gas Machinery Journal welcomes submissions on all aspects of natural gas machin-ery and compressor station design, installation, operations, and maintenance, articles and

case studies relating to topics such as valve performance and wear, pulsation control andmounting issues, and challenges presented by unwanted surge and how to deal with them.Also of interest are contributions on the topics of emissions reduction, engine efciency,performance and reliability, gas/electric regulations, and gas and electric partnership. Weespecially welcome case studies that illustrate implementation of new ideas and technolo-gies, and submissions from the users of gas machinery technology.

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4/16

P. 4 GAS MACHINERY JOURNAL

Dramatic changes in ow for long-haul pipelines to the North -

east are forecast and issues for those pipelines were discussed

by Williams Gas Pipeline representatives.

Offshore Oil and Gas Production

The consultancies of Ineld and Endeavor provided an over-

view of offshore oil and gas production both in the Gulf of

Mexico and worldwide. They show that shale reserves are even

greater in Latin America and China than in North America. Mo -

zambique and Tanzania in East Africa hold 250 tcf gas in the

offshore and thus could become an exporter. Shale is having an

impact on the offshore driving investment in the Gulf of Mexico

pushing activity toward very deep water.

The types of production systems and trends were discussed by

Endeavor and the options were described. The issues for selec-

tion include water depth, whether gas or oil production, geo-

graphical location, role of oil export, gas usage and export op-tions, fabrication, and whether surface, subsea or both.

There is growing interest in Floating Production, Storage and

Ofoading Systems (FPSOs) which were originally considered

an economical solution for the production only for marginal

elds. Later, FPSOs became an essential component in devel-

oping remote offshore elds as production capacity, numbers

of risers, and capability to operate at increasing water depths

allowed their utilization as full eld production facilities.

Now, oating LNG is creating a good deal of interest. Devel-

oped for smaller stranded gas elds, there are some interestingadvantages which may broaden its appeal. According to one

speaker, oating LNG can be developed more quickly with

lower environmental impact than other options.

2013 GAS / ELECTRIC PARTNERSHIP CONFERENCE OVERVIEWContributed by W. Richard Schmeal,

Coordinator of the Gas Electric Partnership

Gas Infrastructure for New Supply and Industrial/Export Markets

The 2013 Gas/Electric Partnership Conference February 5-8

in Houston focused on two major energy issues: the impact of

the game-changing North American shale oil and gas supply

growth and how gas and power industries can coordinate to

provide energy smarter and more efciently. The interest of

the group was on the driving forces impacting infrastructure for

gas and natural gas liquids and focused on compression in the

upstream, midstream, and pipelines. New perspectives on tech-

nology for solving these problems were presented by leading

equipment manufacturers in the technical update sessions.

New Supply and New Markets for Gas

It is broadly appreciated that major new supplies of gas are re-

sulting in competitively priced gas in North America and thishas profound global economic implications. With gas prices

in North America as low as one-eighth the price in the large

markets of Asia, there is a driver for gas exports from locations

in the Gulf Coast, British Columbia, and possibly other areas.

Furthermore, changes in the locus of gas supplies changes po-

litical power dynamics for international actors like Russia, Iran,

and others.

Closer to home, the competitive price of gas is causing new

markets for gas to emerge for a wide range of industries, trans-

portation, power and export. Also of great importance is the

location of new supply and new demands, and the impact ongas pipelines. The gas supplies are emerging in places like the

Marcellus in the Northeast which, in the past, was a major mar-

ket for gas from other areas like the Gulf Coast. It may be that

the sites of new industrial projects that will use gas and natural

gas liquids such as petrochemicals and gas export will be in

the Gulf Coast because of existing infrastructure and political

considerations. These forces cause changes and even reversals

of ow directions for gas pipelines.

On the supply side, discussions revolved around the outlook for

the various shale regions and issues for infrastructure for natural

gas, natural gas liquids (NGLs), and power.

Reviews of infrastructure issues for the Bakken, Eagle Ford,

Permian, Utica and Marcellus pointed out obstacles and oppor-

tunities. A Shale Infrastructure roundtable compared the issues

for the different basins.

Assessments were presented by various speakers to show how

the Marcellus and Utica regions will increase production so sig-

nicantly that these Appalachian regions will become major net

exporters of gas and NGLs in the near future. Projects to usecompetitively priced gas were discussed by Mike Juden, McKin-

sie & Co., and Marybeth Nored, Apache Corp. Ms. Nored pre-

sented a wide array of industrial possibilities, including metha-

nol, ammonia, gas to liquids, combined cycle power, CNG/

LNG fuels, compressor gas for transport, and gas export. Mr.

Juden looked quantitatively at many of these gas demands and

shows that the likely production from Marcellus is large enough

to overwhelm both traditional and new gas uses for quite some

time. This is good news for the economy but not so for those

hoping to see higher gas prices.

Impact of New Gas Supply and Uses for Gas PipelinesAn estimated 29 Bcfd (~$27 Billion) of additional interstate

transport capacity could be required through 2020, but most

will be regional pipelines, expansions or laterals. A large part of

gas infrastructure investment will be in gas and NGL gathering.

LONDON - The bi-annual Oil & Gas Global Capital Condence Barometer released recently high-

lights that nearly half (44%) of the 152 oil and gas company executives surveyed believe the global

economic situation is improving, up from 27% in October 2012. Notably, oil and gas companies

are generally more optimistic than the broader global sample of 1,600 respondents in 50 countries.However, only 27% of the respondents expect to undertake any M&A activity in the next six months,

a decline from six months ago.

Andy Brogan, Ernst & Young’s Global Oil & Gas Transactions Advisory Leader explains this “con -

dence paradox”: “While general condence in the state and outlook of the economy is improving, this

is accompanied by increasing levels of uncertainty about the direction of travel of commodity prices in

general and oil and gas prices in particular. This is leading to a valuation disconnect which is delaying

many transactions.’

Appetite for mergers and acquisitions declines slightly

The oil and gas sector has been one of the most resilient for M&A over the last ve years. However, this

survey sees a slight decrease in sentiment with 27% of respondents now expecting to pursue acquisi-tions over the next 12 months, down from 28% in October 2012 and 31% a year ago. It is not just a

lack of condence in the business environment that is holding companies back — many are also con -

cerned about the gap between their valuation of potential acquisitions and the prices sought by sellers.

For many companies, the appetite for M&A has declined. Five years after the nancial crisis, many

executives are still waiting for more price visibility before taking action. That conservatism aside, oil

and gas respondents expect that global M&A deal volumes will increase over the next 12 months, with

72% expecting volumes to at least modestly improve. Expectations of the larger global sample were

broadly similar.

Growth focus returns

Prioritization of growth had broadly declined as companies in general became more focused on the

fundamentals, but that decline has seemingly ended. Oil and gas companies’ focus on growth had

similarly been declining, but increased sharply in this survey. Notably, our oil and gas respondents

continue to be more focused on growth than the global sample of companies. Compared with six

months ago, our respondents, both in the broader global sample as well as the oil and gas respondents,

report a decreased focus on reducing costs, improving efciency and optimizing capital.

Growth remains the number one objective for a majority of our oil and gas companies, with 61%

reporting that growth is their primary focus, as compared to 20% whose primary focus was on cost

reduction and operational efciency, and 17% whose focus was on maintaining stability. This is thehighest percentage of respondents citing growth as their top priority since April 2011.

Credit conditions improving globally

While credit has remained broadly available, particularly to large-cap enterprises, our global respon-

dents report a substantial increase in credit availability. Compared with two years ago, banks are

OIL AND GAS TRANSACTION APPETITE DOWN SLIGHTLY AS CONFIDENCE IN ECONOMIC OUTLOOK GROWS

-- see “2013 Gas / Electric” next page

-- see “Oil & Gas Transaction” next page


5/16


EPA Current Regulatory Issues

Jeffrey Adams, BP, gave a comprehensive dis-

cussion of the status and impact of numerous

pending environmental regulatory develop-

ments affecting gas compression. The Presi-

dent’s inaugural address emphasized climate

change and the environment. However, the

congressional split limits like legislation and

thus regulations will drive the agenda. NGOs

will continue to press for EPA regulations via

court action, public comments, and “sue &

settle” agreements.

Expected high impact air quality rulemak-

ing includes 75ppb ozone standards, nal oil

and gas New Source Performance Standards

and NESHAPs, existing engine NESHAPs and

source aggregation.

Gas Transmission and Power

Power is a huge market for natural gas and gas

is earning a growing share of the power market.

Kent Saathoff, Vice President of Systems Op-

eration of ERCOT (Electric Reliability Council

of Texas) pointed out that gas is now providing

44.6% of power use in ERCOT and represents

57% of power generation capacity. The inter-

actions between these vital energy commodi-

ties are complex and both are affected by the

growing generation of power by wind. Gas isthe marginal fuel supply and electricity prices

tend to trend with it.

Up to 80 GW of coal capacity may retire by

2020 nationwide, and nuclear challenges re-

main high cost, waste management and Fuku-

shima psychology, according to Gurcan Gu-

len, The University of Texas Center for Energy

Economics. Yet in ERCOT, current prices are

not sufcient to encourage enough generation

capacity to meet forecasted demand, accord-

ing to Mr. Saathoff. New builds will be gas and

wind. He also spoke about various price fore-

casts and the issues of the intermittent supply

of power from wind. Since the peaks and val-

leys of wind generation do not match those of

power needs, natural gas capacity is needed to

ll in the gaps.

A major issue is that smart power is needed

for our nation’s energy efciency. The Fed-

eral Energy Regulatory Agency (FERC) is con-cerned with this issue. A panel with Christina

Hayes, FERC Legal & Policy Advisor to Chair-

man Wellinghoff, Bob Truman, CenterPoint

Energy, and Joseph Pollard, TransCanada

discussed the tight gas/power interaction and

how it leads to a need for “smart gas transmis-

sion.” Issues of concern are pricing structures,

communication protocols, and enhanced

nomination schedules. The interdependence

of gas and power is nowhere more vital than

during weather events such as hurricanes and

ice storms. Thomas Wooden, Spectra Energy,presented a case study on Spectra’s experience

providing natural gas for power in the North -

east during Hurricane Sandy. Another impor-

tant gas/power interface of great concern is the

use of power to drive compressors. Rob Krenz, Williams Gas pipeline, gave an update on a huge

facility which has been operating for several years.

A 15-member consortium has come together with Southwest Research Institute (SwRI) to devel-

op guidelines for electric motor driven centrifugal compressors in pipeline applications and toinvestigate operational reliability and life cycle costs of various commercially available electric

motor drive technologies. The results of this study were presented. The results of this study and

all presentations from this conference can be downloaded at www.gaselectricpartnership.com

2013 Gas / Electric partnership conference overview, cont’d.

on a stronger footing and better capitalized. Yet this healthier picture has not always translated into

increased lending, as many banks tightened their lending standards, particularly for small to-medium

enterprise (SME) borrowers. Banks also face higher capital requirements under impending Basel III

regulations, which could restrict their ability to increase the ow of credit into the economy.

Eighty-ve percent of oil and gas respondents now view credit availability as stable or improving.

Within this, the percentage of oil and gas companies seeing credit conditions loosening has increased

substantially.

Mixed global deleveraging trends

The oil and gas sector has tended towards conservatism with respect to leverage. The improving credit

conditions have prompted many of them to review and adjust their capital structure. Some took ad-

vantage of better credit conditions to take on debt and reduce their overall cost of capital. However,

reecting the industry’s traditional conservatism in this area (and the buoyant oil price), over the last

two years, more oil and gas companies have been looking to deleverage their balance sheets. The

proportion of companies expecting to nance to further expand their operations — and increase theirdebt-to-capital ratios — grew to 28%, up from 21% in October 2012. However the proportion of oil

and gas companies looking to take the opportunity to decrease their debt-to-capital ratios increased

even more sharply to 45%, up from 31% in October 2012.

In our recent survey, more than 74% of the oil and gas respondents reported debt-to-capital ratios

below 50%, with 40% reporting ratios of less than 25%. Both of these percentages declined, however,

from our October 2012 survey. Clearly, some oil and gas companies, as well as companies in general,

are choosing to shed some of their caution.

Debt decreases as a source of deal nancing

Only 30% of the oil and gas respondents were expecting to renance loans or other debt obligations

in the next 12 months, up from 21% from the October 2012 survey, but still down from 49% in the

April 2012 survey. With large-scale changes to their capital structures now completed, oil and gas

companies are focused on renements — reducing interest costs, extending debt maturities and re -

moving restrictive covenants. Declining in importance for renancing has been the optimization of the

corporate structure and retiring of maturing debt.

Brogan concludes: “Throughout the crisis and recovery period the oil and gas sector has proved re-

markably resilient. Many companies have already taken advantage of improving credit conditions

to restructure their balance sheets but overall the industry remains conservative in this area. Goingforward we expect the sector to remain resilient both from an operational and an M&A perspective.

However, with expectations on forward price curves for oil and gas subject to increasing uncertainty

we can see that pricing is going to be a key issue in the transaction markets over the next six months.”

Oil and gas transaction appetite down slightly, cont’d.


6/16


A NOVEL METHOD TO DETECT SURGE DURING SURGE TESTthere is a net force on the impeller that acts toward to the suctionthat is shall not be equal to the difference between the impeller suc-tion pressure and the impeller discharge pressure applied over anarea equal to the impeller eye. This inequality is compensated by abalance drum and /or balance line.

During a surge condition, the gas ows backwards through the im-

peller from the discharge to the suction. This cause the dischargepressure to drop and the suction pressure to rise. This reversal in thepressures causes the net thrust that is normally acting on the rotorto reverse directions. During this cycle, the pressure change acrossthe impeller is proportional to the density of the gas and the impel-ler tip speed squared. This means that for a given compressor, thesurge event is more loud and clear with a gas of higher density andthe speed is higher. The more signicant is the effect of speed beingsquarely proportional. When a compressor is at very low speeds(way out of bottom line of compressor speed line map), the effect ofsurge shall not be severe.

Pressure Fluctuation during surge shall cause axial excursion. Thiscan be well understood by axial loading directional diagram asshown below during normal design range ow conditions for atypical back to back compressor. [1]

Fig -1 A back-to-back compressor conguration with load direction

A case study placed for example - During commissioning of aCentrifugal Compressor before Work range mapping and surge linedrawing , Compressor is run a lower speed with a controlled suc-tion ow and recycle valve fully open. Slowly the recycle valveis modulated towards closure to look into a point of surge locus.Again the same procedure is followed with a bit higher speed andow. During such activity of commissioning of a commissioningof a Gas Turbine driven Centrifugal Compressor a “Cat Scream”sound inside the compressor was observed. At that time recyclevalve was fully open. To avoid any untoward consequence, com-pressor was shutdown. The coast down of the compressor indicatedthe machine to be all right. The test RPM of compressor was slightlylower than 70% of rated RPM during the incident .

Machinery Vibration trends were taken from event log from di-agnostic system. This sound was in cyclic interval as detected byVibration Waveform generated by Machinery analysis Module.

Mantosh Bhattacharya, Petrofac UAE

Centrifugal Compressors are most widely used high speed ma-chines in Oil & Gas industry. A failure of compressor leads to majorrevenue loss and downtime. A good percentage of compressor fail-ure did happen in past due to operational instability which includesSurge. By dint of numerous papers by experts and case studies pre-

sented in various symposiums, end users are now very much awareof consequence of such phenomena. Compressor surge preventionand control are now part and parcel of any software installed inunit control panel which operates the compressors. Most of the al-gorithms for anti surge control work on the data taken from vari-ous process parameters. This paper endeavors to propose a newmethod to identify and mitigate surge related damage, particularlyduring commissioning / surge test of centrifugal compressors whenoperators are mostly dependent on groans / squeals of compressor.

Mechanism of Compressor Surge - When the pressure ratio acrossa centrifugal compressor exceeds the maximum pressure ratio thatcan be produced for that gas and impeller speed, the ow will sud-denly reverse through the compressor. The ow reversal allows thedischarge pressure to drop and at the same time will cause the suc-tion pressure to rise, resulting in a sudden drop in the pressure ratio.The ow reversal essentially relieves the condition that caused theow reversal to occur.

Within few moments after the ow reversal started, the ow willstart moving forward again through the compressor. If the conditionthat has temporarily created a higher than designed pressure ratioacross the compressor is not changed, the ow reversal will repeat.At this point, the compressor shall be in surge. The unit in surgeshall emit a load groaning / squealing sound in every few seconds.

Before surge to occur an “alarm” rings as incipient surge inside the

machine.

Incipient surge occurs when the ow through the impeller is notsufcient to ll the impeller ow passage. Boundary layer separa-tion occurs on the trailing side of the vanes. Stall cells are formedin the separation area and when they reach the impeller exit, itmoves in a counter-rotation direction to another ow passage. Mostof the times rotating stall occur just before the time of surge.

This phenomena a radial pulsation is produced that acts orthog-onally of the axis of Rotation of compressor rotor. The excitingfrequency of the pulsation are transgressed into radial non synchro-nous vibration which normally happens at 0.3 -0.6 X of RPM. This

is mostly combined with a Noisy signal and generally cascaded bylubrication related troubles like whirl ( 0.43-0.47X RPM ).

As with surge, the pressure pulsations that occur during incipientsurge are also a function of the gas density and impeller tip speedsquared. However the magnitude of the pulsations are about 0.05times those experience during surge. Also, the pulsations that occurduring incipient surge act in the radial direction, rather than in theaxial direction.

The biggest problem with incipient surge is the frequency at whichthe pulsations occur. The frequency of incipient surge often is closeto that of the rotor’s natural frequency. If the compressor operates

for very long in incipient surge, the opportunity exists for excitingthe rotor, acts as a catalyst to high radial vibration leading to prob-able damage.

Under normal conditions when the ow is moving forward, thearea of the shroud is exposed to discharge pressure as is the backof the hub. Since the area of the eye is exposed to suction pressure,

Further investigation suggest led to a conclusion in obstruction inRecycle line gas path.

After inspection of inlet suction strainers, it was decided to openthe Anti Surge Valve which was found clogged with foam acting asHeart Pump in recycle line. This means whenever sponge was stuckto cage, ow dropped down and discharge pressure rose to create

a event of surge.

This occurrence and subsequent vibration data acquisition led todraw an alternative method to detect surge particularly duringeld testing. The plots and observations on them are shown below(left) in Figure 2.

It was observed that time interval of “cat scream” sound and Rotoraxial movement trend had some distinct relationship. This excur-sion was detectable as RPM of rotor was quite low, Compressor wasat recycle mode at low suction pressure.

During the whole episode, Gear Box Pinion radial vibration uctu-ation was also found in line with time interval of screaming sound.

Fig-3 Hunting in pinion vibration readings during “Cat Scream”

A rotor rub will lead to high vibration during coast down at ma-chine critical speed, which did not occur.

Change in machine behavior during surge - Usually surge is limitedto be identied with excessive rotor excursion / vibration and au -dible “cat scream” sound yet there are cases when surge was notaudible yet occurred and caused damage to the machine. Gener-ally onset of surge causes uctuation of temperature, differentialpressure uctuation with a high order and change in rotor axial po-sition. Monitoring rst three parameters, require smart and specialtype of transmitters.

High pressure compressor onset of surge is accompanied by a lowfrequency asynchronous vibration which are detected when thesurge energy is quite high. If the Compressor train is driven witha speed increasing gear box, the pinion being the lightest part of

system can demonstrate some excitation in low frequency regimeand a spectrum can easily reveal the symptom.

Fig 4 – Gear Box vibration spectrum

Pressure Fluctuation during Rotating Stall at stage although the lastimpeller of compressor might go to a condition of incipient surgerst shall cause high lateral sub synchronous instability.

Fig-2 Hunting in axial probe reading during “Cat Scream” -- see “A Novel Method” page 8


7/16



8/16


During normal operation pressure differentials between two sidesof each impellers are balanced by end balance drum and centerwall balance drum.

Comparative study on various Possible Setting of a early warningsystem other than Compressor Antisurge control module normallyin use.

Measurement of ow and discharge pressure oscillation is difcultto achieve at site as they require special type of transmitters.[2]

Measurement and monitoring of radial vibration at low frequencycalls for a very accurate band pass lter. Calibrating very low fre-quency accelerometer is difcult task. During compressor opera-tion it is quite difcult to pin point surge with the increase of Nonsynchronous vibration as a tool.

Fig - 5 Compressor shaft vibration spectrum during surge

These can be only used as a diagnostic tool if location of rotatingstall is already detected before tow out. Test and drawing a stall linecan be performed during full load full speed Type -1 test at Com-pressor Manufacturer’s premises.[3]

If the unit uses a speed increaser gear box, a low frequency accel-erometer can pick up the vibration as pinion is the lightest part intransmission. It must use Piezoelectric Transducer, shall be capable

of overcoming monitor noise shall be less sensitive to strain. [4]

Measurement and monitoring of axial vibration. It has been ob-served that axial vibration do occur during surge. To measure axialvibration needs shaft end face minimum surface nish must be incompliance with API 670 latest edition where maximum ARH of1 micron is allowed. Besides this , there are other issues like mis-alignment and bent shaft which may cause axial vibration at 1 and2 times operating frequencies and create a confusion in diagnosis.Rotor speed and the coupling type/stiffness have a strong effect onthe vibration spectra. The level and type of misalignment had asignicant effect on the vibration signature. Due to inadequate datathe effects of machine dynamic stiffness can not be quantied ..Fil-

tering the axial vibration value at particular frequency from directaxial vibration reading may need human interface.

Monitoring Axial excursion level and rate of Rotor. The rotor excur-sion during surge is dependant on dynamic pulsation of machinewhich then is a function of gas density and Square of rotor periph-eral speed.

The schematic diagram of proposed early warning system of surgeis illustrated in Figure 6 (top, right).

• Where CV1= Gear Box casing vibration measured particularlyat Low Frequency .

• CV2 = Casing vibration measured with a band pass lter (should be used as Diagnostic tool to baseline the other inputvalues to rm up a Logic )

• Z1 & Z2 = axial displacement measured by dual probes prefer-ably with a signal booster.

• Z0 = difference between Z1 & Z2. This value shall be countedwith a timer. S is the microprocessor.

The proposed scheme requires a microprocessor with a good scan-ning time with a logic box, a counter, a high value gate, signalbooster and charge amplier to amplify gear box casing / compres-sor casing vibration.

Fig -6 –Schematic of proposed instrument layout

Description of Proposed Logic in Microprocessor S1

Fig -7 Proposed Logic diagram

The Microprocessor S1 shall be armed just after compressor cross-es the 1st Critical speed or 60% of deign speed (base speed). Thenit will start reading Z1 and Z2 (both in microns) and a calculationblock shall calculate difference between Z1 and Z2 (a dimension-less value). It parralelly checks if Z (overall excursion) has crosseda preset limit of A. If the Z remains greater than A for count of morethan M during a measuring span of 2 seconds, Microprocessor shalltrigger an alarm.

The other part of logic shall calculate an invariant (RPS x Z x K2)where RPS is rotation per second, K2 is sensitivity constant i.e howmuch onerous the reading shall be. Parallely, the low frequency ac-celerometer reading CV1 from gear box pinion location. If the CV1remains greater than Y, it shall create an another invariant (RPS xCv x K1) where RPS is rotation per second, K1 is sensitivity constanti.e how much onerous the reading shall be. Due diligence shall beexercised to decide upon A , Y ,K1 & K2 . These two invariants shall pass the high value gate and one of themshall be accompanied with counter output to annuciate an alarmor trip .

The logic box shall attenuate an alarm if number of axial positionof rotor shift is more than Z0 micron counts exceeds A in 2 seconds.Axial position transducers shall be measuring element. The valueof 2 sec is based on numerous vendor experience that compressorcan withstand a surge for 2 seconds with surge event counting of 2.

Fig -8 Axial excursion counter with a set timer.

For those single casing centrifugal compressors those are operatedby a DOL Induction motor at a constant speed and compress a gaswith a rmed up composition ratio within a xed operating regime

this logic can work well.

For a variable speed driver, some more algorithms must be devel-oped like speed x axial probe reading as an invariant taking thestatus of machine as point for deducing the end result.

If this happens and the compressor is operated at a turndown con-dition, there is risk that compressor could drift into surge withoutthe operator knowing about it, which could lead to a machine fail-ure. Monitoring compressor performance is therefore important tonot only ensure efcient compressor operation, but also to protectagainst operating the machine in surge.

A parallel operated valve with Cv of approx to that of ASV (AntiSurge Valve) can be used to be operated as ON /OFF based onsignal by Microprocessor S1 during surge test. The conguration ofthe valve shall be same as a Cold Gas By Pass Valve.

Advantages – The proposed scheme avoids human interface to in-terpret Surge with maximum extent.

All data required can be taken from VMS (Vibration MonitoringRack) directly with RS232 communication.

The proposed system is cheaper and can be used at various siteswith a Laptop having the program.

The author wishes to thank Mr. Abdul Rahman Dandachi, ControlsSpecialist Petrofac for his valuable suggestions.

References –

1. Compressor Handbook by W.E.Frosthoffer

2. Increased Flexibility of Turbo-Compressors in Natural Gas Transmis-

sion Through Direct Surge Control by Robert McKee, Shane Siebenaler

& Danny Deffenbaugh-Southwest Research Institute

3. Application Guideline for Centrifugal Compressor Surge Control Sys-

tems by Klaus Brun & Marybeth Nored-Southwest Research Institute

4. Papers on Non Synchronous Forced Vibration by D.R. Smith & J.C.

Wachel

5. Product Catalog – Wilcoxon

6. Articles by Late Dr. Donald Bently on Rotating Stall

A Novel Method to Detect Surge During Surge Test, cont’d


9/16


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BUSINESS BRIEFS

CALGARY, Alberta - ESG Solutions, an industry leader in microseismic technology and services,

is pleased to announce the successful expansion of a near-surface seismic monitoring system in

Western Canada. Initially installed in 2012 to monitor any potential larger magnitude induced

seismicity during hydraulic fracturing operations, the system was recently expanded to provide

greater monitoring range spanning multiple well pads.

In response to increased concern surrounding subsurface injections and induced seismicity,

many operators are taking the initiative to better understand the response of unconventional res-

ervoirs to hydraulic fracture stimulations, especially in the presence of nearby geological struc-

tures. ESG’s near-surface regional seismic solution encompasses an array of ESG manufactured

surface-based sensors optimized for seismic detection between M0 and M+4. “Operators are

looking for a reliable, cost-effective solution to help them understand the triggering mechanisms

of seismicity detected near injection operations,” says Dr. Ted Urbancic, EVP of Global Energy

Services at ESG. “ESG has been collecting and analyzing induced seismic data for 20 years. This

experience gives us the knowledge to integrate site-specic seismic data with existing regional

networks and decode the trigger mechanisms associated with that seismicity.”

Continuous passive seismic data from the near-surface array is collected using ESG’s 32-bit, high

resolution, low noise Paladin™ digital seismic recorder and the data is integrated seamlessly with

ESG’s Hyperion Seismic Software Suite for accurate processing and analysis. “ESG manufactures

equipment and develops software in-house. Depending on the customer’s needs, we can utilize

third party components for less cost to the client, or custom design and build seismic systems for

each site so that operators have access to the accurate and timely information required to make

operational decisions,” says Urbancic.

Prior to its recent expansion, the regional seismic array deployed to monitor operations in a Ca-

nadian shale play had detected hundreds of events above magnitude 0. By extending the moni-

toring range to cover additional regions of the eld, operators hope to further understand the way

in which the reservoir is responding to stimulation activities, and ultimately maximize production

from the eld. Surface-based regional seismic arrays can complement downhole microseismic

monitoring, integrate with established regional seismic networks or be used independently to

establish a baseline for local seismicity, to better characterize nearby faults or provide a means of

alerting operators to abnormal induced seismicity.

A number of similar ESG near-surface arrays are currently in operation throughout the world

for applications as diverse as natural gas storage, waste injection, reservoir impoundment, car-

bon sequestration, coal-bed methane and mining operations. ESG designs and manufactures itsown permanent microseismic instrumentation for longer-term reservoir stimulations and surface-

based regional seismic networks in addition to providing wireline data acquisition, processing

and advanced analytics for hydraulic fracturing.

Well Stimulation Pumps Unveiled at OTC

Caterpillar Global Petroleum is pleased to an-

nounce the launch of Cat® Well StimulationPumps for the well service market. Starting in

May 2013, Caterpillar will begin accepting

orders for the Cat WS223, a 2250 bhp (1678

bkW) triplex well stimulation pump, as well as

the Cat WS255, a 2500 bhp (1864 bkW) quin-

tuplex well stimulation pump. In addition to

offering the complete pump for well service

customers, Caterpillar will offer a variety of

8” and 10” stroke uid ends individually. A

2700hp triplex pump, available in late 2013,

will be on display along with several uid end

models at the Caterpillar booth #3341 at OTC2013, May 6th – 9th in Houston, Texas.

“At Caterpillar, our goal is to provide the most

reliable and durable power solutions for the

Well Service and Pressure Pumping market.

By adding the well stimulation pumps to our

portfolio of offerings we are able to provide a

more comprehensive pressure pumping solu-

tion for our customers,” Mark Helgren, Cat-

erpillar Global Petroleum-integration man-

ager stated. “Our customers, who have been

pleased with our engines and transmissions,

will be able to readily implement the Cat well

stimulation pumps into their operations with

the utmost condence in their performance

and Cat Dealer support.”

ESG Solutions Announces Successful Expansion of Surface-based Regional Monitoring System for Induced Seismicity

The Cat Well Stimulation Pumps feature uid

ends and power ends designed to an industry

standard footprint. This will allow customers

to easily t the Cat pump into their existingtrailer designs. In addition to the standard uid

end Cat will offer an Extreme Duty (XD) uid

end with superior durability for the harshest

operating conditions. The uid ends on both

models have a valve-over-valve design to sim-

plify valve, seat and plunger installation, and

each uid end block is manufactured with a

robust material conditioning process. A full

assortment of discharge anges, suction mani-

folds, and bore sizes will also be offered.

The new Cat well stimulation pumps will bedistributed, sold and supported through the

worldwide Cat dealer network with trained

technicians to ensure service support is never

out of reach.

Dynamic Gas Blending Retrot Kit for Well

Stimulation Applications Released

Houston, Texas – Caterpillar Global Petro-

leum today announced that it has developed

a Dynamic Gas Blending (DGB) retrot kit

for use on the Cat® 3512C (HD) engine used

in well stimulation applications. Available

to order in June 2013, this system will allow

for maximum substitution of diesel fuel with

natural gas during high pressure pumping op-

erations, and is available in both Air To Air

After Cooled (ATAAC) and Separate Circuit

After Cooled (SCAC) congurations for 2250

hp and 2500 hp @1900rpm ratings.

Heavily leveraging decades of success with

Cat natural gas engines and the recent intro-

duction of the Cat DGB system for land drill-

ing and production, the Cat well stimulation

DGB system makes no compromise with per-

formance, safety, and reliability while burn-

ing a mixture of diesel and natural gas fuels.

“Through our product development work in

the eld with some of the leading well servic-

ing companies, the Cat DGB system has per-

formed exceptionally well. User feedback hasbeen very positive with ease of installation,

engine performance, and the integrated safety

features of the Cat DGB system,” said Scott

Roberts, Caterpillar Global Petroleum Well

Service Product Marketing Manager.

Along with the benet of realizing signicant

fuel cost savings by substituting diesel fuel

with natural gas, there are several other key

features of the Caterpillar DGB system that

make it a winning solution for well stimula-

tion. Operators can run the system with con-

dence on CNG, LNG, and eld gas with a

lower heating value between 850 and 1,250

Btu, knowing that the engine is maintaining

United States EPA Tier 2 level emissions with

the combined mufer and Cat Diesel Oxida-

tion Catalyst (DOC) included in the DGB kit.

The system is capable of achieving maximum

substitution at various speeds and loads overthe full operating range, and will automatical-

ly adjust to changes in gas quality without the

need to perform any recalibration or adjust-

ments to the system during or between jobs.

The DGB system is fully integrated with the

engine control system, optimizing engine per-

formance and ensuring that the engine always

operates within safe parameters while blend-

ing diesel and natural gas. This results in no

compromise with performance, maintenance

intervals, engine reliability, and most impor-tantly, safety. Installation of the Cat DGB kit

on existing engines is streamlined through

efcient design. The combined mufer and

DOC eliminates the need for the customer to

integrate a DOC with their existing mufers,

and a single advanced Engine Control Unit

simplies the electrical system.

Caterpillar Unveils Well Stimulation Pumps and Releases Dynamic Gas Blending Retrofit Kit for Well Stimulation Applications


11/16


12/16


The database has been developed in collabo-

ration with Advanced Energy Economy (AEE),

a national business organization representing

the entire advanced energy industry, from

wind, hydro, solar, and natural gas to efcien-

cy and electric vehicles.

“This online database provides information

on critical state legislation that is available

nowhere else,” said Graham Richard, CEO of

AEE. “AEL Tracker is a nonpartisan tool that

allows researchers, journalists, policymakers

and concerned citizens to follow and analyze

advanced energy legislation, individually and

in aggregate. We hope this unique database

will increase awareness of advanced energy

and the way state action can unleash its eco-

nomic potential for the United States.”

Both Richard and Ritter shared additional

views in videos that can be found on the AEL

Tracker website: www.aeltracker.org.

CNEE operates the database on the Fort Collins

campus of Colorado State University, a land-

grant university with a long history of cutting-

edge research into natural gas emissions and

renewable energy, water resources and the

environment. The university provides credible,

multi-disciplinary solutions to the complexitiesfacing America’s energy industries.

PG&E Ranked One Of The Top Utilities In The Nation For Diversity

Fifth Year in a Row Utility Recognized by Di-

versityInc as a Leader in Diversity

SAN FRANCISCO - Pacic Gas and Electric

Company (PG&E) has been recognized by Di-

versityInc as one of the top regional utilities inthe country for its strong diversity practices.

This is the fth year in a row that the utility

has been recognized by DiversityInc, a lead-

ing publication on diversity and businesses.

“It is clear that U.S. companies are increasing-

ly conscious of the importance of diversity,”

said Luke Visconti, Chief Executive Ofcer of

DiversityInc. “We are very encouraged to see

PG&E applying for this distinction. We also

note a continued positive correlation between

achievement in diversity and overall companyperformance.”

For the 2013 ranking, DiversityInc surveyed

893 companies with at least 1,000 employ-

Business Briefsees. Participating companies were rated by

DiversityInc. in four key areas: CEO Commit-

ment to Diversity Management, Workforce

Diversity and Human Capital, Corporate/Or-

ganizational Communications, and Supplier

Diversity.

“It is an honor to be named by DiversityInc

one of the top regional utilities in the country

for diversity. As a utility that serves some of

the most diverse communities in the nation,

PG&E views diversity as the very fabric of our

corporate culture,” said Laura Butler, Vice

President of Talent Management and Chief

Diversity Ofcer at PG&E. “This commitment

to diversity and inclusion is a critical part of

our values and how we work to provide safe,

reliable and affordable gas and electric ser-vice to our customers.”

Atlas Pipeline Partners, L.P. Closes onAcquisition of TEAK Midstream

PHILADELPHIA - Atlas Pipeline Partners, L.P.

(NYSE: APL) (“APL”, “Atlas Pipeline”, or the

“Partnership”) announced that the Partnership

has closed on its previously announced pur-

chase of TEAK Midstream, L.L.C. (“TEAK Mid-

stream” or “TEAK”), a private midstream com-

pany. The effective date of the acquisitionwas April 1, 2013. Final cash consideration

for TEAK totaled $1.0 billion, subject to work-

ing capital and other adjustments contemplat-

ed by the Purchase and Sale Agreement.

Eugene Dubay, Chief Executive Ofcer of the

Partnership, commented, “As I mentioned in

the initial announcement, we are very excited

about this acquisition of TEAK Midstream.

This is the right entry point into the Eagle Ford

with the right infrastructure and with tremen-

dous future growth potential. After success-

fully executing organic growth across all of

our legacy systems, we look forward to doing

the same with our new Eagle Ford assets.”

Upon the closing of this transaction, the Partner-

ship will own 100% of the following TEAK assets:

• 200 MMcfd of cryogenic processing ca-

pacity (“Silver Oak I”);

• A second 200 MMcfd cryogenic process-

ing facility to be in service in the rst

quarter of 2014 (“Silver Oak II”);• 265 miles of primarily 20” to 24” gather-

ing and residue lines with 750 MMcfd of

throughput capacity; and

• 275 miles of low pressure gathering lines

Additionally, the Partnership has acquired

a 50%-75% interest in various joint venture

agreements that currently exist between TEAK

and TexStar Midstream Services, L.P. The

Partnership will be the operator of the joint

venture assets following the transaction,

which include:• 235 miles of pipeline, including rich gas

gathering, header, and residue pipelines;

• 3 miles of NGL pipeline; and

• A Co-Gen facility, which will produce

power for the Silver Oak complex as well

as the ability to sell power to third-parties

and back to the grid during peak season

The Silver Oak processing complex is ex-

pected to expand in early 2014 by installing

a new 200 MMcfd facility, the Silver Oak IIplant, and potentially expand further thereaf-

ter by adding an additional 200 MMcfd facil-

ity. Any expansions will be 100% owned and

operated by Atlas Pipeline.

New Database At Colorado State University Tracks Energy Legislation In All 50 States

FORT COLLINS, Colo. - Colorado State Uni-

versity’s Center for the New Energy Economy

(CNEE) today announced the rollout of the

Advanced Energy Legislation (AEL) Tracker –

a new online database of energy-related state

legislation pending in all 50 states, from solar

to natural gas and everything in between. This

rst-of-its-kind database, created in partner-

ship with Advanced Energy Economy (AEE),

will also enable CNEE to conduct analysis of

trends in state energy legislation.

Today, state legislatures are considering more

than 2,100 bills that could change the way

Americans produce, buy and use energy.AEL Tracker identies all those measures and

monitors the progress of many advanced en-

ergy bills as they move forward.

“If we look at where the country is going on

advanced energy policy, overwhelmingly that

transition is being led by states,” said Bill Rit-

ter, Jr., director of CNEE and former governor

of Colorado. “To get the pulse of where the

country is going we need to understand what

the states are doing. AEL Tracker brings to-

gether information on energy-related legisla-

tion in all 50 states, in a form that is easily

accessible not only to lawmakers at all levels

of government, but to academics, analysts,

environmentalists, funders, business leaders

and the general public. It will allow our Cen-

ter to conduct critical academic analysis of is-

sues related to energy legislation nationwide.”

Based on information available only in AEL

Tracker:

• Nearly 25 percent of pending state ener -gy legislation call for new nancing tools

– including tax incentives – for the instal-

lation of energy facilities;

• Roughly 21 percent of pending bills pro-

mote development of clean energy sourc-

es; and

• About 8 percent encourages adoption

of energy-efcient appliances, building

codes and practices – the low-hanging

fruit in America’s energy supply chain.

The Center’s rst trend analysis is on energyefciency, entitled “Rediscovering the First

Fuel.” The Center expects to publish 2-3 trend

analyses per month and will next publish a

white paper on nancing of advanced energy.

-- continued next page

May 20-22 – Houston

The 2013 CORE program will be focused primarily

on On-Board Diagnostics (OBD) tools for the natu-

ral gas transmission industry. A review (with case

studies) of current and planned industry research

will presented including how OBD can be used as

a tool to provide emissions compliance verication,

diagnose and identify critical equipment faults. Dis-

cussions will also include the integration of sensors,

actuators and controllers to move further to an “ex-

pert” level of OBD.

CORESymposium.com


13/16


ACI Services, Inc. • Cambridge, Ohio • www.ACIServicesInc.com • (740) 435-0240

Compression requirements

change. ACI Services will guide

you to the most cost-effective

compressor solutions. ACI

has the expertise to develop

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Engineering Analysis

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Business Briefs -- continued

-- continued next page

ROBERT EARL HOLDING, FORMER OWNER OFSINCLAIR OIL DIES AT 86

Wyoming billionaire Robert Earl Holding, died onApril 19 at age 86, apparently from old age andcomplications related to a 2002 stroke. He attend-ed school in Salt Lake City and after serving in theArmy Air Corps, he earned a Civil Engineering De-gree from the University of Utah. He married CarolOrme and in 1952 they moved to southwest Wyo-ming to manage a money-losing motel/gas station inisolated Little America. He eventually bought outthe other owners and started adding gas pumps. Helater borrowed to buy the Mobil renery in Casper,Wyoming in 1968 and went on to purchase SinclairOil in 1976. A year later he bought the Sun ValleySki Resort in Idaho.

Despite his business success, Earl never forgot that it was the people he worked with who madethe difference. He often remarked that “you do business with your friends.” He inspired thosearound him to give their best efforts, and then, even a little more. He was as ercely loyal to his

family and his employees as they were to him. Most of the employees hired by Earl in the earlydays spent their entire careers with him and even their children work with the company to thisday. Earl enjoyed working alongside his people and watching them succeed.

Earl deeply loved the land and the beauty of the American West. He looked for every oppor-tunity to spend time at the ranch working the elds, cattle and crops and being surrounded bythe natural beauty of God’s creations. Many of his business ventures were centered on creatingsomething from nothing, making improvements, and building f rom beautiful natural materials.When planning the Grand America Hotel he personally traveled to Bethel, Vermont to selectthe granite for the project. He was fascinated by the possibilities found in nature, from drillingfor oil to preserving a stand of trees on a ski run.

Earl’s tireless efforts on behalf of the Olympics helped bring the 2002 Winter Games to SaltLake City. He was an enthusiastic supporter of the Olympics believing the Games stood for theideals of athletic excellence and international cooperation.

Earl is survived by his wife, Carol, their three children, Anne, Kathleen, and Stephen, theirspouses, twelve grandchildren, his brother, Ralph, and many extended family members, busi-ness associates and friends who were just like part of the family. He was predeceased by hisparents, his sister, Helen Jean, and his close business partner and childhood friend, KennethY. Knight.


14/16


Business Briefs -- continued REGISTRATION NOW OPENGas/Electric Partnership

Midcontinent Natural Gas Production ChallengesSeptember 12 – Oklahoma City This one-day workshop will explore solutions, best

practices, and emerging technologies for address-

ing the challenges associated with compression

and processing of natural gas from wellhead gath-ering to the point of delivery into long-haul pipe-

lines. Although focusing primarily on issues en-

countered by Midcontinent gas and oil producers,

many of the topics will be relevant to operations in

other regions of the U.S. Topics will cover a broad

range of issues including the gas and oil industry

outlook; strategies for utilizing stranded gas; rich

gas treating and processing; gas and electric driv-

en compression; compliance with current and pro-

posed environmental regulations – exhaust emis-

sions, greenhouse gases, HAPs; vapor recovery;

fuel conditioning; and more.

CECO’s Combustion CharacteristicsJune 4-7 – Colorado Springs - Instructor: Randy Anderson Combustion Characteristics covers all aspects of

combustion and emissions, with a primary focus

on troubleshooting operating changes on a variety

of reciprocating engines—two–stroke cycle (2SC)

and four–stroke cycle (4SC) engines, as well as

naturally aspirated 4SC engines used as genera-

tors. Students of this course will receive instruction

covering peak ring pressure (PFP), mean effec-

tive pressure (MEP), exhaust temperatures, turbo-charger speed, fuel consumption, and emissions.

CECO’s Compressor CharacteristicsAugust 20-21 - Oklahoma City - Instructor: Randy Anderson This class provides a solid foundation of basic troubleshooting skills. It introduces

the student to various troubleshooting techniques and their applications and limitations.

Course topics include integrated operational excellence for gas machinery, analyti-

cal fundamentals of troubleshooting, twenty-ve (25) diagnostic troubleshooting tools,

ignition troubleshooting, power cylinder troubleshooting, compressor troubleshooting,

auxiliary and rotating equipment troubleshooting and unit startup troubleshooting.

CECO’s Fundamentals of TroubleshootingAugust 22-23 - Oklahoma City - Instructor: Randy Anderson Compressor Characteristics teaches concepts of reciprocating compressor application

and operation. It covers naturally aspirated 4-stroke cycle, piston scavenged 2-stroke

cycle, pure turbocharged 4-stroke cycle, and turbocharged 2-stroke cycle engines. The

course is divided into two sections: Compressor Fundamentals (A lecture describing

physical components, mechanical linkages, fundamental operating theory, and oper-

ating characteristics) and Compressor Characteristics (a series of problems that de-

scribe certain changes on a compressor and their effect on critical compressor perfor-

mance parameters)

Visit www.striker-ent.com or www.GasMachineryJournal.comto register for any of our 2013 Knowledge Transfer events.

Platts Project Tracker Shows Early-Year Improvement After Marked Slowdown in 2012

LONDON, May 8 - Asian power generation development activity in the rst three months of

2013 totaled 62.74 gigawatts (GW), according to the latest quarterly project tracking report by

Platts, a leading global provider of energy, petrochemicals and metals information.

“This was 12% lower than in the same period of 2012, but was well up on the prior quarter – in

fact, more than a fth higher than in the last three months of 2012,” said Martin Daniel, editor of

Platts Power in Asia, the newsletter in which the quarterly data is published.

The earliest stage of the project development process is the announcement of planned new ca-

pacity. The amount of new capacity announced in the rst quarter of 2013 was much the same

as in the same period of 2012.

“But at more than 21 GW, the level of Q1 activity was almost double that of the fourth quarter of

2012, which appears to indicate an improvement in developer condence,” said Daniel.

First quarter project approvals were approximately 12.85 GW, which was down versus a year

ago but up almost twofold compared to Q4. But the amount of planned new power capacity

actually signed to construction and equipment contracts was down 40% from both the prior

quarter and Q1 of 2012.

“This seems to indicate that the revived condence visible at the start of the project development

pipeline has yet to turn into rm orders,” Daniel said. “This is not surprising, given the long gesta-

tion period of most power generation projects.”

The Platts power project tracker shows that the pattern of new capacity build in Asia was not uni-

form. In India, where new power development had been hindered for much of 2012 by fuelingand nancing issues, there was a signicant revival in activity of approximately 8.1 GW during

the rst three months of this year. New power development in China, of nearly 12.5 GW, also

was up compared to a year ago and versus the last quarter of 2012. Southeast Asia and west Asia

also saw continued buoyant new capacity activity at 19.1 GW and 12.5 GW, respectively.

In terms fuel and technology, a clear winner in the new power capacity build in Q1 was solar

power. New programs in India, China and numerous other Asian countries caused Q1 solar sec-

tor development to treble versus Q4.

Capacity expansions for coal-red plants accounted for 45% of total activity in the rst quarter of

2013, little changed from the prior quarter and rst quarter of 2012. Data showed a close split ofabout 13.8 GW of new plant capacity going to the use of local coal and approximately 14.3 GW

dedicated to or potentially using imported coal. By contrast, most of the 15.1 GW of natural gas-

red plant capacity that changed status in Q1 will go to use of either imported or indigenous gas.

The Platts Power in Asia project tracker was developed by Platts in 2011 to identify trends in the

Asian power generation market. It is a bottom-up aggregation of identied individual projects.

Platts tracks these projects as they move through the development pipeline from announcement

to completion. The Platts tracker only tracks projects registering a signicant change in status dur-

ing the quarter such moving from announcement to approval or to start of construction. It does

not capture the much broader amount of capacity under development in Asia.

Platts: Asia’s Power Capacity Expansion Saw Upswing in Q1 2013

l l


15/16

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Dresser-Rand Services cover everything from upgrades, revamps, rerates, product training, and field services, right down

to the nuts and bolts. And with the largest installed base of rotating equipment in the industry, Dresser-Rand is ready to deliver

comprehensive service solutions for your centrifugal and reciprocating compressors, steam and gas turbines, and control

systems—quickly, efficiently and safely. With approximately 40 service centers around the world, our personnel stand ready

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» www.dresser-rand.comCompressors–Turbo & Recip / Steam Turbines / Gas Turbines / Engines / Control Systems / Expanders

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