Compressor Tech 12 2014
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ENGINE REVAMP OF A NORTH DAKOTA SPECS-AT-A-GLANCE RECIP COMPRESSOR TARGETS FLARING DECEMBER 2014 COMPRESSOR DEMAND MAY HAVE PEAKED EXTERRAN’S HIGHLY CONFIGURABLE PACKAGES REPLACEABLE SEAT PLATE FOR CPI VALVE WWW.COMPRESSORTECH2.COM/SUBSCRIBE/
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Transcript of Compressor Tech 12 2014
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ENGINE REVAMP OF A NORTH DAKOTA
SPECS-AT-A-GLANCE RECIP COMPRESSOR TARGETS FLARING
DECEMBER 2014
COMPRESSOR DEMAND
MAY HAVE PEAKED
EXTERRAN’S HIGHLY
CONFIGURABLE PACKAGES
REPLACEABLE SEAT PLATE
FOR CPI VALVE
WWW.COMPRESSORTECH2.COM/SUBSCRIBE/
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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 competitiveadvantage 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 Ewww.elliott-turbo.comThe world turns to Elliott.
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arielcorp.com
The new
Simple. Reliable. Ariel.
Discover what’s new at www.arielcorp.com
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Page4CT2 Founder .......................... Joseph M. Kane
PUBLICATION STAFFPublisher .....................................Brent Haight
Associate Publisher ..............Roberto Chellini
Editor ..........................................Patrick Crow
Executive Editor .............................. DJ Slater
Deputy Editor ..............................Mark Thayer
Senior Editor ................. Michael J. Brezonick
Senior Editor ............................. Mike Rhodes
Associate Editor ...............................Jack Burke
Associate Editor ............................Chad Elmore
Associate Editor ...................................Art AielloCopy Editor ............................... Jerry Karpowicz
Digital Content Manager ...........Catrina Boettner
Advertising Manager ...................Sarah Yildiz
Circulation Manager ..................Sheila Lizdas
Production Manager ............ Marisa J. Roberts
Graphic Artist .......................Brenda L. Burbach
Graphic Artist ............................Carla D. Lemke
Graphic Artist ..........................Amanda J. Ryan
Graphic Artist ...............................Alyssa Loope
PUBLICATION HEADQUARTERS20855 Watertown Road, Suite 220Waukesha, Wisconsin 53186-1873
Telephone: (262) 754-4100 Fax: (262) 754-4175
CONTRIBUTING EDITORSNorm Shade - Cambridge, Ohio
Mauro Belo Schneider - Rio Grande du Sul, Brazil
HOUSTON, U.S.A.Brent Haight, Publisher
Patrick Crow, EditorMike Rhodes, Senior EditorMark Thayer, Deputy Editor
12777 Jones Road, Suite 225Houston, Texas 77070
Telephone: (281) 890-5310 Fax: (281) 890-4805
GERMANYLisa Hochkofler, Advertising ManagerGabriele Dinsel, Advertising Manager
Niemöllerstr. 973760 Ostfildern, Germany
Telephone: +49 711 3416 74 0 Fax: +49 711 3416 74 74
UNITED KINGDOMIan Cameron, Regional Manager/EditorLinda Cameron, Advertising Manager
40 Premier AvenueAshbourne, Derbyshire,
DE6 1LH, United KingdomTelephone: +44 20 31 79 29 79 Fax: +44 20 31 79 29 70
ITALYRoberto Chellini, Associate Publisher
44, Via Delle ForbiciI-50133 Firenze, Italy
Telephone: +39 055 50 59 861 Fax: +39 055 57 11 55
Roberta PrandiVia Fitta, 21a
I-38062 Arco, ItalyTelephone: +39 0464 014421 Fax: +39 0464 244529
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Telephone: +46 70 2405369 Fax: +46 122 14787
JAPANAkiyoshi Ojima, Branch Manager
51-16-301 Honmoku Sannotani, Naka-kuYokohama, 231-0824 Japan
Telephone: +81 45 624 3502 Fax: +81 45 624 3503
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Rm 1903A, 19/F, Sunbeam Commercial Building469-471 Nathan RoadKowloon, Hong Kong
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Telephone: +82 2 391 4254 Fax: +82 2 391 4255
DIESEL & GAS TURBINE PUBLICATIONSPresident & CEO ....................Michael J. Osenga
Executive Vice President ...Michael J. Brezonick
COMPRESSORA Member of the Diesel & Gas Turbine Publications Group
Brent Haight, publisher
Russia has broken ground on
the Power of Siberia, a 2465
mi. (3968 km) pipeline that
will link gas fields in eastern Siberia to
China. The project is part of a US$400
billion deal inked in May between Rus-
sia’s Gazprom and the Chinese Na-
tional Petroleum Corporation (CNPC).
China will begin construction of its sec-
tion of the pipeline early next year.
Under the first phase of the 30-year
contract, Russia will supply China 1.3
Tcf (38 x 109 m3) per year of natural
gas starting in 2018. Future phases
could increase this volume to as much
as 2.1 Tcf (60 x 109 m3) per year.
When complete, the Power of Si-
beria will be the largest fuel network
in the world, linking the Chayandins-
koye and Kovyktinskoye gas fields in
eastern Siberia with Khabarovsk and
Vladivostok on Russia’s Pacific coast.
Spurs will be drawn to China at Bla-
goveshchensk and Dalnerechensk,
and an LNG terminal will be built in
Vladivostok. Russian President Vladi-
mir Putin and China’s Vice Premier
Zhang Gaoli have called the venture
the world’s largest construction proj-
ect, as investment from both countries
will be more than US$70 billion.
This contract is Gazprom’s biggest
to date and is viewed as a win/win for
each country as China struggles to
meet its energy demands and Russia
faces growing sanctions from the west
due to the ongoing situation in Ukraine.
China’s natural gas demand has
been growing as the government
seeks to move away from coal in favor
of cleaner fuels. Last year, China con-
sumed about 6 Tcf (170 x 109 m3) of
natural gas and expects to consume
14 Tcf (420 x 109 m3) per year by
2020. China’s northern and eastern
provinces have growing natural gas
demands that cannot be met by ex-
isting pipelines or imported LNG. Be-
ginning in 2019, the Power of Siberia
will pump gas from Siberia to China’s
populous northeast region.
For Russia, the deal will lessen its
dependence on European buyers that
have imposed economic sanctions
because of the Ukraine crisis. Europe
still remains Russia’s largest energy
market, buying more than 5.6 Tcf (160
x 109 m3) of Russian natural gas in
2013, but countries within the Europe-
an Union do not mask their frustration
with Russia and their desire to break
free from Russia’s energy monopoly.
What remains to be seen is the im-
pact the pipeline will have on natural
gas prices and availability worldwide.
While specific pricing details of the
Russia/China deal have not been dis-
closed, some energy experts warn that
the deal could drive up prices for Euro-
pean gas consumers who are becom-
ing increasingly dependent on Russia
and now face competition for supplies.
The planned LNG terminal could
pose a threat to LNG producers in Aus-
tralia, Canada and Africa without con-
tracts, and could undermine the U.S.’s
LNG export efforts by offering better
pricing to LNG-addicted countries like
Japan, South Korea and India.
Taking it one step further, some
analysts warn that the impact of the
Russia/China deal in displacing Chi-
nese LNG demand increases the
likelihood of LNG oversupply.
Much uncertainly remains. What is
clear is that Russian gas will remain
an influencing factor in the global
energy landscape, regardless of in-
creased supplies and availability from
rising players around the world. CT2
Russian Gas BringsChina Relief, PotentiallyPains The West
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Featured Articles 16 2014 Engine Specs-At-A-Glance
18 CPI Develops Compressor Valve With Replaceable Seat Plate
34 Exterran Offers Highly Configurable Compressor Package
36 Revamp Of A Reciprocating Compressor Unit
40 2014 Year In Review
48 Cozzani’s Stepless Capacity Control Tested
54 GEA Gradually Expands Compression Range
TECHcorner 20 Combustion Solutions For Achieving Low Exhaust Emissions
In Integral Gas Compressor Engines
Departments 4 Page 4 — Russian Gas Brings China Relief, Potentially
Pains The West
8 Global Perspective — Gazprom, Ukraine Agree On Gas Sales
10 Meetings & Events
12 About The Business — Ebbing Oil Prices Erode Gas
Compressor Demand
14 Monitoring Government — North Dakota’s Flares Begin To Flicker
47 Prime Movers
56 Recent Orders
58 Featured Products
59 Literature
60 Scheduled Downtime
61 Marketplace
62 Advertisers’ Index
64 Cornerstones Of Compression — ‘Breaking The Ice’ For
Mechanical Refrigeration
December 2014
Follow Us @COMPRESSORtech2
Cover Designed By
Marisa Roberts
MEMBER OF BPA WORLDWIDE ®
PRINTED IN THE U.S.A.
MEMBER OF …
COMPRESSORtech 2 ( ISSN 1085-2468)
Volume 19, No. 10 — 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, U.S.A. Subscription rates are $85.00 perear/$10.00 per copy worldwide. Periodicals post-ge paid at Waukesha, WI 53186 and at addi-onal mailing offices. Copyright © 2014 Diesel &
Gas Turbine Publications. All Rights Reserved.Materials protected by U.S. and international copy-ght laws and treaties. Unauthorized duplicationnd publication is expressly prohibited.
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Return Undeliverable Canadian Addresses to: P.O.
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Industrial engines rarely rest, pumping out power hour after hour.
That 1,000 hp engine would have filled the USS Macon airship of
1933 with 6 1/2 million cubic feet of helium in just 20 hours.
But of course power isn’t the only thing these engines put out. To handle the resulting
emissions demands a catalyst of equal durability, one that can remove 6 tons of Carbon
Monoxide and Oxides of Nitrogen every 1000 hours.
It is not surprising, then, that more and more companies are turning to the global leader in
the research, design, engineering and manufacturing of advanced emission
control technologies: DCL International. And that’s not just hot air either.
877.897.9759 dcl-inc.com
AND THAT’S NOT JUST HOT AIR.
A 1,000 HP ENGINE GENERATES
332,000 CU. FT. OF EXHAUST
EVERY HOUR.
D a l l a s • H o u s t o n • l o s a n g e l e s • o k l a H o m a C i t y
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Much has been said about Russia shutting off pipe-
line shipments of natural gas to Ukraine and Europe
to counteract the U.S. and European sanctions.
But in reality nobody has an interest in altering the sta-
tus quo. Russia needs the money Gazprom collects for gas
sales. Europe is its major customer. Ukraine, on the edge of
bankruptcy, has problems paying Gazprom’s invoices from
last winter. So at the end of the day, the parties needed to
sit at a table and try to resolve their problems — and that is
what happened.
Russia and Ukraine have finalized an agreement that will
see the resumption of natural gas supplies to Ukraine. The
gas price was negotiated at US$378/1000 m3 until the end
of the year, then US$365 until the end of next March. Be-
yond that, no secure deal is in place.
The accord is also dependent on Ukraine paying the first
tranche of its gas arrears — US$1.45 billion — before sup-
plies are restarted. The European Commission acted as a
third party signatory, guaranteeing both sides would fulfill
the obligations of the document, essentially ensuring Rus-
sia will receive payment.
The agreement should eradicate fears of gas shortages
in Europe this winter, particularly in the central and south-
eastern European nations that are dependent on Ukraine
as a transit route for gas deliveries. The deal also comes
just in time for the start of the winter heating season, when
countries begin to draw down on gas storage.
The deal is crucial for Russia and Gazprom, which have
been impacted by lower revenues from the loss of the
Ukrainian gas market over the summer, compounding the
impact of European Union and U.S. sanctions on the ability
of oil and gas companies to borrow money.
Gazprom’s profits fell in the first half of 2014 due to the
lower prices it charged Ukraine over the winter — just
US$285/1000 m3. Gazprom cut supplies to Ukraine com-
pletely last June, and Business Monitor International (BMI)
expects its third quarter 2014 earnings to be poor.
In 2013, Ukraine was Russia’s third largest gas customer,
importing over 882 Bcf (25 x 109 m3) of gas for domestic
use. BMI predicts a significant reduction in natural gas con-
sumption in Ukraine due to higher prices curbing demand
and the government-implemented gas savings plan. The
government has introduced measures aimed at cutting gas
use, including a 30% cut in consumption from the manu-
facturing and municipal sectors and a 10% cut by schools
and hospitals.
Due to its size, the long-term loss of the Ukrainian mar-
ket would not be in Russia’s interest. The increase of gas
prices from US$285 to US$365 will also mitigate any loss
in revenues from reduced consumption in Ukraine. Re-
gaining such a large market at an improved sales price
will be a boon to Gazprom, and the Russian government
especially, at a time when European gas consumption is
dwindling and gas deliveries to China are still some four
years from realization.
BMI’s outlook for the European gas market remains
bleak, considering weak industrial growth and poor pric-
ing dynamics for power generation. Currently, one can-
not see anything that would change forecasts that Euro-
pean gas consumption will be lower in 2023 than it was
in 2006. Russia’s market share will also be challenged
by Azerbaijani gas, which is expected to be flowing into
southern Europe by 2019, and by increased European
LNG import capabilities.
Securing the return of gas sales to Ukraine, backed by
a European Commission guarantee, will be an important
source of revenue for Gazprom. This will help the company
support investments in its other major projects, particularly
those in the Far East targeting a diversification of gas sales
to China. CT2
Gazprom, Ukraine Agree OnGas Sales >BY ROBERTO CHELLINI
ASSOCIATE PUBLISHER
Global Perspective
EC-brokered deal ensureswinter supplies for Europe
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in compressor valve performance
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DECEMBERDec. 4-6Shanghai International PetroleumPetrochemical Natural Gas TechnologyEquipment Exhibition — ShanghaiTel: +86 21 6592 9965Web: www.sippe.org.cn/en
Dec. 4-7Basra Oil & Gas Conference andExhibition — Basra, IraqTel: +90 21 23 56 0056Web: www.basraoilgas.com
Dec. 9-11*Power-Gen International —Orlando, FloridaTel: +1 (918) 831-9160Web: www.power-gen.com
Dec. 10-12International Petroleum TechnologyConference — Kuala Lumpur, MalaysiaTel: +971 4 457 5800Web: www.iptcnet.org/2014/ kualalumpur
JANUARY 2015Jan. 20-22Offshore West Africa — Lagos, Nigeria
Tel: +1 (713) 963-6283Web: www.offshorewestafrica.com
Jan. 26-28Offshore Middle East — Doha, QatarTel: +44 1992 656 629Web: www.offshoremiddleeast.com
FEBRUARYFeb.15-18*Middle East TurbomachinerySymposium — Doha, QatarTel: +1 (979) 845-7417Web: middleeastturbo.tamu.edu
Feb. 18-19*Gas/Electric PartnershipConference — Cypress, TexasTel: +1 (713) 529-3216Web: www.gaselectricpartnership.com
Feb. 22-25Laurance Reid Gas ConditioningConference — Norman, OklahomaTel: +1 (405) 325-3891Web: www.ou.edu/outreach/engr/ lrgcc_home.html
MARCH
March 11-13Australasian Oil & Gas Conference —
Perth, Western AustraliaTel: +61 3 9261 4500Web: www.aogexpo.com.au
March 16-19Nigeria Oil & Gas Conference —Abuja, NigeriaTel: +234 706 911 7347Web: www.cwcnog.com
March 18-19
Turkish International Oil and
Gas Conference 2015 —Ankara, Turkey
Tel: + (44) 020 7596 5000Web: www.turoge.com
March 22-26
*Sour Oil & Gas Advanced
Technology 2015 —Abu Dhabi, U.A.E.Tel: +971 2 674 4040Web: www.sogat.org
March 23-24
*European Gas Transport &
Storage Summit — MunichTel: +44 20 7202 7690Web: www.gtsevent.com
Meetings & Events*Indicates shows and conferences in which COMPRESSORtech2 is participating
DECEMBER 2014 10 COMPRESSORtech2
www.hoerbiger.com
E
im
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March 25-27
*Offshore Mediterranean
Conference — Ravenna, ItalyTel: +39 0544 219418
Web: www.omc.it
March 25-26
Georgian International Oil, Gas,
Infrastructure & Energy Conference —
Tbilisi, GeorgiaTel: +44 207 596 5000
Web: www.giogie.com
March 26-28
*China International Offshore Oil &
Gas Exhibition — Beijing
Tel: +86 10 5823 6555Web: www.ciooe.com.cn/2014/en
March 31-April 2
Offshore Asia Conference & Exhibition
— Kuala Lumpur, MalaysiaTel: +44 (0) 1992 656 651
Web: 10times.com/offshore-asia
APRILApril 12-15
*Gas Processors Association
Annual Convention — San AntonioTel: +1 (918) 493-3872Web: www.gpaglobal.org
April 20-22*Gas Compressor Association Expo& Conference — Galveston, TexasTel: +1 (972) 518-0019Web: www.gascompressor.org
April 27-30*Gulf South RotatingMachinery Symposium —Baton Rouge, Louisiana
Tel: +1 (225) 578-4853Web: www.gsrms.org
April 28-30
*Gas Compressor Institute —Liberal, KansasTel: +1 (620) 417-1170Web: www.gascompressor.info
MAYMay 4-7*Offshore Technology Conference — HoustonTel: +1 (972) 952-9494Web: www.otcnet.org
May 12-14*Eastern Gas CompressionRoundtable — Moon Township,PennsylvaniaTel: +1 (412) 372-4301Web: www.egcr.org
May 12-14Oil & Gas Uzbekistan —Tashkent, UzbekistanTel: +44 207 596 5144Web: www.oguzbekistan.com
May 19-21
*Sensor+Test —Nuremberg, GermanyTel: +49 5033 9639-0Web: www.sensor-test.de
JUNEJune 2-5Caspian Oil & Gas — Baku, AzerbaijanTel: +44 207 596 5000Web: www.caspianoil-gas.com
June 9-11*Power-Gen Europe — AmsterdamTel: +44 1992 656 617Web: www.powergeneurope.com
DECEMBER 2014 11 COMPRESSORtech2
For a complete listing of upcoming events, please visit our website at www.compressortech2.com/events/
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For the past four years, while natural gas prices stag-
nated, strong oil and gas liquids prices have fueled
growth in domestic shale development. That has
driven exceptional demand for compressors, especially for
gas lift, gathering and processing applications, as well as
for vapor recovery.
The Energy Information Administration (EIA) reported that
U.S. oil production in October was at the highest level since
the 1980s. It expects that U.S. shale oil production in Decem-
ber will increase by 125,000 bbl/d from November. Almost all
of this growth will come from the Permian Basin, Bakken and
Eagle Ford plays. The Eagle Ford alone has grown 42% in
the past year. The long-term growth outlook remains bullish,
and Platts recently projected that the U.S. could soon sur-
pass Saudi Arabia as the top global oil producer.
Meanwhile, despite less than spectacular prices, natu-
ral gas production has also grown, led by the Appalachian
Basin. EIA expects the Marcellus Shale flow to reach 16.04
Bcfd (4.5 x 108 m3 /d) in December, with the Utica Shale
adding 1.67 Bcfd (0.47 x 108 m3 /d).
This record gas production has pushed prices from above
US$4.50/Mcf in the first half of 2014, down to the US$3.80
to US$4 range since August. By mid-November, New York
Mercantile Exchange (NYMEX) prices appeared to be drift-
ing even lower.
Sooner or later, just like the natural gas industry, oil had
to recoil from its booming success. Production growth has
exceeded demand, causing oil and gas liquids prices to
plummet. Since early August, NYMEX West Texas Inter-
mediate crude oil prices have fallen steadily from above
US$100/bbl to below US$80/bbl by early November. Gas
liquids prices have suffered similar declines.
As oil prices have fallen, the obvious question is: “At
what price does shale oil become uneconomic to produce?”
Some believe it begins at US$80/bbl; others see it as low
as US$50/bbl because shale oil extraction is getting more
efficient. According to the EIA, production per rig has in-
creased by more than 300% over the past four years. The
International Energy Agency (IEA) estimates that about
98% of crude oil and condensate production in the U.S.
has a break-even price of below US$80 and 82% has a
break-even price of US$60 or lower. That may only temper
the shutdown of drilling operations but it will certainly put a
damper on expansion plans.
For the first time since 2010, domestic oil output is ex-
pected to grow at a slower rate than the year before. Some
producers, including Continental Resources, ConocoPhil-
lips and Pioneer Natural Resources, have already an-
nounced postponements of their 2015 expansion plans.
Major oil companies, such as Chevron, ExxonMobil and
Shell, are also deferring expansions and scrapping opera-
tions that have narrow profit margins, according to The Wall
Street Journal .
Halliburton Chairman, President and CEO Dave Lesar
opined that the crude oil market should correct itself next
year. He said that shale operations are more responsive
to market signals than is conventional oil production, so an
oversupply can be erased more quickly. He also indicated
that demand is creeping up, albeit at a lower rate.
Some Marcellus gas producers are also re-evaluating
their operations because the surge in their output, which
has exceeded pipeline capacity, is driving gas prices lower.
For example, Cabot Oil & Gas intends to finish its pipeline
projects in the Marcellus Shale and then transfer invest-
ments to other fields until additional pipeline capacity be-
comes available in 2017.
As it did last year, the intensity of the winter will deter-
mine the near-term pricing levels for gas. Storage levels
were depleted last winter and their replenishment has
helped hold prices up in some regions. EIA reported that
working gas storage at the end of October was still 6.2%
less than a year ago and 6.8% below the five-year aver-
age, despite a record summer injection of 2749 Bcf (7.8
x 1010 m3).
All the signals suggest that compressor demand has
probably peaked already, and at least a temporary retreat
is a certainty for 2015. How steep and how long the decline
will be depends on whether oil and gas prices begin to re-
cover without significant production cuts. CT2
Ebbing Oil Prices
Erode Gas CompressorDemand > BY NORM SHADE
About The Business
Signals indicate equipment ordersmay have peaked
BY NORM SHADE
Norm Shade is senior consultant and president emeritus of ACI
Services Inc. of Cambridge, Ohio. A 44-year veteran of the gas
compression industry, he has written numerous papers and is
active in the major industry associations.
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Phasedown begins for burningof wellhead gas
BY PATRICK CROW
North Dakota’s
Flares Begin ToFlicker >
DECEMBER 2014 14 COMPRESSORtech2
N
orth Dakota’s push to slash gas flaring finally is
in motion.
The surge in Bakken Shale oil production, which
jumped from more than 230,000 bbl/d in January 2010 to
more than 1.1 million bbl/d last August, has opened a flood-
gate of associated gas. However, gas pipelines in the oil-
prone Williston Basin are often full or far apart. Long lead
times are needed to build pipeline infrastructure (see COM-
PRESSORtech 2 , July 2013, p. 14).
The only way for producers to sell their crude has been
to burn the gas. That’s become increasingly unacceptable,
most of all for a state government witnessing prospective
gas royalties go up in smoke.
For the compression sector, the anti-flaring movement in
the Williston Basin will create opportunities to sell packages to
move the gas from the wellhead to the gathering line and on to
the processing plant, which will need compression yet again.
According to the U.S. Energy Information Administration
(EIA), a third of the natural gas produced in North Dakota in
recent years has been flared. At times, the rate has hit 36%.
The gas is burned, rather than vented to the atmosphere,
because pure methane has a much higher global warming
potential than carbon dioxide, the main component of com-
busted gas. The state bans gas venting.
The North Dakota Industrial Commission (NDIC) has re-
ported that nearly 28% of gas output was flared last August,
or 375 MMcfd (10.6 x 106 m3 /d) out of a total production of
1340 MMcfd (38 x 106 m3 /d). The other 72% was either sold
or used at the production site.
NDIC has established goals to decrease flaring over
coming years. It set a target of 26% for the fourth quarter of
this year, phasing down to 10% by 2020.
In its July 1 order, the commission pledged to reduce flar-
ing even if it had to restrict the oil flow from major sources
such as the Bakken Shale and the Three Forks formation.
However, NDIC said it recognized the difficult economics
that companies face from rapidly declining oil and gas pro-
duction curves at newly drilled wells and that it would con-
sider exemptions on a case-by-case basis.
The state has estimated that more than a third of flared
gas results from the lack of gathering pipelines. The largest
challenge there, according to the NDIC, is securing land-
owner permissions, which can delay projects half a year or
longer. Other obstacles include zoning and permitting de-
lays, harsh weather and labor shortages.
The remaining two-thirds of flared gas is due to the chal-
lenges of altering existing infrastructure, such as the need
for additional pressure on gathering lines to offset the high-
er pressure from newly drilled wells and increased pipeline
capacity from high-pressure wells.
Another challenge is the necessity to strip more liquids
from the wet gas before it enters trunk lines. EIA said by
the end of the year, new gas processing plants in the state
would boost capacity to 1.454 Bcfd (41.1 x 106 m3 /d), or
440 MMcfd (12.5 x 106 m3 /d) more than last year. There
are plans to build another 400 MMcfd (11.3 x 106 m3 /d) of
processing capacity by the end of 2016.
Even that won’t be enough. As the Bakken oil wells mature,
they will yield less crude but proportionately more liquids-rich
gas. The state has estimated the gas processing need may
grow to 2.5 Bcfd (70.8 x 106 m3 /d) within 10 to 15 years.
NDIC said the Fort Berthold Indian Reservation — home
to the Mandan, Hidatsa and Arikara tribes — is a major part
of the gas-flaring problem. Last August, 35.5% of gas pro-
duced on the reservation was burned. The rate peaked at
64% in 2011.
The reservation produces roughly a third of North Dako-
ta’s oil. Last August the flow was more than 333,000 bbl/d,
of which 134,000 bbl/d was from tribal lands and 199,000
bbl/d from private lands. If the reservation were a separate
state, it would be the nation’s seventh largest oil producer.
The Three Affiliated Tribes organization has said that
construction of gathering lines, processing plants and trunk
lines has been complicated by the overlap of governmen-
tal rules. State regulators insist that their flaring regulations
apply even on tribal lands. The tribes are developing their
own approach, and the U.S. Department of the Interior is
drafting its own flaring rule for federally managed lands. CT2
Monitoring Government
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NEAC Compressor Service Ltd.Located in Rayong, Thailandwww.neac.net
Contact me for South East Asia:
Teerawat KijsawasSenior Technical Service [email protected] Phone: +66-38-923713
NEA GROUP Headquarters in Germany
THINK GERMAN,ACT LOCAL.DO YOU FEEL THE "HEARTBEAT"OF YOUR COMPRESSOR?
ALSO COMPRESSORS NEED HEALTH CHECKS!
For your compressor health check come to NEAC
Compressor Service. We have the know-how and
specialists to verify the machine capability through
pV analysis and a vibration survey. Our health checks go
beyond. We make in depth measurements and review
valve performance, piston ring and packing conditions,
gas composition and possible pressure pulsations.
This all has one target: No surprises.
COMPRESSORSERVICE
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Diesel or Heavy Fuel Gaseous Fuel Dual Fuel
ABC –Anglo Belgian Corp.
Caterpillar GlobalPetroleum
Caterpillar MarinePower Systems
Cummins
Daihatsu
Dresser-Rand
Electro-MotiveDiesel (EMD)
Fairbanks Morse
GE Power & Water,Distributed Power
Guangzhou
H. Ceglielski –Poznan S.A.
Hyundai HeavyIndustries
Jinan
1 9 , 0 0 0
1 8 , 0 0 0
1 7 , 0 0 0
1 6 , 0 0 0
1 5 , 0 0 0
1 4 , 0 0 0
1 3 , 0 0 0
1 2 , 0 0 0
1 1 , 0 0 0
1 0 , 0 0 0
9 0 0 0
8 0 0 0
7 0 0 0
6 0 0 0
5 0 0 0
4 0 0 0
3 0 0 0
2 0 0 0
1 9 0 0
1 8 0 0
1 7 0 0
1 6 0 0
1 5 0 0
1 4 0 0
1 3 0 0
1 2 0 0
1 1 0 0
1 0 0 0
1000 to 5200
1000 to 2670
31 to 16,226
71 to 6100
8 to 16,000
41 to 6729
37 to 3281
172 to 2000
66 to 6600
66 to 6600
170 to 1465
150 to 1350
288 to 768
1249 to 3729
750 to 23,850
1255 to 18,000
120 to 9500
660 to 4400
660 to 1080
500 to 30,000
575 to 10,000 15,000 to 25,000
455 to 880 2880 to 9600
2880 to 4320
10 to 6300
400 to 1000
KILOWATTS
DECEMBER 2014 16 COMPRESSORtech2
2014
ENGINE
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MAN Diesel & Turbo
MaschinenbauHalberstadt
Mitsubishi HeavyIndustries Marine
Machinery & Engine
Mitsubishi PowerSystems Americas
Moteurs Baudouin
MTUFriedrichshafen GmbH
MWM
Niigata
Perkins
Rolls-Royce
Rumo
Wärtsilä
Yanmar
1 9 , 0 0 0
1 8 , 0 0 0
1 7 , 0 0 0
1 6 , 0 0 0
1 5 , 0 0 0
1 4 , 0 0 0
1 3 , 0 0 0
1 2 , 0 0 0
1 1 , 0 0 0
1 0 , 0 0 0
9 0 0 0
8 0 0 0
7 0 0 0
6 0 0 0
5 0 0 0
4 0 0 0
3 0 0 0
2 0 0 0
1 9 0 0
1 8 0 0
1 7 0 0
1 6 0 0
1 5 0 0
1 4 0 0
1 3 0 0
1 2 0 0
1 1 0 0
1 0 0 0 KILOWATTS
Diesel or Heavy Fuel Gaseous Fuel Dual Fuel
450 to 87,220
548 to 2061
1740 to 87,220
1740 to 87,220
75 to 10,000
200 to 2530
400 to 4300
30 to 4000
1350 to 35,520
1350 to 35,520
3760 to 15,400
3650 to 5500
60 to 883
500 to 13,768
1007 to 6032
4 to 2000
322 to 1042
1685 to 12,000
1425 to 9620
800 to 4224
800 to 1045
800 to 1000
2700 to 80,080
4320 to 19,260
4050 to 17,550
250 to 3530
300 to 2000
DECEMBER 2014 17 COMPRESSORtech2
SPECS-AT-A-GLANCE
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Compressor Products Interna-
tional (CPI) has developed a
compressor valve with a re-
placeable seat plate for quick recon-
ditioning in critical operations or in re-
mote/hazardous environments.
The Hi-Flo RS valve is a refine-
ment of the company’s Hi-Flo R and
V valves.
CPI noted that unscheduled recip-
rocating compressor shutdowns can
lead to costly production losses.
Compressor valves have many
active parts and are responsible for
more unscheduled shutdowns than
any other compressor component.
When a valve fails, it not only reduces
efficiency and capacity but also can
result in secondary damage to other
parts of the compressor.
CPI said its Hi-Flo R radius valves
have performed reliably in the oil, gas
petrochemical and air separation in-
dustries worldwide.
The radiused profile of the valve
rings (Figure 1), which control and seal
the process gas as it flows into and
from the compressor cylinder, provides
several important characteristics.
The main advantage is that the
Hi-Flo R valves provide very long
running times, typically up to three
years between planned maintenance
and overhauls. This is an advantage
when service or reconditioning — re-
quiring specialized skills, equipment
and facilities — are needed for com-
pressors that are operating in remote
or difficult environments.
When an overhaul is needed,
valves are shipped to a CPI facility or
an approved workshop, resulting in
downtime that costs time and money.
CPI developed the Hi-Flo RS valve
at the request of a customer who oper-
ated compressors using Hi-Flo V and
R valves on offshore production plat-
forms, floating production, storage and
offloading vessels and other facilities
far from properly equipped mainte-
nance workshops.
The Hi-Flo RS has a replaceable
seat plate that is integrated into the
valve seat housing. Over time, any
normal wear will be on the seat plate
rather than on the valve seat itself.
CPI Develops Compressor
Valve With Replaceable
Seat Plate > Designed for critical operations, remote/ hazardous environments
nCPI developed this replaceable seat compressor valve to simplify overhauls.
DECEMBER 2014 18 COMPRESSORtech2
nFigure 1: This drawing shows the
profile for the Hi-Flo R valve.
nFigure 2: This is a finite element analysis of
the new seat plate in PEEK.
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When valve efficiency begins to decline, the seat plate
can be popped out and a new seat plate can be snapped
into place.
Because the new seat plate has the same dimensions
as the original, there is no need for complicated depth and
clearance adjustments, using shims and gaskets, when re-
installing the valve.
The seat plate is made of polyetheretherketone (PEEK),
the same rugged and durable material used to manufacture
the rings. The difference in the strength of the replaceable
PEEK seat plate compared to a traditional seat is negligible,
as proven by engineering studies (Figure 2) and field tests.
CPI said the Hi-Flo RS valve performs extremely well un-
der severe operating conditions and for processing of gases
that contain liquid slugs and debris. Figure 3 shows the good
condition of a valve removed preventively after 13 months of
operation on a gas lift three-stage compressor offshore.
Total E&P Congo, equipped all stages of its PAC4 com-
pressors with this technology in 2012 and is preparing to
equip a General Electric Nuovo-Pignone 6HM3 with the
technology by the end of 2014.
“The CPI Hi-Flo RS is the response to our problems. We
don’t need to re-machine or use special tooling for mainte-
nance,” a Total E&P representative said.
“Furthermore, we don’t need to keep complete valves in
stock — only rebuild kits. We have also reduced the un-
scheduled shutdown time and some valves installed two
years ago are still running.”
The company said the new valve could be completely
reconditioned on location without specialized tools, re-ma-
chining, presses or other equipment. The rebuild kit includes
the replaceable plate, new valve rings, springs and buttons.
CPI said since there is no reduction in valve seat thick-
ness, no adjustments are needed if unloader forks are fitted
on the suction valves. CT2
DECEMBER 2014 19 COMPRESSORtech2
nFigure 3: This clean valve came
from a third-stage gas lift com-
pressor in service offshore.
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David Lepley has a bachelor’s degree in electrical engineer-
ing from Youngstown State University. He is Product Manager
– Ignition Systems for Altronic, with responsibility for devel-
oping and promoting advanced ignition technologies for gas
engines. Luigi Tozzi has a doctorate in mechanical engineering
from the University of Naples, Italy. His emphasis has been on
lean burn gas engine combustion since the early 1980s. As
president of Prometheus Applied Technologies, he leads the
development and commercialization of precombustion cham-
ber systems for large lean burn gas engines. Emmanuella Soti-
ropoulou has a master’s in electrical engineering from Colorado
State University. As vice president at Prometheus Applied
Technologies, she is in charge of the development of precom-
bustion chamber systems for large lean burn gas engines.
This paper was presented at the Gas Machinery Research
Conference in Albuquerque, New Mexico, in October of 2013.
Combustion Solutions For Achieving
Low Exhaust Emissions In Integral GasCompressor Engines >
O
perators of lean-burn natural gas engines are con-
stantly striving to meet emissions requirements in
the most cost effective way possible. More specifi-
cally, the conversions of legacy large-bore (greater than 9.8
in. [250 mm]) natural gas engines can easily reach in ex-
cess of US$100,000.
This approach still provides some cost savings over a
new engine installation, but is no longer necessary thanks
to recent breakthroughs in high-energy ignition systems
and the design of passive prechamber plugs via the use of
computational fluid dynamics (CFD) [1-6].
This paper provides a summary of the advancements made
in the past year by coupling emerging technologies such as
the high-energy ignition and passive prechamber spark plug
technologies and applying them to large-bore gas engines.
Two different configurations are covered. The first is the
combination of the high-energy ignition technology with the
passive prechamber spark plug in an open-engine com-
bustion chamber configuration. The second is the same
combination but this time the passive prechamber spark
plug is located inside a fuel-fed precombustion chamber
and referred to as the “dual-stage prechamber” technol-
ogy (patent pending). Both combinations have achieved in-
cremental reduction in exhaust emissions with large-bore,
slow-speed natural gas engines. The engine results of both
of these combinations have been previously published [7].
In this paper, the continuation of the technology validation of
the combination of the high-energy ignition and the dual-stage
prechamber technology will be presented in terms of the com-
plete engine test on an integral gas compressor engine.
While the dual-stage prechamber technology described
in this paper was tested on a legacy integral gas compres-
sor engine, the concept is also believed to be applicable to
newer, high brake mean effective pressure (BMEP), large
bore two-stroke or four-stroke engines. The paper merely
intends to present the potential of this technology and calls
for the next step of generating specific production solutions
to address the industry’s needs.
The information in the following section has been pub-
lished previously [7] and is presented to provide an adequate
foundation for the new results presented later in this paper.
Engine system configuration
The authors decided to model and test the solutions
proposed in this paper on a representative large-bore gas
engine residing at the Engines and Energy Conversion
Laboratory at Colorado State University. It is a four-cylinder
Cooper Bessemer GMV-4TF with in-cylinder fuel injection.
Figure 1 shows the engine installation. Table 1 contains the
specifications of the engine as tested.
Each cylinder of this engine can be configured in two ways.
One way is to use two spark plugs per cylinder. The other
way is to use a precombustion chamber, which has its own
separate fuel line. The fuel admission into the precombustion
chamber is controlled by a mechanical check valve. For the
purposes of the test, an electronic fuel control valve (ePCC [8],
Figure 2) was installed, which is able to control the admis-
sion timing and fuel amount in the precombustion chamber.
This electronic fuel-control valve allows to deliver the fuel in
the under sonic conditions.
TECH c or n er
DECEMBER 2014 20 COMPRESSORtech2
Passive prechamber, dual-stageprechamber methods explored
BY DAVID LEPLEY, LUIGI TOZZI
AND EMMANUELLA SOTIROPOULOU
continued on page 22
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The specific advantages resulting from using an electron-
ic fuel control valve compared to a mechanical check valve
have been discussed in a previous publication [9] and are
not addressed in this paper. However, the need to use this
type of fuel delivery system in this study was mainly to con-
trol the fuel amount delivered independently of the cylinder
pressure during the time of admission.
nFigure 2. The ePCC electronic fuel control valve and CPU-XL
ignition system on engine installation.
The engine is outfitted with the latest available ignition
system technology as shown in Figure 2. A tunable, high-
energy ignition system able to assure reliable ignition with
lean air-fuel mixtures, while maintaining long plug life, was
selected for this test [1].
This system was chosen because it allows the user the
flexibility in selecting a spark waveform profile based on the
flow velocity at the spark plug gap, which is determined with
the help of CFD for a particular application. The specific
advantages resulting from using this ignition system com-
pared to a conventional system are the subject of a previ-
ous publication [10].
Combustion pressure transducers are installed in all four
cylinders, allowing for high-speed combustion pressure
measurements via a high-speed data acquisition system
(HSDA). The HSDA was controlled by a National Instru-
ments PXI-1002 system.
The software computed combustion parameters such as
peak cylinder pressure and location, heat release rate, in-
dicated mean effective pressure (IMEP) and cycle-to-cycle
variations. It was possible to monitor exhaust gas emis-
sions of the entire engine.
The five-gas analyzer used for the test was a Rosemount
five-gas emissions analyzer that measures CO, CO2, THC,
NOx and O2 concentrations. Both measuring systems are
shown in Figure 3.
n Figure 3. The data-acquisition equipment (left) and the gas-
analyzer rack.
The engine air-fuel ratio is controlled by independently
setting the air mass flow rate and the fuel mass flow rate.
The engine is configured to maintain a constant differential
pressure of 17.2 kPa (2.5 psi) between intake and exhaust.
The air mass flow rate is controlled by adjusting the back-
pressure. A variable-speed Roots blower is used to supply
air to the engine and a variable-exhaust restriction is used
to control the backpressure and to simulate a turbocharger.
Passive prechamber spark plugs for open chamber
configuration
In the first combination of the high-energy ignition system
and prechamber plugs, the two conventional spark plugs in the
open chamber engine configuration are replaced with passive
prechamber spark plugs. The plugs are located in the 0° loca-
tion and the -45° location as shown in the model of Figure 4.
CFD analysis indicated that a relatively large variation in
the mixture distribution is to be expected in the two loca-
tions with a lambda of 1.75 (f = 0.571) in the 0° location
RPM 300
Bore (mm) 356
Stroke (mm) 356
CR 10
continued on page 24
nFigure 1. The Cooper Bessemer GMV-4TF at the EECL-CSU.
nTable 1. The Cooper Bes-
semer GMV-4TF as tested at
the EECL-CSU.
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and a lambda of 2.35 (f = 0.426) in the -45° location. This
was observed at the time of spark of 5 crank angle degrees
(CAD) before top dead center (BTDC). The results are
shown in Figure 5.
nFigure 5. The lambda distribution of the two spark plug locations [7].
Due to the large variation in lambda distribution observed
in the CFD results, the two designs shown in Figure 6 were
developed. The prechamber plug designs were able to suc-
cessfully trap some fuel during the direct injection event to
provide a richer environment than the conventional spark
plug for the initial flame development.
nFigure 6. These are the two passive prechamber plug designs.
The CFD results of the prechamber plug designs are
shown in Figure 7 as compared to the open spark plug
(J-gap type). The mixture at the gap of the open spark
plug is 1.55 (f = 0.645) while that of the prechamber plug
is 1.25 (f = 0.800) with an even richer mixture surrounding
it (l=1.15, f = 0.870) to ensure strong flame jet formation.
nFigure 7. The lambda comparison at the electrode gap region
between the two spark plugs [7].
The results of the initial flame development initiated from
two different spark locations for both the conventional open
plug and the prechamber plug are shown in Figure 8. The
conventional spark plug (left) and the prechamber plug (right).
Comparison of initial flame development from two different
spark locations (isothermal surface at 1500K) [7]. The flame
is represented as an isothermal surface at 1500 K, seen in
red. These results indicate that the use of the prechamber
plugs on engine will improve engine stability and, hence, ex-
tend the lean flammability limit. This was later confirmed by
the engine test at a constant load of 500 hp (372 kW).
nFigure 8. The conventional spark plug (left) and the prechamber
plug (right). Comparison of initial flame development from two dif-
ferent spark locations (isothermal surface at 1500K) [7].
The results indicated that the bullet prechamber plug de-
sign provided the most stable operation as seen in Figure
9. The engine stability, measured as the coefficient of varia-
tion of indicated mean effective pressure (COV of IMEP)
versus NOx emissions is improved by more than a factor of
2 at less than 2 g/bhp-hr operating conditions.
Further improvements in the stability at lean operating
points are made by the use of the high-energy ignition sys-
tem. In conclusion, these results indicate that the combina-
tion of passive prechamber spark plugs and the high-energy,
tunable, ignition system provide the most robust solution
for the 500 mg/Nm3 (1 g/bhp-hr) operation for large-bore
natural gas engines.
nFigure 9. The COV of IMEP vs NOx and excess air ratio (l=1/f) for
the three configurations [7].
DECEMBER 2014 24 COMPRESSORtech2
continued on page 26
nFigure 4. The rela-
tive location of the
two spark plugs is
shown.
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Dual-stage precombustion chamber concept
In order to improve the efficiency and emissions trade-off
obtained by the standard precombustion chamber, a second
concept was developed. Here, the reduction in emissions is
obtained by reducing the fuel present in the precombustion
chamber. To ensure consistent flame propagation within the
now lean, homogenous precombustion chamber, flame jet
ignition must be utilized.
To address this problem, the “dual-stage prechamber” ap-
proach was created and is currently patent pending. Here,
the combination of a smaller, fuel-rich prechamber (first
stage) inside a larger, fuel-lean prechamber (second stage),
are used to initiate the combustion in the main chamber.
This combination leads to a reduction in the NOx pro-
duction compared to the conventional configuration. To
achieve the desired distribution in the dual-stage precham-
ber and appropriate flame jet penetration in the main cham-
ber, a new design had to be developed for the second stage
(Figure 10) to be coupled with a passive prechamber spark
plug that served as the first stage. In addition, the fueling
of the prechamber was controlled by an electronically actu-
ated sonic valve as opposed to a mechanical check valve.
It is important to note that the use of the timed fuel deliv-
ery was done to prove the ability of this approach to reduce
emissions while increasing efficiency. Once this technology
proves sound, a development process will be necessary
to fit this approach in meeting different application needs,
such as the combination of the dual-stage prechamber with
the use of a mechanical check valve.
Comparative CFD analysis of the baseline conventional
configuration (fuel-fed precombustion chamber with con-
ventional spark plug) and the new dual-stage prechamber
approach is shown in Figure 11. As expected, the conven-
tional configuration is overly rich at approximately l=0.85 (f=
1.18) while the dual-stage prechamber has a lambda of 1.5
in the second stage and 1.2 in the first stage.
nFigure 11. The lambda distribution in the conventional precham-
ber (left) and dual-stage prechamber (right) [7].
Ignition is initiated in the passive prechamber spark plug,
which receives its fresh air-fuel mixture during compression
from the first stage. The ensuing flame jets from the passive
prechamber spark plug initiate combustion in the fuel-fed
second stage, which in turn initiates combustion in the main
chamber. The combustion simulation of Figure 12 demon-
strates this combustion sequence.
n Figure 12. The dual-stage prechamber/flame jet development
(isothermal surface at 1500K) [7].
Dual-stage precombustion chamber concept
— full engine test
The first step for proving this technology was to perform an
engine test in which one of the four cylinders of the Cooper
Bessemer GMV-4TF was outfitted with the new dual-stage
prechamber approach. The results from this test were pub-
lished in a previous publication [7]. Due to the promising results
of the single cylinder test, a full engine test was performed.
The baseline (conventional configuration) used the me-
chanical check valve for the fuel admission in the precom-
bustion chamber. In the case of the dual-stage prechamber,
as described previously, all prechamber fuel lines were in-
stalled with electronic fuel control valves.
This was done as an expediency to proving out the dual-
stage prechamber technology. The fuel admission by these
valves was kept under sonic conditions throughout the du-
ration of the test. Future plans include the development and
application of the dual-stage prechamber with the use of a
mechanical check valve.
The test was performed at two different load conditions to
gain an understanding of the behavior of the new technol-
ogy under different engine power ratings; 500 hp (373 kW)
and 350 hp (260 kW). The spark timing selected for the
baseline is the optimum timing for this engine configuration
and is set to 3 CAD BTDC.
To better characterize the performance of the dual-stage
prechamber concept, three different spark timings were in-
vestigated during the test: 3, 5 and 8 CAD BTDC. For each
timing, the air manifold pressure was increased to reduce
the fuel injected in the main chamber and achieve leaner
in-cylinder conditions. No attempt was made to optimize the
timing of the electronic fuel admission valve of the second
stage. Following are the comparative results of the baseline
and the dual-stage prechamber concept (DS).
DECEMBER 2014 26 COMPRESSORtech2
continued on page 28
nFigure 10. The original
precombustion cham-
ber hardware compared
to the new design of the
dual-stage prechamber
technology.
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reliability and environmental compliance — are the direct
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centers around the world. That’s why our “World of Quality”
initiative is constantly striving to make sure our people,
processes and equipment deliver consistently superior
results for you.
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The most comprehensive picture of the combustion re-
sults is shown in Figure 13 in terms of the trade-off between
brake thermal efficiency (BTE) and brake specific (BS) NOx
emissions at 500 hp. All spark timings of the dual-stage pre-
chamber produce a higher BTE with lower NOx emissions
compared to the baseline.
At 0.75 g/bhp-hr of BS NOx emissions, the efficiency gain
ranges from approximately 0.5% points to 1.5% points. It
was expected that the dual-stage prechamber would require
more advance timing than the baseline due to the leaner sec-
ond stage and to the time delay introduced by the first stage.
The dual-stage prechamber achieves a BTE range be-
tween 30.6 and 31.8% at 0.5 g/bhp-hr. It was not possible to
obtain any data points at leaner than 0.35 g/bhp-hr because
the engine had reached the airflow limit.
nFigure 13. The 500 hp BTE/NOx trade-off comparison of the con-
ventional precombustion chamber (baseline) and the dual-stage
prechamber.
The improved trade-off between BTE and NOx emissions
can be attributed mostly to the leaner conditions occurring in-
side the second stage and to the enhanced flame propagation
resulting from the flame jet ignition of the rich first stage. It
can be further confirmed by comparing the mass of fuel in the
second stage at 4.85 mg per injection to that of the baseline
at 20.2 mg per injection (approximately 76% reduction in fuel).
Another contributing factor for this gain in efficiency is the
increased engine stability due to the more efficient design
of the second stage producing three flame jets instead of
one (Figure 10), increasing the main chamber turbulence
and, therefore, flame propagation. The engine stability is
measured in terms of the coefficient of variation of indicated
mean effective pressure (COV of IMEP). A comparison be-
tween the baseline and the dual stage is shown in Figure
14. The results indicate that the baseline has an acceptable
COV of IMEP of less than 5% at NOx levels higher than 0.75
g/bhp-hr. In contrast, the dual-stage prechamber is able to
operate at a comparable COV of IMEP of less than 5% at
a NOx level of less than 0.4 g/bhp-hr and is limited by the
engine’s airflow limit. Another observation can be made at
the same emissions of 0.75 g/bhp-hr, where the dual-stage
prechamber improves the COV of IMEP from 4.75 to 2.2%.
A comparison of the combustion pressure for the two points
indicated in Figure 13 is provided in Figure 15 for all four
cylinders. These two points were selected at similar COV of
IMEP and have approximately 1% point difference in BTE.
It is easy to see the difference in manifold air pressure as
indicated by the two black arrows. Even though the dual-
stage prechamber is running at leaner conditions, it is able to
produce higher peak pressures leading to higher efficiency.
n Figure 15. The 500 hp combustion pressure comparison for
baseline (dotted line) and dual-stage prechamber(solid).
Taking a look at the BTE/NOx trade-off of the 350 hp power
rating, shown in Figure 16, one can see that the dual-stage
prechamber technology offers more stable operation at 0.5 g/
bhp-hr of NOx emissions with approximately 1.0% point in effi-
ciency gain. Further insight into the engine stability is shown in
Figure 17 where the baseline maintains an acceptable opera-
tion (COV of IMEP < 5%) at a NOx emissions level of approxi-
mately 0.6 g/bhp-hr, while the dual-stage prechamber achieves
the same at a NOx emissions level of less than 0.3 g/bhp-hr.
These results confirm that the benefits of the dual-stage pre-
chamber are maintained at lower engine power ratings.
DECEMBER 2014 28 COMPRESSORtech2
continued on page 30
nFigure 14. The 500 hp combustion stability comparison.
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Insight onsite.™
Harsco Air-X-Changers: Since 1954, we’ve set the industry standards in natural
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nFigure 16. The 350 hp BTE/NOx trade-off comparison.
nFigure 17. The 350 hp combustion stability comparison.
Conclusions and next steps
This paper is a continuation of a previous study published
in the 2013 CIMAC congress. The study was possible
thanks to recent significant advancements in CFD com-
bustion technology and high-energy ignition system tech-
nology. Two cost-effective approaches are investigated for
their ability to reduce emissions in large-bore natural gas
engines (greater than 250 mm).
The first is the use of two passive prechamber spark
plugs in place of the conventional spark plugs (J-gap type)
in an open chamber engine configuration. This approach
was able to reduce the NOx emissions level to 1 g/bhp-hr
while maintaining good combustion stability (COV of IMEP
less than 5%).
To provide further improvements to the efficiency and
emissions trade-off of engines configured to use a fuel-fed
precombustion chamber, the second approach investigated
is the use of a dual-stage prechamber (patent pending).
Here, the existing, fuel-rich conventional precombustion
chamber and spark plug are replaced with the combination
of a small fuel-rich prechamber (first stage) inside a larger,
leaner prechamber forming the dual-stage prechamber.
Both stages are especially designed to function together.
Combustion of the leaner mixture inside the second stage
is initiated by flame jets produced by the first rich stage.
In this paper, a full engine test is performed to determine
the merit of this new technology. The engine used is a Coo-
per Bessemer GMV-4TF with four cylinders that are all instru-
mented. The results of the test validate the expectations set
forth by a previously published single cylinder test, showing
a reduction in NOx emissions much below 0.5 g/bhp-hr while
gaining 1.5% points in BTE at a 500 hp engine rating. Fur-
thermore, this approach demonstrated great improvements
in combustion stability at lower engine ratings (350 hp).
Both approaches presented in this paper provide a flex-
ibility of choice to the operator in meeting emissions require-
ments in a more cost effective way. The dual-stage precham-
ber approach has demonstrated large gains over the present
state of the art, warranting the continuation of developing
application specific solutions. The immediate next step is the
development of an optimized dual-stage prechamber config-
uration that allows retrofitting of integral compressor natural
gas engines that use precombustion chamber fuel admission
systems with subsonic check valves. This development will
be the subject of a subsequent publication. CT2
References
[1] Lepley, J. M., et al, “A New Technology Electronic Igni-
tion Which Eliminates the Limitations of Traditional Ignition
Systems,” CIMAC Congress 2010, Bergen, Paper No. 173.
[2] Yasueda, S., et al, “Predicting Autoignition caused by
Lubricating Oil in Gas Engines,” CIMAC Congress 2013,
Shanghai, Paper No. 37.
[3] Sotiropoulou, E., et al, “A Method for Predicting Knock
in Gas Engines by means of Chemical Precursors from De-
tailed Chemistry CFD,” Proceedings of the Eighth Dessau
Gas Engine Conference, 2013.
[4] Tozzi, L., et al, “Passive prechamber spark plugs:
Then and now,” Proceedings of the Seventh Dessau Gas
Engine Conference, 2011, pp. 157-168.
[5] Martinez-Morett, D., et al, “A Reduced Chemical Ki-
netic Mechanism for CFD Simulations of High BMEP, Lean-
Burn Natural Gas Engines,” Proceedings of the ASME
Internal Combustion Engine Division Spring Technical Con-
ference, 2012, ICES2012-81109
[6] Convergent Science Inc. website: http://convergecfd.
com/.
[7] Sotiropoulou, E., et al, “Solutions for Meeting Low
Emission Requirements in Large Bore Natural Gas En-
gines,” CIMAC Congress 2013, Shanghai, Paper No. 278.
[8] Altronic Inc., website: http://www.altronicinc.com/pdf/
HVT Sales Sheets/ePCC_6-12.pdf.
[9] Lepley, D.T., et al, “Development and Performance
Analysis of an Advanced Combustion Control System on a
Fuel-Admitted High-Speed Natural Gas Engine,” Gas Ma-
chinery Conference, 2012.
[10] Bell, D.E., et al, “Field Validation of a Directed En-
ergy Ignition System on Large Bore Natural Gas-Fueled
Reciprocating Engines,” Gas Machinery Conference, 2012.
DECEMBER 2014 30 COMPRESSORtech2
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Exterran has launched its C-
Series 3516 line of com-
pressor packages to provide
customers with both customization
options and speedy delivery.
By using a tool on Exterran’s web
page, customers can designate the
features for compression packages
that precisely meet their operational
needs. The pre-engineered C-Series
3516 offers more than 60 basic options.
Exterran’s goal is to respond to
the customer with a proposal within
48 hours. It can send the production
drawings (with dimensions, weights
and connection points) within two or
three business days. The package
typically would be delivered within 10
to 14 weeks from one of the two Ex-
terran assembly plants in Houston.
The C-Series 3516 is available in
seven base models: in one-, two-
and three-stage configurations and
a range of bore sizes. Exterran said
those choices, with others, create
a spectrum of more than 1000 pos-
sible configurations.
The series is available up to 1380
hp (1029 kW) and outfitted with a
Caterpillar 3516B lean-burn engine
and an Ariel JGT4 compressor. The
package is built on a heavy-duty,
12 ft. (3.65 m) wide skid suitable for
mounting on a compacted gravel pad
or concrete foundation.
Exterran said the C-Series pack-
ages could be used in a wide array
of natural gas applications generally
above 5 psi (0.35 bar) inlet pressure
and up to 1300 psi (90 bar) discharge
pressure. Typical applications would
include wellhead, gas gathering, flare
Exterran Offers Highly ConfigurableCompressor Package > C-Series 3516 units have
10- to 14-week delivery
BY PATRICK CROW
DECEMBER 2014 34 COMPRESSORtech2
n One of the first C-Series
3516 packages sits in an Ex-
terran assembly bay.
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elimination, gas processing and plant
inlet and residue.
William Sayre, vice president, prod-
uct lines and marketing at Exterran,
said the company interviewed its cus-
tomers and its sales staff to determine
the crucial issues surrounding com-
pression package purchases.
“For a significant number of our cus-
tomers, speed of delivery was critical
to their operations,” Sayre said. “We
also found that many times they had
to sacrifice or compromise some of
their technical preferences in order to
get the packages delivered faster. Our
customers would buy available stock
packages but say they wished those
had certain options that would make
them better fits.”
Exterran responded with the C (for
configurable) Series, which has the
dual goals of flexibility and fast deliv-
ery. Sayre said ordering a C-Series
package essentially is similar to a
consumer ordering a computer on the
internet, selecting the basic machine
and its key components to fill a par-
ticular need.
DECEMBER 2014 35 COMPRESSORtech2
www.aciservicesinc.com
740-435-0240
“This method allows our customers
to designate exactly the composition
they want and get it manufactured and
delivered very quickly,” Sayre said.
Exterran launched the C-Series
3516 last January and formally intro-
duced it about a month ago.
“Since January, we’ve experienced
higher market demand for this product
that we had predicted,” Sayre said.
“The reaction has been extremely
positive. We’re going strong with the
product and have delivered dozens to
the field at this point.”
Even if customers don’t necessar-
ily need fast delivery, Sayre said the
flexibility to customize a package is
a major advantage for them, as is
the unit’s simple assembly and com-
missioning.
“We have competitors who offer
many ranges, sizes and configura-
tions of compressors and drivers,”
he said. “But because of long engine
and compressor lead times, they of-
ten assemble standard or specula-
tive packages that are not tailored
to a specific end use. And if they’re
building a customized package, that
can take a long time.”
Sayre said Exterran collaborated
with the managers of its more than
4 million hp (2980 MW) contract
fleet, the largest in the industry, on
the design of the C-Series. It has
become the new standard package
for the fleet.
Some of the options for the C-Series
3516 line include the quiet Harsco/
Air-X-Changers fin fan cooler, Hot-
start system and Murphy Centurion
Plus control panel.
Standard safety features include
automatic shutdown controls and
checker-plated, skid-resistant work
surfaces. Safety is enhanced be-
cause all local instrument gas vents
are collected, manifolded and routed
to connections at the skid edge. The
design facilitates air emissions com-
pliance with a catalyst housing and
NPT sampling ports.
Selectable safety options include
exhaust insulation, caged ladders, and
Occupational Safety and Health Admin-
istration-compliant work platforms. CT2
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C
ustomers are requesting com-
pressor adaptations due to
new or extended process re-
quirements. Reciprocating compres-
sors are always tailor-made and
designed for a specific operating con-
dition and for long lifetime. New devel-
opments and requirements or product
specifications demand changes in op-
erating conditions.
Thus, it makes sense to verify the
existing compressor equipment, to
see whether it can be modified or
revamped to make the new process
conditions or capacity feasible. The
procedure to handle revamp business
is presented based on a case study.
Introduction
In 2003, Neuman & Esser Group
delivered a reciprocating compres-
sor size 2SZL320H to a refinery in
Eastern Europe for a desulfurization
process, compressing hydrogen from
406 psi (28 bar) suction pressure up to
1232 psi (85 bar) discharge pressure.
The reciprocating compressor is
a two-crank, horizontal, two-cylinder
stage, double-acting, lubricated ser-
vice machine and 121,000 lb (530 kN)
allowable rod load.
The compressor is directly driven
by a rigidly coupled electric motor
with a nominal driver power of 2280
hp (1700 kW). The original design ca-
pacity was approximately 1.1 MMcfh
(33,000 Nm³/hr).
The NEA scope for the compressor
unit as a whole included the pulsation
vessels, interstage cooler and inter-
stage separator up to the last stage
check valve. After only five years of
successful operation, the hydrogen
gas demand increased approximately
15% due to clean fuel requirements.
Initially, the existing reciprocating
compressor is re-calculated accord-
ing to the original or as-built situation
with the compressor design tool KO³
(Compressor Optimization Version 3).
This verifies that the compressor ful-
fills the designated process conditions
without deviations and avoids general
mechanical or performance problems.
Following this, a calculation is made
with new operating conditions.
In a first step, a pre-check is made in
order to see if an adaptation of the com-
pressor for the new operating condi-
tions is possible in principle. The modifi-
cation of both the compressor itself and
the surrounding accessories needs to
be considered. If the pre-check result
is positive, a revamp project is realistic.
Compressor verification
The second step is the detailed veri-
fication of a compressor revamp as an
engineering study. It starts with a ther-
modynamics and compressor calcula-
tion by incorporating the specific com-
pressor details into KO³. In order to be
able to run the thermodynamic calcu-
lation, the gas analysis, suction pres-
sure, suction temperature, discharge
pressure and required capacity must
be known for each process or case.
For this case study the conclu-
sion was to install a new compressor
crankshaft with an increased stroke to
fulfill customer requirements within the
allowable compressor limits. The pis-
ton rods and piston had to be replaced
due to the existing cylinders’ running
length. The advantage here is that the
cylinders are not changed; the general
compressor arrangement can remain.
Each variation in process conditions
of compressor properties has an im-
pact on compressor valves. After the
detailed compressor layout calcula-
tion, the valve design needs to be con-
firmed. Since the valve dynamics exert
a major influence on compressor per-
formance, valve checking is manda-
tory to confirm the compressor layout.
After the thermodynamics and
valves are confirmed, the compressor’s
Revamp Of A ReciprocatingCompressor Unit > Case study details work for
Eastern European refinery
BY ANDREAS HAHN
n NEA delivered recips to a refinery in
Eastern Europe in 2003. Recently NEA in-
stalled new compressor crankshafts with
an increased stroke to fulfill the changed
hydrogen gas demand.
DECEMBER 2014 36 COMPRESSORtech2
Andreas Hahn is head of revamp and
modernization at Neuman & Esser in
Übach-Palenberg, Germany. continued on page 38
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flexibility
comes standard
changing to meet your needs
Keep the simple configuration tool you want and add to it
rod load capability • choice of displays • expansion options
More options, more choices, more control
For those who prefer custom over configured, Centurion offers expandable I/O capabilities,tailored operation programs, personalized rod load calcs, enhanced user interface and more.Flexible standards can easily be customized to your needs.
c o n t r o l l e r
M u r p h y ’ s
1 4 1 1 5 3 4 1 0 -1 4
Make the flexible choice.Call 918-317-2620 or go to www.fwmurphy.com/centurionct2
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nFigure 1. View of the elasto-hydrodynamic load situation
under (left) maximum tension load and (right) maximum
compression load calculated with KO³.
DECEMBER 2014 38 COMPRESSORtech2
i
[email protected], +420 483 363 642
www.tedomengines.com
ENGINES FOR GASCOMPRESSIONReliable heart for your unit
Power range: 40-170 kW
Fuels: NG, Wellhead gas, LPG,Biogas, CBM gas and others
Version for Zone 2 available
(II, 3G, T1 equipment)
mechanical properties must be verified. The safety relief valve
settings of each stage are an important fact for compressor
layout for verification of the mechanical properties, because
the set pressures determine the maximum rod forces and
static design pressures.
Typically, the crosshead bearing is one of the most criti-
cal components in a reciprocating compressor. This bearing
can fail due to hydrodynamic oil pressure being too high,
minimum oil film thickness being too thin or rod load rever-
sal being insufficient.
KO³ accommodates this fact by checking these three
scenarios individually. For this purpose, Dr. Klaus Hoff and
Egidius Steinbusch developed an elasto-hydrodynamic tool
(EHD) to assess bearing hydrodynamics. This EHD tool is
an integral part of KO³. Figure 1 shows the elasto-hydrody-
namic load situation of the crosshead bearing under maxi-
mum tension load and maximum compression load.
Increasing the stroke of a crankshaft apparently pro-
duces higher stress levels which need to be checked in
terms of fatigue strength. The crankshaft load is generally
dominated by bending and torsion. The fillets at the crank
webs are prospective critical locations. This verification
can be best quantified by utilizing finite element analysis
(FEA) models.
Once a sufficient number of FEA simulations have been
performed, their results can be used to identify and ad-
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just analytical approaches which produce approximately
the same results as the FEA. That way, the individual
crankshaft strength for a given job can be verified most ac-
curately and quickly in KO³ without the need for intensive
FEA studies.
Verification of accessories
The current API 618 Rev.5 for instance requires sufficient
motor power to cover all compressor operating cases and
up to the safety valve set pressure in all stages, plus a 5%
safety margin.
For directly coupled compressors it is mandatory to run
a new torsion analysis. Only new torsion analysis can verify
the components of the drive train and avoid torsion vibra-
tions and compressor damage.
If there is an increase in capacity and power, the coolers
must be verified for the new operating conditions. These
detail checks must be conducted by the original equip-
ment manufacturer (OEM) for the heat exchangers. Fur-
thermore, the piping and vessels are affected. The sizing
and ratings need to be confirmed for new flow or new op-
erating conditions.
To avoid unallowable high pulsation, a damper check is
performed based on the existing vessel design and accord-
ing to the limits of API 618. The damper check can be run
with the KO³ calculation also and considers the new com-
pressor layout, overall processes and operating cases.
After that a pulsation and mechanical response study is
carried out. Changes in compressor design and thermody-
namic operating conditions were communicated to the sup-
plier to re-investigate and validate the compressor unit.
Risk analysis
The NEA Group has generated a spark hazard analysis
and risk assessment for reciprocating compressor units. If
there is a substantial modification, the assessment is per-
formed and measures are indicated.
Special management for product safety is necessary for
revamping and modernization. It must be assured by the
OEM or an expert authority that the considered revamp
measures are a safe solution and the means by which the
revamp is selected and designed.
Just as for new compressor design, the major revamp
jobs or modifications must comply with the advised product
process. This means use of a procedure for all scheduled
quality control instructions, for feasibility study, risk assess-
ment design engineering and fabrication.
Revamp/modernization is a special product that needs
special handling. Due to the fact that large numbers of
reciprocating compressors operate over several decades
and can run far longer, it is a good opportunity to make
them fit for current technical specifications and process
conditions by revamping. With the right technical support
by a compressor OEM, the reciprocating compressor can
be prepared for long-term operation and to match the op-
erating company’s demands while remaining technically
safe and economically reasonable. CT2
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4
NOVEMBER 2013Nov. 5 – India launches its first rocket to Mars, aiming to put a
satellite in orbit around the red planet. It began orbiting Mars
in September, searching for methane and signs of minerals.
Nov. 12 – FS-Elliott Co. LLC, a manufacturer of oil-free cen-
trifugal air and gas compressors, expands into the South-
east Asia region by establishing a new representative of-
fice in Selangor, Malaysia.
Nov. 12 – Dresser-Rand joins Gaelectric, a renewable en-
ergy firm, in the development of its compressed air energy
storage (CAES) site near Larne, Northern Ireland. They also
form an alliance to develop other European CAES projects.
Nov. 14 – EQT Corp., one of the largest producers in Appa-
lachia, gives Valerus a contract to provide 15,000 hp (11.2
MW) of compression for two pipeline stations in south-
western Pennsylvania.
Nov. 21 – Detechtion Technologies receives an undisclosed
investment by Element Partners, a growth equity fund fo-
cused on energy and industrial technology companies.
Concurrent with the investment, Chris Smith also joins the
company as president and CEO, with Gerry Conroy serv-
ing in the newly created role of senior vice president of
products and portfolio.
Nov. 21 – Valerus receives a contract to provide engineer-
ing, procurement and construction for a natural gas condi-
tioning and condensate stabilization facility in Venezuela.
Nov. 22 – The U.S. House of Representatives approves a
bill to expedite the permitting of interstate gas pipelines,
but Senate action appeared unlikely due to the threat of a
Presidential veto.
DECEMBERDec. 2 – Siemens Energy improves its STC-SOL turbocom-
pressor for coking industry applications by reducing the
number of casting components and using an impeller tech-
nology that improves compressor efficiency up to 15%.
Dec. 3 – Rolls-Royce receives a US$28 million contract to
DECEMBER 2014 40 COMPRESSORtech2
0YEAR
2 1
2 0 0 02001
2002
2 0 0 3
2 0 0 4
2 0 0 5
2 0 0 6
2 0 0 7
2 0 0 8
2 0 0 9
2 0 1 0
2 0 1 1
2 0 1
2 2 0 1 3
IN REVIEW
B Y D J
S L A T E R
Expansions aboundas the shale gasboom continues
There’s no business like the oil and gas business right now. The shale gas
boom continued through 2014, with several manufacturers and packagers tak-
ing advantage in the form of acquisitions and mergers.
The biggest players were GE and Siemens. GE acquired Cameron’s reciprocating
compression business in early June, and then followed it up with plans to nab Alstom’s Power and Grid
businesses. Siemens, meanwhile, inked deals to acquire Rolls-Royce’s power turbine and compressor
business, as well as Dresser-Rand.
The compressor rental and packaging sectors also saw a flurry of activity during 2014. Exterran
Partners acquired 334 compression units totaling 440,000 hp (328 MW) from MidCon Compression in
February, only to go back for 162 more in July. Enerflex Ltd. purchased Axip Energy Services’ interna-
tional contract compression and processing operations, as well as its after-market services business.
In August, Compressco Partners boosted its fleet from 87,000 to 1,045,000 hp (65 to 780 MW) with the
purchase of Compressor Systems Inc. (CSI).
The year was not without its drawbacks, however. Compressor station protests were common through-
out the year. In addition, the U.S. Department of Energy (DOE) announced plans in July to establish
energy efficiency standards for new natural gas compressors as part of a program to reduce methane
leaks from natural gas pipelines.
A slowdown in the boom, though, does not appear to be forthcoming. On Nov. 11, three more news
stories broke, all dealing with acquisitions and expansions. Motor-Services Hugo Stamp (MSHS) an-
nounced that it would expand its service facility in New Orleans, Louisiana. Rexnord Power Transmission
announced an agreement to acquire Euroflex Tranmissions (India) Pvt. Ltd. T.F. Hudgins also completed
its acquisition of Jamison Products on the same day.
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supply PetroChina with equipment and services to expand
the flow of natural gas through the Lunnan – Tulufan branch
of the second West to East Pipeline Project (WEPP II).
Dec. 5 – Nelson Mandela dies at age 95. South Africans
and world leaders pay tribute to Mandela, who led the
transition from white minority rule in South Africa. Mandela
spent 27 years in jail before becoming South Africa’s first
black president in 1994.
Dec. 5 – Dresser-Rand successfully tests its small-scale
liquefied natural gas (LNG) plant, known as LNGo, and
expects to begin delivering the 6000 gpd (22,700 L/d)
units in 2014.
Dec. 9 – GE unveils plans to build its Global Research Cen-
ter in Oklahoma City, Oklahoma. The 95,000 sq.ft. (8826
m2) center will focus on accelerating mid- to later-stage oil
and gas technologies developed in the company’s labs,
such as production systems, well construction, water use
optimization, CO2 products, and energy systems.
Dec. 9 – Valerus agrees to sell Valerus Field Solutions for
US$435 million to Kentz Corp. Ltd., the holding company
of the Kentz engineering and construction group.
Dec. 11 – Flowserve Corp. acquires Innovative Mag-Drive,
LLC, or Innomag, a privately owned American manufac-
turer of sealless magnetic-drive centrifugal pumps used
primarily in the chemical and general industries.
Dec. 16 – Wood Group GTS appoints Mike Fisher as
president of its U.S. oil, gas and industrial services
(OGIS) business.
Dec. 17 – GE Oil & Gas signs a 12-year contractual service
agreement with Yara International ASA, a global chemical
company based in Oslo, Norway, to maintain an array of
GE rotating equipment at Yara’s fertilizer complex in Slu-
iskil, in the province of Zeeland, Netherlands.
Dec. 18 – Ronald Biggs dies. Involved in the “Great Train
Robbery” of 1963, he became one of the world’s most leg-
endary criminals. He spent more than 30 years as a fugi-
tive before turning himself in.
Dec. 19 – Cuba lifts a ban on imported autos that it imposed
in 1963.
JANUARY 2014Jan. 7 – Ojibway Enclosures completes its move from its for-
mer Janesville, Wisconsin, production facilities and offices
into Universal Acoustic & Emission Technologies’ Center of
n The LNGo system
is shown with 3-D
CAD software created
by the development
team at Painted Post,
New York.
Excellence on the Ironworks campus in Beloit, Wisconsin.
Ojibway was acquired by Universal AET in July 2013.
Jan. 9 – Harsco Corp., the parent of Harsco Air-X-Changers,
acquires Hammco Corp., an Owasso, Oklahoma-based
provider of process coolers for the natural gas and petro-
chemical processing industries.
Jan. 20 – GE Oil & Gas agrees to acquire Cameron’s Re-
ciprocating Compression division for US$550 million. The
division provides reciprocating compression equipment
and aftermarket parts and services for oil and gas pro-
duction, gas processing, gas distribution and independent
power industries.
Jan. 24 – Happy Birthday, Macintosh. On this day 30 years
ago, the Apple Macintosh, later known as the Macintosh
128, was released.
Jan. 28 – Axip Energy Services becomes the new name
for Valerus Compression Services, which began operating
as a stand-alone company on Jan. 3 when Valerus Field
Solutions was sold to Kentz Corp. for US$435 million.
Jan. 29 – Caterpillar Oil & Gas releases a low-emissions
upgrade kit for select G3516 LE petroleum engines used
in gas compression applications. The upgrade kit allows
operators to modify existing engines to a lower emission
configuration, enabling operation at 0.5 or 1.0 g/bhp-hr
NTE NOx levels.
Jan. 30 – Valerus Field Solutions receives a US$62 mil-
lion contract to provide engineering, procurement, con-
struction and commissioning of two compressor stations
in Doddridge County, West Virginia, for Crestwood Mid-
stream Partners.
FEBRUARYFeb. 2 – The Seattle Seahawks defeat the Denver Bron-
cos 43-8 in Super Bowl XLVIII at MetLife Stadium in East
Rutherford, New Jersey. It was the first Super Bowl played
outdoors in a cold-weather city.
Feb. 3 – GE launches a downstream technology solutions
(DTS) business to supply equipment and services more
efficiently to the US$10 billion refining, petrochemical, in-
dustrial and distributed gas segments.
Feb. 10 – Film star Shirley Temple dies at 85.
Feb. 10 – GE Oil & Gas makes the first Latin American sale
of its advanced ICL compressors to Total S.A., which will
nCaterpillar Oil & Gas’ upgrade kit for select G3516 LE
petroleum engines allows operators to modify existing en-
gines to a lower emissions configuration.
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use two of the single-stage units at a new compressor sta-
tion for the Incahuasi project in Bolivia.
Feb. 13 – IMI Sensors (IMI), a division of PCB Piezotronics
Inc., receives CSA approval of its Echo Wireless Vibration
Monitoring System (model CS672A01) for vibration moni-
toring in Class 1 Division 2 Hazardous Area applications.
Feb. 24 – The Board of Supervisors for the South Buffalo
(Pennsylvania) Township denies a request from XTO En-
ergy to build a natural gas compressor station on the Mc-
Intyre Farm near Grandview Drive and Ford City Road.
About 60 residents attend the meeting, with concerns
ranging from the station’s proximity to residential property
to the potential for noise and air pollution.
Feb. 25 – Chromalloy renews a 10-year agreement with
Solar Turbines Inc. to provide component repairs and new
production support for the manufacturer’s power systems
in the oil, natural gas and power generation industries.
Feb. 26 – Two days after denying a request from XTO
Energy to build a natural gas compressor station on the
McIntyre Farm in South Buffalo, Pennsylvania, township
officials approve a smaller proposal from Snyder Brothers.
The Snyder Brothers’ proposal has one compressor, com-
pared with XTO Energy’s four, and would be built 2000 ft.
(610 m) from homes on Grandview Drive over a hill. XTO’s
station would have been 500 to 1000 ft. (152 to 305 m)
from the homes.
Feb. 28 – CDM Resource Management LLC’s contract
compression fleet announces that it passed the 1 million
hp (745 MW) level late last year and since has grown to
1.2 million hp (895 MW).
Feb. 28 – Exterran Partners announces that it is acquiring
334 compression units totaling 440,000 hp (328 MW) from
MidCon Compression LLC, a subsidiary of Chesapeake
Energy Corp., for US$360 million. The assets will provide
compression services to Access MLP Operating LLC, a
subsidiary of Access Midstream Partners LP.
MARCHMarch 3 – Kinder Morgan orders two of Everest Sciences
Corp.’s ECOChill units for its Uniondale Compressor sta-
tion on the Tennessee Gas Pipeline near West Clifford,
Pennsylvania.
March 8 – Malaysia Airlines Flight MH370, which departed
from Kuala Lumpur International Airport en route to Bei-
n The new certification
for IMI Sensors’ vibration
monitoring system con-
tains the following approv-
al: Class I, Div. 2, Groups
A, B, C and D, T4 (-20°C <
Ta < 70°C).
jing, loses contact with air traffic control less than hour af-
ter takeoff. No distress signal or message was sent and
the plane remains missing.
March 14 – GE opens its newly expanded oil and gas fa-
cility in Fót, Hungary. The manufacturing plant was sub-
stantially enlarged with the addition of a new 86,111 sq.ft.
(8000 m2) manufacturing facility and a 32,292 sq.ft. (3000
m2) office building.
March 19 – ICF International prepares a report for the IN-
GAA Foundation and America’s Natural Gas Alliance. The
report states that the United States and Canada will re-
quire annual average midstream natural gas, crude oil and
natural gas liquids midstream infrastructure investment of
nearly US$30 billion per year, or US$641 billion (in 2012
dollars) from 2014 to 2035.
March 21 – Despite the state’s efforts to limit flaring, the
North Dakota Department of Mineral Resources reports
that production of “nonmarketed” natural gas was 310
MMcfd (8.8 x 106 m3 /d) in 2013, almost double the 160
MMcfd (4.5 x 106 m3 /d) in 2011. Most nonmarketed natural
gas is flared into the atmosphere.
March 27 – Kinder Morgan Energy Partners LP an-
nounces plans to build a 213 mile (343 km), 16 in. (400
mm) pipeline to move carbon dioxide (CO2) from the
St. Johns field in Apache County, Arizona, to its Cortez
Pipeline in Torrance County, New Mexico. The new Lo-
bos pipeline will have an initial capacity of 300 MMcfd
(8500 m3 /d).
March 31 – Paris celebrates 125 years of the Eiffel Tower.
The wrought-iron lattice tower is one of the most iconic
structures in the world.
APRILApril 3 – MarkWest Energy Partners LP orders more than
70 Caterpillar G3600 engines. A combination of G3608 en-
gines rated at 2370 hp (1.7 MW) and G3612 engines rated
at 3550 hp (2.6 MW) will be used to support gas gathering
operations across the Utica and Marcellus shale produc-
ing regions.
April 7 – India begins its elections, one of the biggest vot-
ing events in the world. Some 814 million voters — 100
million more than the last elections in 2009 — are eligible
to cast ballots at 930,000 polling stations, up from 830,000
in 2009.
April 11 – Cook Compression completes its move of its
Oklahoma City service center to 6836 Pat Ave. The new
facility offers complete cylinder and power repair services
for all major reciprocating compressors.
April 11 – Shell indefinitely postpones a project to install
subsea compression at Ormen Lange field in the North
Sea due to rising costs in Norway’s offshore oil sector. The
company explained that compression was not time-critical
to the ultimate recovery from the field.
April 14 – Enerflex Ltd., Calgary, names Marc Rossiter as
president of United States and Latin American operations
and Bradley Beebe as president of Canadian operations.
April 17 – Gabriel Garcia Marquez, the Colombian novelist
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whose One Hundred Years of Solitude established him as
a giant of the 20th century literature, dies.
April 17 – Sundyne announces that it is merging with Pres-
sure Products Industries (PPI), a manufacturer of sealless
reciprocating diaphragm compressors for the refining,
petrochemical, chemical, liquefied natural gas and semi-
conductor markets.
April 22 – Dresser-Rand launches its Magnum Hammer-
Head valve, designed for high-molecular-weight applica-
tions at both low and high compressor speeds. The valve
can be used in all brands of reciprocating compressors.
April 25 – Zahroof Valves Inc. moves to a larger facility in
Houston to improve compressor valve product turnaround,
optimize testing and R&D capabilities and add employees.
April 25 – China’s Shenhua Ningmei Coal Group places
a follow-up order with Siemens Energy for four identical
CO2 compressor trains. Each train consists of one STC-
GV integrally geared compressor driven by an SST-600
condensing steam turbine via an intermediate gear.
MAY
May 1 – Exterran Holdings signs a 12-year compression serv-
ices contract with the consortium BCAM-40 for its compres-
sor station in Bahia, Brazil. Petroleo Brasileiro S.A. (Petro-
bras) will serve as the field operator for the project, which will
use 28,000 hp (20,880 kW) of compression equipment, as
well as associated natural gas production equipment.
May 7 – Rolls-Royce announces that it is selling its ener-
gy gas turbine and compressor business to Siemens for
US$1.32 billion.
May 9 – CDM Resource Management completes construc-
tion of a 16,000 sq.ft. (1486 m2) training facility in Houston
as part of its enhanced training program initiative. The fa-
cility has three classrooms, a conference room and 10,000
sq.ft. (930 m2) of space for instruction.
May 15 – Audax Private Equity acquires Miratech Corp., aug-
menting it with the silencing business of another company
it owns, Phillips & Temro Industries (PTI). Tulsa, Oklahoma-
based Miratech was renamed Miratech Group LLC.
May 19 – Altronic’s GTI Bi-Fuel product line receives af-
termarket certification from the Air Resources Board of
the state of California Environmental Protection Agency
(CARB) for use on off-road compression-ignition engines in
stationary applications.
JUNEJune 3 – GE completes its US$550 million acquisition of
Cameron’s reciprocating compression business, which
was merged into the GE Oil & Gas Downstream Technolo-
gy Solutions business. The new business unit was formed
to deliver products and services and packaged products
for the traditional downstream and unconventional oil and
gas markets.
June 4 – The Canadian government announces mandatory
emissions standards for major industries, including the sta-
tionary engines used to drive gas compressors. The reg-
ulation also affects air pollution from boilers, heaters and
cement kilns. It brings Canada’s air quality rules closer to
DECEMBER 2014 43 COMPRESSORtech2
continued on page 44
nThe GTI Bi-Fuel system
is designed to allow diesel
engines to operate on ablend of diesel and gas-
eous fuels.nSiemens will deliver its largest CO2 compressors to a
coal liquefaction plant in Ningxia Province, China.
May 16 – Sulzer begins reorganizing its Pumps Equipment
division to make it more market focused and move the
service aspect of the pumps business into a combined
Rotating Equipment Services division. Rotating Equip-
ment Services merges engineering services for large tur-
bines, compressors, motors and generators. Sulzer also
creates a water-related business unit within the Pumps
Equipment division.
May 16 – The Bharatiya Janata Party (BJP) and Prime Min-
ister Narendra Modi’s landslide win is celebrated through-
out India. The party wins a majority in Parliament, giving
Modi the most decisive mandate for any leader since the
1984 assassination of Prime Minister Indira Gandhi pro-
pelled her son to office. Since 1989, India has been gov-
erned by coalitions.
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those issued by the U.S. Environmental Protection Agency.
June 5-7 – Commemoration events marking the 70th anniver-
sary of the D-Day landings are held in Normandy, France.
June 12 – Motortech opens a newly constructed training
center at its headquarters in Celle, Germany.
June 13 – Sulzer, an independent service provider for
rotating equipment, completes an agreement to acquire
Grayson Armature Large Motor Division Inc. and Grayson
Armature Orange Texas Inc. Founded in 1980, Grayson
Armature offers electro-mechanical repair services (at an
in-house machine shop), remanufacturing, redesign, up-
grades, modifications and other services.
June 15 – In a rematch from the previous season, the San
Antonio Spurs avenge their 2013 NBA Finals loss by beat-
ing the Miami Heat 104-87 in Game 5 to win their fifth NBA
title. The Spurs take the series 4-1.
June 19 – BP and the China National Offshore Oil Corp.
(CNOOC) agree to a deal for the supply of up to 1.7 million
tpy (1.5 million T/yr) of LNG over 20 years starting in 2019.
June 26 – Industry companies form the Oil and Natural Gas
Information Sharing and Analysis Center (ONG-ISAC) to
protect infrastructure — including gas compressor stations
— from cyber attacks. The American Petroleum Institute
(API) helped launch the data hub, which will operate as
an independent organization. ONG-ISAC will facilitate the
exchange of information, help evaluate risks and provide
up-to-date security guidance to companies operating in
the U.S.
June 28 – 100 years ago, the Archduke Franz Ferdinand,
heir to the Austro-Hungarian crown, and his wife, the
Duchess of Hohenberg, were shot dead in Sarajevo by an
assassin. The killings ignited the First World War.
June 28 – Theodore (Dutch) Van Kirk, the navigator and
last surviving crew member of the Enola Gay, the B-29
Superfortress that dropped the atomic bomb on Hiroshima
in the last days of World War II, dies at his home in Stone
Mountain, Georgia. He was 93.
JULYJuly 1 – Enerflex Ltd. of Calgary completes its US$430 mil-
lion purchase of Axip Energy Services’ international con-
tract compression and processing operations, as well as
its aftermarket services business.
July 7 – Kobelco Machinery do Brasil Ltda. begins market-
ing nonstandard compressors (custom-engineered pro-
cess compressors) in South America from its headquar-
ters in Sao Paulo.
July 13 – Germany wins its fourth World Cup title by beat-
ing Argentina 1-0 at the Maracanã in Rio de Janeiro, Bra-
zil. The lone goal in the soccer game came in extra time
from Mario Gotze.
July 14 – Exterran Partners acquires another 162 com-
pression units, totaling 110,000 hp (82 MW), from MidCon
Compression for US$135 million.
July 17 – Corac Group expands its test facility at its Tech-
nology Centre in Slough, England, with the commissioning
of a “dirty gas” flow loop.
July 17 – Siemens announces that it is manufacturing
four large integrally geared compressors for the Shenhua
Ningmei Coal Group for installation at a 4.4 million tpy
(4 million T/yr) coal liquefaction plant in Ningxia Province.
July 21 – The Alstom Board of Direction unanimously de-
cides to recommend GE’s offer to acquire its Power and
Grid businesses.
July 23 – Southwest Research Institute (SwRI) receives a
US$1.8 million contract from the U.S. Department of En-
ergy to develop, build and test a linear motor reciprocating
compressor (LMRC). The goal of the project is to increase
efficiency and reduce costs for hydrogen compression.
July 23 – Compass Compression Services Ltd. and
Compass Compression Solutions Inc. break ground on
a 75,000 sq.ft. (6970 m2) plant in Calgary’s Southeast
Frontier Industrial Park. When the building is completed
in the second quarter of 2015, Compass Compression
will have 125,000 sq.ft. (11,600 m2) of gas compression
fabrication capacity.
nSiemens made this integrally geared turbocompressor for
CO2 applications.
DECEMBER 2014 44 COMPRESSORtech2
nCorac Group has commissioned a “dirty gas” flow
loop at its Technology Centre.
nCompass Compression began constructing a 75,000 sq.ft.
(6970 m2) plant in July.
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of the Panama Canal, an engineering marvel that perma-
nently changed world trade and still plays an essential role
in global commerce.
Aug. 18 – Cameron announces that it is selling its centrif-
ugal compression division to Ingersoll Rand for US$850
million as part of a long-term business strategy to focus on
its core markets.
Aug. 19 – Festivities in Hungary mark the 25th anniversary
of the opening of its borders to the noncommunist West.
The open Hungarian border with Austria allowed thou-
sands of people to leave communist Eastern Europe. The
decision paved the way for the fall of the Berlin Wall three
months later.
Aug. 29 – A Morgan Stanley subsidiary applies to the U.S.
Department of Energy for a permit to export up to 60 Bfcy
(1.7 x 109 m3 /y) of compressed natural gas (CNG) gas
from a proposed terminal near Freeport, Texas.
SEPTEMBERSept. 3 – The Atlas Copco Gas and Process Division in-
troduces its single-shaft RT153 turbocompressor, which
provides flow volumes beyond 14.1 MMcfhr (400,000 m3 /
hr) for large air separation units and fertilizer production.
Sept. 3 – MAN Diesel & Turbo delivers two compression
modules designed for quick and easy integration into
a floating production, storage and offloading vessel for
Petrobras in offshore Brazil. Modec and Toyo Offshore
Productions Systems ordered the modules for the Cidade
de Mangaratiba MV24 FPSO.
Sept. 5 – Sponsors of the Alaska LNG Project file with the
U.S. Federal Energy Regulatory Commission to begin the
permitting process for construction of an 800 mi. (1300
km) gas pipeline from Prudhoe Bay field to a planned liq-
uefaction plant at Nikiski on the Kenai Peninsula.
Sept. 10 – GE gets an order for electric-motor-driven tech-
nology that will enable the Freeport LNG export project, on
the Gulf of Mexico south of Houston, to comply with local
air emissions standards.
Sept. 15 – Anthony (Tony) Gioffredi
joins Zahroof Valves Inc., Houston,
as its CEO. Gioffredi spent 12 years
with EnPro Industries Inc. and
Compressor Products International.
Sept. 16 – Siemens Energy receives an order from Cheng-
du Cryogenic Liquidation Equipment Co. Ltd. to provide
two compressor trains for an LNG project with an annual
capacity of 400,000 tonnes of LNG.
Sept. 22 – Siemens announces that it will acquire Dresser-
Rand for US$7.6 billion, filling out its portfolio of compres-
sors, steam turbines, gas turbines and engines.
Sept. 23 – GE launches its 16.5 MW gas turbine (NovaLT16)
for compression and power generation applications in the
DECEMBER 2014 45 COMPRESSORtech2
July 24 – CDM Resource Management LLC announces
plans to expand its Greeley, Colorado, facilities to meet
growing demand for compression services in the Niobrara
Shale play of Colorado and Wyoming. The company will
add 2100 sq.ft. (195 m2) of office space at 1919 65th Ave.,
a few miles from its existing 5000 sq.ft. (464 m2) ware-
house at 917 E 18th St. in Greeley.
July 24 – U.S. natural gas exports to Mexico were a record
2.5 Bcfd (70.8 x 106 m3 /d) on this day and averaged 2.3
Bcfd (65.1 x 106 m3 /d) from June through August, more
than double the pipeline flow in 2010.
July 30 – The U.S. Department of Energy announces plans
to establish energy efficiency standards for new natural
gas compressors as part of a program to reduce methane
leaks from natural gas pipelines.
July 31 – ElectraTherm partners with ConocoPhillips to
capture waste heat from a compressor station at Cessford,
Alberta, and generate 90 kW of electricity. The company’s
“Green Machine” generates power from low temperature
waste heat using the Organic Rankine Cycle (ORC) and
patented technology.
July 31 – After 46
years, Joe Kane, the
founder of COMPRES-
SORtech 2 , retires.
AUGUSTAug. 4 – Compressco Partners completes its previously an-
nounced purchase of Compressor Systems Inc. (CSI) from
Warren Equipment Co. for US$825 million. The purchase
boosts Compressco’s fleet from 87,000 to 1,045,000 hp
(65 to 780 MW) allowing the company to offer an expand-
ed range of compressor packages from 20 hp to 2370 hp
(15 to 1760 kW).
Aug. 5 – 100 years ago, the first electric traffic light was in-
stalled on a city street in Cleveland, Ohio, marking a mile-
stone in traffic management.
Aug. 15 – This day marks the centennial of the opening
continued on page 46
nA tanker squeezes
through the Panama
Canal, which is un-
dergoing a US$5.25
billion expansion.
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oil and gas industry. The NovaLT16 is rated for 16.5 MW
and 7800 rpm.
Sept. 30 – The Federal Energy Regulatory Commission
authorizes Dominion to convert its Cove Point, Maryland,
liquefied natural gas import terminal on the Chesapeake
Bay into a 5.75 million Tpy (5.22 million T/yr) export facility.
OCTOBEROct. 1 – Scott Rowe becomes Cameron’s president and
chief operating officer.
Oct. 2 – Hoerbiger Corp. of America Inc. hires John Metcalf
as its senior vice president and head of OEM Sales and
Engineering.
Oct. 2 – Caterpillar Oil & Gas updates its natural gas fueled
G3600 engine line, offering customers expanded fuel flex-
ibility, a 5.6% power increase and greater altitude and am-
bient temperature capabilities.
Oct. 2 – H2scan Corp., a provider of process gas monitor-
ing solutions for industrial markets, signs a long-term sup-
ply agreement with ABB.
Oct. 6 – Exterran launches its C-Series line of configurable
compression packages, pre-engineered with a wide range
of configuration options.
Oct. 7 – Southwest Research Institute (SwRI) opens a
high-horsepower engine dynamometer facility, allowing it
nCaterpillar Oil & Gas’s updated G3600 engine line comes with
the latest ADEM A4 engine control unit.
to improve its engine research and evaluation services
to industries that use engines up to up to 7000 hp (5220
kW) for applications in transportation, pipelines and pow-
er generation.
Oct. 14 – Exterran gets an order to provide equipment to
support 210 MMcfd (6 x 106 m3) of natural gas processing
capacity at the Woodford Express facility in Grady County,
South Central Oklahoma.
Oct. 21 – Former Washington Post editor Ben Bradlee dies
at 93. He oversaw the paper’s coverage of the Watergate
scandal.
Oct. 27 – A floating storage and regasification unit (FSRU)
— The Independence — arrives in Klaipeda, Lithuania. Its
arrival signals the end of Gazprom’s monopoly in several
Baltic nations. The terminal will have a send out capacity
of 71 to 106 Bcfy (2 to 3 x 109 m3 /yr).
Oct. 29 – Statoil says the world’s first subsea wet gas
compressor station is ready for final testing before being
installed next year at Gullfaks C field in the North Sea.
Subsea compression, combined with conventional low-
pressure production in a later phase, will extend the pro-
ductive life of the Brent crude reservoir. Output will grow
10%, or 22 million barrels of oil equivalent, to 73%.
Oct. 29 – The San Francisco Giants defeat the Kansas
City Royals 3-2 at Kauffman Stadium in Kansas City,
Missouri, in Game 7 of the World Series. It was the Gi-
ants’ third world championship baseball title in the past
five seasons.
Oct. 31 – BG Group selects the Trent 60 DLE industrial gas
turbine from Rolls-Royce as the driver for the main refrig-
eration compressors in the proposed Lake Charles LNG
export project in Louisiana.
DECEMBER 2014 46 COMPRESSORtech2
nTwo new 7000 hp (5220 kW) engine test cells are the latest
additions to SwRI’s expanding large engine test and develop-
ment facilities.
n The Trent 60 DLE industrial gas turbine will serve as the
driver for the main refrigeration compressors in the proposed
Lake Charles LNG Export project in Louisiana.
nH2scan Corp. nets long-term supply agreement with ABB.
nGE’s NovaLT16 gas turbine is suited for pipeline compression,
power generation and oil and gas plant compression applications.
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USA Compression
USA Compression Partners (USAC)
has reported its fleet totaled 1.4 million
hp (1044 MW) on Sept. 30, up 24%
from the third quarter of 2013.
Part of that growth was from its
US$187 million acquisition of 138 million
hp (103 MW) from S&R Compression in
the fall of 2013. USAC said over the past
year, revenue-generating horsepower in-
creased 22% to 1.3 million (970 MW). As
of Sept. 30, its fleet utilization was 94%,
compared to 94.5% a year earlier.
The partnership spent US$320 mil-
lion for new compression units over the
last year, mostly for large horsepower
equipment employed in fee-based mid-
stream gathering applications. It has
NOVEMBERNov. 3 – The first Godzilla movie is re-
leased 60 years ago on this day in Ja-
pan. Titled Gojira , the filmmakers took
inspiration from various dinosaurs,
such as the tyrannosaurus rex, iguan-
odon, and stegosaurus, to shape
Godzilla’s final and iconic design.
Nov. 3 – After receiving the required
approvals, Triton legally finalizes its
acquisition of GEA Heat Exchangers.
Triton says that the heat exchanger
business will be further developed
as part of an autonomous group un-
der the aegis of the new investor.
Nov. 5 – Dean Glover is named the
CEO of Miratech Group, with Kevin
O’Sullivan moving from president
and CEO to chairman.
Nov. 11 – Motor-Services Hugo
Stamp Inc. (MSHS) expands its ser-
vice facility in New Orleans, Louisi-
ana. MSHS, a turnkey supplier of
engine and auxiliary systems ser-
vice, parts and overhauls, said the
expansion enhances its existing
New Orleans-based turbocharger
service facility with comprehensive
in-house and on-site engine service
and overhaul.
Nov. 11 – Rexnord Power Trans-
mission (RXN) enters into a defini-
tive agreement to acquire Euroflex
Transmissions (India) Pvt. Ltd.
Nov. 11 – T.F. Hudgins Inc. com-
pletes the acquisition of Jamison
Products, a Houston-based pro-
vider of engineered pipeline and
filtration products used in a wide
range of gas and fluid handling ap-
plications including strainers, sepa-
rators, filter vessels, pig launchers
and closures. CT2
DECEMBER 2014 47 COMPRESSORtech2
MOVERSPRIME
continued on page 57
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New technologies and the cost
reduction of electronic compo-
nents have enabled the devel-
opment and diffusion of capacity regu-
lation devices, which allow optimizing
both compressor energy consumption
and its global control.
The stepless capacity control of re-
ciprocating compressors is generally
achieved by systems based on variable-
speed drive (VSD), or on reverse flow
regulation, which acts on the suction
valve opening timing.
Cozzani reecently developed a step-
less capacity control system, named
FluxtoFlow, which allows adjusting
the capacity through the reverse flow
method. The company said it was in-
novative because it is the first to be
operated only by electric current in
order to control the closing of the com-
pressor suction valves at each com-
pression cycle. Thanks to this method,
the compressor processes the exact
capacity required by the end user.
The new system was applied to a
new compressor installed in 2013 in
parallel with an identical unit operating
in the same plant, but equipped with a
conventional control system. After the
new compressor was installed, its con-
trol system was measured to analyze
its behavior at the different set points
required by the production plant. Sig-
nificant parameters, such as pressure
trends, PV diagrams, regulation range,
repetitiveness of the actuator positions,
etc., were kept under control over time.
At Rosignano, Italy, Ineos has
produced high-density polyethylene
(HDPE) through a hexane slurry pro-
cess since the 1960s.
It recently revamped the ethylene
recovery plant at a cost of nearly €2
million. The surplus of ethylene that
doesn’t react with other raw materi-
als in the polymerization reactors has
to be recovered and properly treated
to be used again, so as to reduce
the polymer production costs. The
recovery plant is therefore essential
to assure the minimization of produc-
tion costs that would become unbear-
able in case it malfunctioned. In fact,
the cost of ethylene represents more
than 80% of the final sale value of the
product and the efficiency of the re-
covery system is fundamental to en-
sure competitiveness.
The unreacted gas coming from the
reactors is conveyed at a pressure
of about 4.3 psi (0.3 bar) to a group
of reciprocating compressors that, in
three subsequent compression and
cooling phases, allow the recovery of
hexane and butene in liquid form. The
ethylene compressed to about 435 psi
(30 bar) is then delivered to other fi-
nal treatment columns to obtain a gas
that can be used again in the reaction.
The object of the revamping at the
compression and interstage condens-
ing plant consisted of three Termomec-
canica balanced/opposed reciprocat-
ing compressors working in parallel,
with a capacity of 31.8 Mcfh (900 Nm3 /
hr) each. Two of these compressors
allowed a variable gas flow rate from
zero to about 49.4 Mcfh (1400 Nm3 /
hr), while the third is a backup.
All compressors run at a constant
speed, and one of them has been
equipped with the FluxtoFlow elec-
tric stepless capacity control system,
controlled by DCS on the basis of the
suction pressure setpoint that must be
kept constant. In addition, the system
was equipped with a bypass between
the first and third stages with a manual
valve used only during the plant start-
up, before the treated gas reaches the
minimum flow rate for the activation of
the capacity control system.
The Cozzani system continuously
performs diagnostic functions on
each actuator. If a fault is detected,
the electromechanic actuator is dis-
abled and the system continues op-
erating with the other actuators. The
end user can also disable an actuator
by acting on the software. If in a sys-
tem, for whatever reason, there are
disabled actuators, the system adopts
Cozzani’s Stepless Capacity
Control Tested > FluxtoFlow, VSD performancescompared on compressorsBY A. RAGGI AND A. GIAMPÀ, COZZANI S.R.L.
DECEMBER 2014 48 COMPRESSORtech2
nFigure 1. Slight signs are visible on the plate produced by the
fingers. They had no effect on regulation.
continued on page 50
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the strategies studied for that specific
compressor and makes it possible to
control the capacity through the avail-
able actuators.
The system has been running for
a year, controlling the compressor
capacity required by the plant. After
about 8000 running hours (equivalent
to 235.2 million cycles of actuations
on the suction valves and conse-
quently actuator rod displacements),
valves and actuators were inspected.
All inspected parts showed very slight
wear and the system was controlling
correctly (Figure 1) before the com-
pressor was shut down.
New compressors
Ineos has installed two new com-
pressors (Figure 2). The three-stage
compressors have three double-act-
ing cylinders and compress ethylene
up to a pressure of 435 psi (30 bar).
Each compressor has a nominal pow-
er of 476 hp (355 kW) and a capacity
of 64 Mcfh (1800 Nm3 /hr).
Both machines need a capacity con-
trol system. Ineos chose the Cozzani
capacity control system for one com-
pressor and the VSD method for the
other. The two compressors have been
equipped with taps for cylinder pres-
sure acquisition in order to allow the
installation of a data acquisition system
used to analyze and to optimize the
behavior of the system and to evaluate
the global behavior of the compressors.
Both machines are monitored by
the control room, which generates
outputs for each of the two capac-
ity control systems, in order to keep
the first-stage suction pressure con-
stant (Figure 3). The compressors are
equipped with bypass valves: One is
automatic and can be controlled from
the control room either with the invert-
er or with reverse flow capacity con-
trol system and the other is handled
manually by the local staff.
Experiences
The Cozzani control system ex-
changes compressor signals for
management and monitoring with the
control room and receives the refer-
ence signal to control the capacity.
The compressor is controlled from the
control room by implementing a logic
that generates the reference signal for
the reverse flow capacity control sys-
tem and for the bypass valve.
Ineos has developed its own logic
for the plant start-up: The compressor
is started when the bypass valve is
closed and the capacity control sys-
tem switches between the minimum
capacity and the idle condition, as
long as the discharge pressure reach-
es 145 psi (10 bar). After that, the
control logic changes and the step-
less capacity control regulation drives
the process up to the steady working
condition of 435 psi (30 bar).
The compressor is controlled, to
keep the suction pressure constant,
through a PI controller.
If the suction pressure drops down
under the reference value, the regula-
tion system reacts by increasing the
delay in suction valve closing (this re-
duces the capacity).
If, on the other hand, the suction
pressure increases, the regulation
system reacts by decreasing the suc-
tion valve closing delay (this increas-
es the capacity).
The control logic manages both the
reverse flow capacity system and the
automatic bypass valve. In order to
guarantee minimum energy consump-
tion, the bypass is closed from the
rated capacity up to the lowest one
allowed by the reverse flow control
system; only if the required capacity is
lower than this value, the control logic
starts to open the automatic bypass.
A VSD-controlled compressor
The control room regulates the com-
pressor flow rate by means of a refer-
ence signal for the VSD to change the
DECEMBER 2014 50 COMPRESSORtech2
nFigure 2. The new compression and interstage condensing plant is
shown after the revamp of August 2013.
nFigure 3. This is a control
room screenshot of the com-
pressor with the reverse flow
capacity control system.
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compressor speed, or by means of
the actuators which command the un-
loading of part of the cylinders acting
on the automatic bypass valve.
The compressor is started running
at 50% of its maximum speed with the
bypass valve kept closed and only one
cylinder end loaded for each stage. In
this condition, if the first-stage suc-
tion pressure decreases, the bypass
valve is opened. On the contrary, if the
pressure increases, the bypass valve
is kept closed and the compressor
speed is increased.
When the speed reaches a defined
threshold, the control room sets the
compressor to work with both ends of
each stage loaded. This produces an
instantaneous gas flow doubling that
introduces a discontinuity in the com-
pressor capacity.
The nonlinearity is managed con-
trolling the first-stage suction pres-
sure. If the pressure increases, the
speed is reduced and the bypass
valve opened (all cylinder ends are
still loaded). The control for the un-
loading of one cylinder end per stage
is generated only if the pressure
reaches a second threshold (different
from the one defined before).
It is important to notice that the switch-
ing between single- and double-acting
operation generates a discontinuity in
the flow which can cause an imbalance
in the plant. The compressor working
cycles have been evaluated acquiring
cylinder pressures of each stage. As
flow rate is controlled by changing the
compressor speed, the pressure has
the typical trend of a full-load running
machine. The pressure trend analysis
at several speeds allows observing the
presence of pulsation during the suc-
tion or the discharge phase. This phe-
nomenon is emphasized in particular
at low speeds.
These pressure fluctuations are typ-
ically due to valve plate (or ring) flut-
tering phenomena and can negatively
influence valve life especially if the
compressors often run at low speeds
due to plant requirements.
VSD, reverse flow comparison
The two compressors under inves-
tigation are identical, therefore the de-
tected differences in power consump-
tion and valve behavior depend on the
system adopted to adjust the flow rate.
The power comparison between
the two systems neglects the contri-
bution of the inverter (Figure 4).
The discharge temperature trends
detected in the two compressors for
different flow rates have been com-
pared. The temperatures of the re-
verse flow system controlled com-
pressor are higher than those of the
VSD-controlled machine and de-
crease with the flow. This phenom-
enon is typical in capacity control
systems based on the reverse flow
method. In fact, the gas flows back
from the cylinder into the suction pip-
ing with a temperature that is higher in
comparison to the temperature of the
gas coming from the process. This
produces an increase of the average
suction temperature and consequent-
ly of the discharge temperature.
The graph in Figure 5 shows the
DECEMBER 2014 51 COMPRESSORtech2
nFigure 4. Cylinder pressures with reverse flow system. nFigure 5. Temperature versus flow.
nFigure 6. Cylinder pressures during
suction phase.
continued on page 52
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temperature trends measured on the
two compressors. The temperature in-
crease in the case of the reverse flow
system is minimal and doesn’t affect
the process.
The analysis of the cylinder pres-
sure trends (Figure 6) highlights that,
at the same flow rate, the pressure
fluctuations during the suction phase
are significantly higher in the com-
pressor equipped with the VSD sys-
tem compared to the one equipped
with the reverse flow system.
The difference is related to the
control strategies. The reverse flow
system performs a flow regulation by
controlling the closing instant of the
suction valves. To perform this func-
tion, the valve finger is actuated in
order to keep the sealing element in
open position starting from the first in-
stant of the suction phase up to the
one defined by the control system.
Suction occurs when the valve is
forced in open position, thus fluttering
phenomena are not possible. This re-
duces the wear on springs and plate/
rings, ensuring better reliability and
longer valve life.
It must be considered that oscilla-
tions are generally emphasized when
compressor speed is lower than the
asynchronous motor nominal speed.
The compressor set with the reverse-
flow system works always at the nomi-
nal speed, whereas the one controlled
by an inverter generally operates at a
lower speed.
When the compressor runs at full
load, the suction valve is not con-
trolled and fluttering phenomena may
occur. These phenomena are sensi-
bly reduced when valve plate/ring po-
sition is driven by the valve capacity
control system.
The behavior of the two compres-
sors has been monitored and analyzed
beginning in August 2013. The reverse
flow system has shown a higher capa-
bility in capacity control (up to 15% of
the nominal flow rate) in comparison to
VSD (up to 50% the nominal flow rate)
(Figure 7). For this reason at the oper-
ating range required by the plant, the
use of the bypass was not necessary
for the compressor with the reverse
flow system. On the contrary, the com-
pressor with VSD was mainly run with
the bypass open. The use of the re-
verse flow system has contributed to a
decrease in power consumption.
Conclusions
The capacity control in reciprocat-
ing compressors required to adapt the
compressor flow to process demands
DECEMBER 2014 52 COMPRESSORtech2
n Figure 7. Power versus capacity is
shown for both compressors (Inverter
power consumption is not considered.)
can be performed through different
devices. The good results obtained by
the first compressor convinced Ineos
to install the system on a new machine
at the same plant in August 2013.
A direct comparison between two
different capacity control methods
has been possible thanks to a second
compressor controlled through VSD
and bypass. Temperatures, cylinder
pressures and power consumptions
in both cases have been acquired for
the same capacity and advantages/
disadvantages have been evaluated.
The reverse flow system has proved
a better capacity control capability (up
to 15% of nominal flow rate) in com-
parison to VSD (up to 50% of nomi-
nal flow rate). For this reason, in the
operating range required by the plant,
the compressor with reverse flow sys-
tem has mainly run with closed by-
pass while the machine with VSD has
mainly run with open bypass.
In addition, the analyses on valve
behavior have confirmed that the sys-
tem can reduce valve plate impact
stresses and can assure its fully ax-
ial motion. This allows a better valve
reliability. On the contrary, the VSD
system does not offer the same ad-
vantage and increases the stress on
the valves. CT2
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III
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GEA Group is a global busi-
ness concentrated in applica-
tions/equipment for the food
industry (75 to 80% of its turnover)
but it also operates in other markets.
In particular, it is developing solutions
for energy markets.
COMPRESSORtech 2 interviewed
Ivano Camaggi, president of GEA Re-
frigeration Italy’s Power Technology
Center at Castel Maggiore on the out-
skirts of Bologna.
The Italian business unit has spe-
cialized in the engineering, and pro-
duction and installation and service
of gas skids. GEA Refrigeration Italy
installed the first screw-oil-injected
fuel gas compressor for gas turbines
in 1990 and recently has widened the
spectrum of its activities to cover com-
pression of natural gas for pipeline
applications, associated gas, biogas,
coalbed methane and syngas. It also
provides chillers for inlet turbine cool-
ing and for production of cool water,
such as at power generating plants.
Most of their fuel gas skids use an
oil-flooded GEA screw compressor
made in Berlin (by the former Gras-
so). To meet customer specifications,
a number of skids have been engi-
neered to host reciprocating compres-
sors and integrally geared centrifugal
compressors from several OEMs.
Camaggi said GEA’s operation in
Berlin manufactures the screw com-
pressor and delivers standard pack-
ages (skids) for the food industry.
“While in Bologna, we engineer
each skid tailored to customer speci-
fications. Our gas skids are used to
power both aero derivative and indus-
trial gas turbines in 6700 to 134,100
hp range (5 to 100 MW) including the
LM2500 and 6000 from GE, RB211
and Trent from Rolls-Royce and the
Siemens line from Finspong, Sweden.
“The great majority of the skids
manufactured for Russia are based
on screw compressors built in Berlin,”
Camaggi said. “GEA has supplied 600
screw compressors for this application
in the last 10 years. The Russian mar-
ket for such skids is the biggest and
presently is about 30 units per year.”
GEA Gradually ExpandsCompression Range > Latest venture is natural-gas-
engine driven packages
BY ROBERTO CHELLINI
DECEMBER 2014 54 COMPRESSORtech2
nGEA supplied this oil-free reciprocating compressor package to EnerjiSA for its Bandirma power plant in Turkey. The
electric driven compressor handles 5.3 MMcfh (150,000 m3 /hr) of gas from a variable inlet pressure of 350 to 550 psi (24
to 38 bar) to a discharge pressure of 580 psi (40 bar).
nIvano Camaggi
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GEA’s reciprocating compressor skid activity started in
2008 with a GE compressed natural gas (CNG) compres-
sors for Iran (56 packages before the international econom-
ic embargo) and China (another 56 packages).
The China packages were quite powerful for such serv-
ice, 536 hp (400 kW), Camaggi said. They were used at
“mother stations” to fill large cylinders transported by trucks
to remote areas not served by pipelines. The gas was dis-
tributed to the public through “daughter stations.”
Successively GEA Refrigeration Italy developed fuel gas
reciprocating compressor packages and in 2009 sold its first
five skids to Spain’s Technicas Reunidas. About 150 pack-
ages are now in operation at compressor stations, the last of
which was commissioned in Turkey during September.
Four reciprocating compressors driven by GE Waukesha
gas engines have been delivered for pipeline compression
in Uzbekistan.
“These were GEA’s first skids where the compressor was
driven by a gas engine, a challenging solution from the en-
gineering point of view, and interesting also for the after-
market service required by the driver.
“The use of gas engine-driven compressor packages is
very common in North America but still in its infancy in Eu-
rope and other parts of the world. At GEA we are promoting
this solution because we believe it has advantages espe-
cially in areas provided with weak electric grids.”
Camaggi said his engineering team should gradually ex-
pand the spectrum of skid-mounted compressor packages.
“That’s why from the start of this activity with screw com-
pressors the company has gradually expanded to recips
first, then to centrifugal compressors and now is looking
into the gas engine solution,” Camaggi said. “We have to
closely follow the state-of-the-art in our product line not only
to survive, but with the aim of expanding in a highly com-
petitive world.
“Compressors and drivers, the core of our skids, are sup-
plied by a group of international OEMs, all of which provide
high-quality components. Once you are included in the ven-
dor list, you are automatically qualified from the technical
point of view. At that point, acquiring an order is only a ques-
tion of being competitive.
“This is only possible through a lean organization staffed
with skilled personnel. Operating in a ‘custom market’ where
each skid is designed in accordance to unique specs is not
an ‘off-the-shelf’ activity. Each project requires a dedicated
engineering activity.
“However, it would be impossible to start from scratch
each time. To be competitive it is essential to standardize
components and use a wide array of subassemblies (mod-
ules) that at the same time reduce engineering cost, pro-
duction time and increase reliability of the final product.”
Camaggi said investing in human resources is the sec-
ond pillar essential for success. “To be competitive these
days you need skilled, motivated and competent personnel
who are prepared to introduce any type of innovation in the
organization structure,” he said.
DECEMBER 2014 55 COMPRESSORtech2
continued on page 56
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He said being a part of an interna-
tional company such as GEA offers
the advantage of having a worldwide
organization with the knowledge of
industrial processes and with direct
contacts with customers.
“Customers are looking for a solu-
tion partner who knows their whole
production process and can provide
an application,” Camaggi said. “That’s
why we anticipate, in the near future,
offering our packages to chill the air at
gas turbine inlet for power augmenta-
tion during the hot season.
“Recovery of associated gas at the
wellhead is another interesting appli-
cation that GEA will develop to reduce
flaring and make gas available to fuel
turbines. The associated gas, prior
to compression, has to be treated in
a separate skid to separate solid, liq-
uid and gaseous impurities that could
damage an oil-flooded screw com-
pressor (oil contamination) or the gas
turbine combustion system.”
Compressor packages from GEA
Refrigeration Italy have been installed
in 20 different nations. Camaggi said
his company plans to increase its
market share in Russia and the for-
mer CIS nations and to expand in the
Middle East and Africa.
“Very active engineering, procure-
ment and construction (EPC) com-
bines are now located in Turkey and
South Korea,” Camaggi said. “South
Korean EPCs are presently handling
60% of Middle Eastern projects and
it is essential to work with them to
penetrate this area of the oil and gas
marketplace.” CT2
DECEMBER 2014 56 COMPRESSORtech2
nThis is a GE Frame 9FA gas turbine fuel gas booster system. The 7770 hp
(5.8 MW) electric motor drives a skid-mounted, three-stage, integrally geared
centrifugal compressor.
Recent Orders
Rolls-Royce
Rolls-Royce said BG Group has selected the Trent 60
DLE industrial gas turbine as the driver for the main refrig-
eration compressors in the proposed Lake Charles LNG
Export project in Louisiana.
Each of the three liquefied natural gas (LNG) trains will
use four Trent 60 DLE gas turbines as part of the Air Prod-
ucts C3MR refrigeration process. Each train will employ two
Trent 60 DLE gas turbines driving propane compressors
and two Trent 60 DLE gas turbines driving mixed-refriger-
ant compressors.
BG Group and Rolls-Royce have also agreed to the terms
of a long-term service agreement covering the support and
maintenance of the equipment for up to 25 years.
The equipment and service contracts are expected to be
activated in the first half of 2015, subject to the federal per-
mits process and final investment decisions by BG Group
and Energy Transfer, the developers of the project.
GE
GE Oil & Gas will supply a gas turbine-driven compres-
sor train and mechanical drive technology to Petronas, for
a second floating liquefied natural gas (FLNG) facility being
developed off East Malaysia.
GE also supplied turbomachinery solutions for Petronas’
first FLNG, which is being constructed in South Korea. GE
will supply four of its PGT25+G4 gas turbine generator sys-
nGE’s LM6000 is scheduled for its first application on a floating
LNG Vesel.
tems and two nitrogen trains featuring two LM6000-PF+
2BCL907 aeroderivative gas turbines in mechanical drive
mode. The company said this is the first time an LM6000
gas turbine is being applied to an FLNG project.
The project will enable offshore LNG production in certain
smaller gas fields that are lacking pipelines to an onshore
LNG plant. The second FLNG plant will support the growing
demand for gas in peninsular Malaysia, where many power
plants and commercial customers are located, GE said.
GE’s equipment will be manufactured at the company’s
assembly facilities in Florence and Massa, Italy. Commercial
operation is expected to begin in the third quarter of 2017.
Once operational in the first quarter of 2018, the second
FLNG facility will produce 1.36 million tonnes/yr of LNG. CT2
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signed, or has pending, contracts for
90% of the midstream-oriented horse-
power that it expects to receive during
the rest of this year, the company said.
MAN Diesel & Turbo
Uwe Lauber has
been named chair-
man of the execu-
tive board of MAN
Diesel & Turbo ef-
fective Jan. 1, 2015.
Lauber headed
the oil and gas busi-
ness unit before
becoming the ex-
ecutive board member responsible for
global sales and aftersales on Oct. 1,
2014. He joined the Augsburg, Germany-
based company in 2000.
“MAN Diesel & Turbo is a company
that always led the way, and it still
does to this day in many areas,” Lau-
ber said. “I look forward to continuing
to extend this pioneering role together
with my executive board colleagues
and our 14,000-strong workforce.”
Triton, GEA
Triton has completed its acquisition
of GEA Heat Exchangers, absorbing
all companies as well as all staff.
Triton said it plans to further develop
the heat exchanger business. Except
for a for a new brand name that will be
rolled out later, Triton said nothing will
change for GEA customers.
The GEA Heat Exchangers Group
will be reorganized into three segments:
climate and environment, with activities
including all products for applications
of HVAC technology; solutions in major
power generation projects, including wet
cooling towers, dry cooling systems, fil-
ing media for cooling towers, as well as
further applications; and systems and
components for further heat exchanger
application areas such as those in the
markets of oil and gas and petrochem-
istry, marine and transportation systems,
among others.
The GEA name will continue to be
used until the introduction of the new
brand, Triton said.
Miratech
Kevin O’Sullivan, the president and
CEO of Miratech Group, will become
chairman and Dean Glover has been
named CEO.
Glover most recently was senior vice
president of the products division of
Global Power, which provides custom-
engineered auxiliary equipment and
maintenance support services for the
power generation industry. He is a cer-
tified Six Sigma Master Blackbelt.
Miratech provides emissions and
acoustical reduction solutions for natu-
ral gas and diesel reciprocating engines
used in the natural gas production, oil
and gas drilling, power generation, in-
dustrial, rail and marine industries.
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DECEMBER 2014 57 COMPRESSORtech2
U. Lauber
continued from page 47
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Online Mobile App
Cummins Inc. has released a free
QuickServe Online (QSOL) mobile app
for Apple iOS devices that provides ac-
cess to parts options, catalogs and en-
gine dataplate information for 15 mil-
lion Cummins engine serial numbers.
It also includes a fault code analyzer
for Cummins electronic engines.
The QSOL mobile app is available
globally for download in the Apple Store
by searching for QuickServeMobile. Us-
ers of the QSOL app are encouraged to
use the feedback button in the Settings
menu to suggest enhancements.
QSOL is continually updated with
the latest Cummins parts and service
information, the company said.
www.cummins.com
Pressure Relief Valve
Total Valve Systems (TVS) has in-
troduced its model 6820 TRV, the first
nonreclosing pressure relief valve that
can be reset in seconds from the field
or remotely, according to the compa-
ny. Related product model 6220 is a
shutdown version that shuts off when
the valve reaches the set pressure or
is triggered remotely.
Total Valve’s model 6820 TRV sys-
tem includes TRV module, actuator and
isolation valve for high-pressure lines.
The 6820 TRV requires no external
power and its performance is not im-
pacted by system backpressure.
Triple-offset valves are standard
across the spectrum of temperature,
pressure and sealing classes, and
operate from -450° to 1500°F (-267°
to 816°C) in accordance with valve
specifications. The device is a full-
face design with pipe flange bolting
for lug, wafer and short pattern body
configurations. Flange ratings are
150, 300 and 600. Set pressures are
from 3 to 1500 psi (0.2 to 103 bar).
www.totalvalve.com
Reservoir Sensor
A low-level sensing reservoir sys-
tem from Dymax Corp. prevents emp-
ty material reservoirs from introducing
air into dispensing lines, thereby elimi-
nating contamination during the dis-
pensing process.
The system utilizes an adjustable
sensor for use with pressurized res-
ervoirs and features an SB-100 con-
troller that activates a warning when
the material in the reservoir reaches a
specified low level. The controller also
features an external PLC connection
that allows for a total line shutdown,
saving time and money by stopping
the dispense system when material
reservoirs are empty, Dymax said.
The sensor configuration is adjust-
able, allowing operators to set specific
levels of material to signal warning and
automatic shutoff options. The low-level
functions include remote visual beacon,
audio buzzer and auto shutdown. There
are no wetted components; the sensor
does not contact fluids, so it’s compat-
ible with a wide range of materials.
www.dymax.com
(918) 283-9200 Fax (918) 283-9229 www.axh.com
Experience, Reliability, Integrity...
Now with three plants totalingover 400,000 SF on 53 acres
PRODUCTSFEATURED
DECEMBER 2014 58 COMPRESSORtech2
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Coalescer/Separator Systems
Hilliard Corp.
has released in-
formation about
its coalescer/
separator sys-
tems, which re-
move moisture
and particulate
contamination
from steam and
gas turbine lube
oils. Details are provided about its self-
sufficient stand-alone or portable models,
single- or multiple-element vessels and
custom designs.
www.hilliardcorp.com
Control Systems
Petrotech Inc.
has released lit-
erature detailing
its turnkey instru
mentation and
electrical serv-
ices, and control
systems for a
variety of turbo-
machinery as-
sets, such as
centrifugal and reciprocating compressors.
The company’s solutions are found up-
stream in oil and gas production, midstream
in pipeline and natural gas processing and
downstream in petrochemical and refining.
www.petrotechinc.com
Flow SensorsA product catalog
has been pub-
lished by Siargo
Ltd., which spe-
cializes in and
manufactures
MEMS flow sen-
sors, modules
and system prod-
ucts across a
wide range of ap-
plications. The sensors can mea-
sure gas flow in a pipe diameter from
0.019 in. (0.5 mm) to 6.56 ft. (2 m)
and with a flow speed of 0.19 in./s
(5 mm/s) up to 246 fps (75 m/s).
www.siargo.com
Component Repair
Improving equipment performance and reducing operat-
ing costs are the focus of new literature from Mountaineer
Industrial Services in Beckley, West Virginia. The com-
pany repairs and rebuilds cylinders, rods, pistons and
other components used in gas production and transmis-
sion. The company also finishes those components with
thermal-applied coatings or laser processing.
www.bmrgroup.net
LITERATURE
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Summit’s wide selection of Barrier Fluids
provide a wide range of viscosities
for mechanical seals. These fluids
offer low temperature fluidity, and
high temperature stability. Summit’s
Barrier Fluids efficiently transfer
heat, and they keep the seal face cool.
_
DECEMBER 2014 59 COMPRESSORtech2
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3
2
4
56
S D A N S X T P A N A M A L A Y S I A S
I E L A P E T S G R V Y A D H T R I B H
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Advertisers’ Index
Kiene Diesel Accessories ...........................................................55
Middle East Turbomachinery Symposium ................................53
MIRATECH ...................................................................................39
MOTORTECH GmbH ...................................................................13
Murphy by Enovation Controls ......37, Fourth Cover, Bellyband
Neuman & Esser Group ..............................................................15
PROGNOST Systems GmbH ......................................................23
Reynolds French .........................................................................19
SOGAT 2015 ................................................................................61
Summit Industrial Products .......................................................59
*Tech Transfer Inc. ......................................................................2-3
TEDOM a.s. - Engines Division ..................................................38
*Testo, Inc. ....................................................................................47
Toshiba International Corporation ............................Third Cover
Volvo Penta ..................................................................................49
Zahroof Valves Inc. .......................................................................9
ACI Services, Inc. ........................................................................35
Air-Cooled Heat Exchangers ......................................................58
*ARIEL .............................................................................................1
*Compressor Products International ............................................5
Cook Compression .....................................................................27
DCL International Inc. ...................................................................7
*Dresser-Rand ...............................................................................21
*Elliott Group ............................................................Second Cover
*Ellwood Crankshaft Group .........................................................39
E Instruments International ........................................................38
Enerflex Ltd. ................................................................................25
Exline, Inc. ....................................................................................57
Hahn Manufacturing Company ..................................................55
Harsco Industrial Air-X-Changers .............. .............. ............... ..29
*HOERBIGER Kompressortechnik .........................................10-11
*KB Delta Compressor Valve Parts, Mfg. ................ ..............32-33
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of mechanical refrigeration. Frick also introduced long-
stroke horizontal compressors in 1911, which remained in
use through the 1950s.
As the open-type compressor was made in smaller and
smaller sizes, the A frames that supported the cylinders
were finally combined into one piece. From this arrange-
ment, the enclosed compressor was later developed. First
built in 1915, these machines were available in a range of
sizes in time to serve the pressing demands of camps, food
and powder plants, hospitals and ships in World War I. The
enclosed design retained many of the desirable features
of the slow-speed machines, but enclosed machines with
automatic lubrication operated safely without constant at-
tention. This opened the way for systems with automatic
control in 1922.
In the 1920s, the range of practical refrigeration was ex-
tended to well below 0°F (-18°C). Frick built some of the first
successful large-scale CO2 compressors for making dry ice.
In the succeeding years, Frick played a leading part in
many types of commercial, industry and building refriger-
ating and cooling systems, extending its line to include a
nine-cylinder machine. By the late 1960s, screw compres-
sors were beginning to displace reciprocating compressors
in refrigeration and air conditioning applications. By 1982,
Frick had introduced its own screw compressors and pro-
duction of reciprocating units ended soon thereafter. CT2
n Caption
Frick Eclipse Refrigerating & Ice-Making Compressors Two Single-Acting
Compressor Cylinders Per Machine Ref.: 1895-96 Combined Catalogue
24 hr.
Capacity TonsDimensions
M a c h i n e N o . Compressor
Bore x Strokein.
(mm)
Steam EngineBore x Stroke
in.(mm)
SteamEngine Type
Speedrpm
Power hp(kW)
I c e - M a k i n g
R e f r i g e r a t i n g L x W x H
ft.(m)
ShippingWeight
lb.(kg)
1 4 x 8(102 x 203)
7 x 8(178 203)
Slide valve 80 5(4)
1 2 6.6 x 6.2 x 7.7(2.0 x 1.9 x 2.3)
16,000(7256)
2 5.5 x 8(140 x 203)
8.5 x 8(216 x 203)
Slide valve 80 8(6)
2 4 6.6 x 6.2 x 7.7(2.0 x 1.9 x 2.3)
17,000(7710)
3 6 x 14(152 x 356)
10 x 14(254 x 356)
Slide valve 75 14(10)
4 7.5 11.5 x 10.5 x 12.5(3.5 x 3.2 x 3.8)
26,000(11,791)
4 7.5 x 14(190 x 356)
11 x 14(279 x 356)
Slide valve 75 18(13)
66 10.5 11.5 x 10.5 x 12.5(3.5 x 3.2 x 3.8)
28,000(12,698)
5 8.5 x 14(216 x 356)
13 x 20(330 x 508)
Corliss 70 28(21)
10 18 14.2 x 11.4 x 13.5(4.3 x 3.5 x 4.1)
48,000(21,769)
6 9.5 x 14(241 x 356)
15 x 20(381 x 508)
Corliss 70 42(31)
15 27 14.2 x 11.4 x 13.5(4.3 x 3.5 x 4.1)
59,000(26,757)
7 10.5 x 14(267 x 356) 16 x 24(406 x 610) Corliss 65 48(36) 20 32 16.7 x 12.7 x 15.5(5.1 x 3.9 x 4.7) 68,000(30.839)
8 11.5 x 14(292 x 356)
17 x 24(432 x 610)
Corliss 65 60(45)
25 40 16.7 x 12.7 x 15.5(5.1 x 3.9 x 4.7)
70,000(31,746)
9 12.5 x 14(318 x 356)
19 x 28(483 x 711)
Corliss 60 75(56)
30 50 18.5 x 13 x 17.5(5.6 x 4.0 x 5.3)
82,000(37,188)
10 13.5 x 14(342 x 356)
20 x 28(508 x 711)
Corliss 60 96(72)
35 60 18.5 x 13 x 17.5(5.6 x 4.0 x 5.3)
84,000(38,095)
11 14 x 32(356 x 813)
22 x 32(559 x 813)
Corliss 60 105(78)
40 70 20.5 x 14 x 19.5(6.2 x 4.3 x 5.9)
105,000(47,619)
12 15 x 32(381 x 813)
24 x 32(610 x 813)
Corliss 60 128(95)
50 85 20.5 x 14 x 19.5(6.2 x 4.3 x 5.9)
110,000(49,887)
13 16 x 32
(406 x 813)
26 x 36
(660 x 914)
Corliss 55 150
(112)
60 100 24.5 x 15.5 x 24.2
(7.5 x 4.7 x 7.4)
165,000
(74,630)14 16 x 36
(406 x (914)28 x 36
(711 x 914)Corliss 55 165
(123)65 110 24.5 x 15.5 x 24.2
(7.5 x 4.7 x 7.4)175,000(79,365)
15 17 x 36(432 x 914)
30 x 36762 x 914)
Corliss 55 195(145)
75 130 25.5 x 15.5 x 25(7.8 x 4.7 x 7.6)
185,000(83,900)
16 20 x 36(508 x 914)
32 x 36(813 x 914)
Corliss 55 228(170)
95 155 25.5 x 15.5 x 25(7.8 x 4.7 x 7.6)
193,000(87,528)
17 22.5 x 36(572 x 914)
36 x 36(914 x 914)
Corliss 55 300(224)
120 200 27 x 17 x 26.5(8.2 x 5.2 x 8.1)
217,000(98,413)
Cornerstones Of Compression story continued from page 64
nThe 1895-6 Frick Eclipse product catalogue indicates that the company was building ice making and refrigerating ammonia compressors
ranging from 2 to 500 tons (1.8 to 454 tonnes) for packing houses, breweries, cold storage depots, ice-making factories, etc.
Frick Compressors 1895–96
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Cornerstones Of Compression
George Frick, an engineering genius born in 1826,
undertook to ease the labor of men and animals
with power machinery. His portable and traction en-
gines were among the first in the U.S., and were followed
by Corliss steam engines in sizes up to 5000 hp (3729 kW).
Established in 1853 at Waynesboro, Pennsylvania, dur-
ing the Civil War, Frick’s plant was subjected to numer-
ous Confederate raids and was closed for a month when
Waynesboro was occupied before the Battle of Gettysburg.
After the war, Frick prospered building steam engines,
threshers and sawmills.
During the 1870s, numerous European designs of refrig-
erating machinery began appearing in the U.S. In 1882,
Frick entered the refrigerating machinery field by building
an ammonia compressor cylinder mounted on the frame of
an existing vertical steam engine. George retired in 1886,
three years after the Frick Co. was incorporated and 43
years after building the industrial firm.
The first complete Frick refrigerating machine, built in
1883, had two 12 x 16 in. (305 x 406 mm) [bore diameter
x stroke] ammonia cylinders with a steam cylinder between
them. It ran at 50 to 55 rpm and developed 25 tons (22.7
tonnes) of refrigeration.
Success of its first ammonia compressors stimulated a
demand, and Frick Co. in the mid-1880s developed an en-
tire line of large refrigerating machines, driven by the new
Frick Corliss steam engines.
By 1886, four of the machines were running. Eight more
were shipped in 1887, including a 20 x 36 in. (508 x 914
mm) compressor delivering 150 tons (136 tonnes) of re-
frigeration. These early Frick machines not only set the
standard for the refrigeration industry for the next 30 years,
but most of their design features remained in use until the
1950s. Breweries and packing houses vied with ice-making
plants in adapting the pioneer machines to their needs and
many early compressors operated for 40 to 60 years.
An 1896 ammonia compressor at the Marshall, Missouri
Ice Co. plant ran until 1949, when it was replaced by two 7 x
7 in. (178 x 178 mm) Frick enclosed machines. Three gigantic
36 in. (914 mm) stroke machines operated for nearly 50 years
at the Armour meat packing plant in Kansas City, Missouri.
In 1896, Frick built the largest refrigerating machine in
the world for Armour. The 30 ft. (9.14 m) tall, 27 x 48 in.
(696 x 1219 mm) giant, with tandem 26 x 48 in. (660 x 1219
mm) high-pressure and 50 x 48 in. (1270 x 1219 mm) low-
pressure compound steam engine cylinders, measured 50
ft. (15.2 m) long. Its rated capacity was 350 tons (317.5
tonnes) at 60 rpm, with a maximum speed of 70 rpm.
By the late 1890s, Frick anticipated a demand for smaller
sizes, with lighter parts running at higher speeds, for mod-
erate capacity refrigerating systems to serve hotels, res-
taurants, hospitals and various industrial plants. As steam
power was not always available, other drive types were
introduced. Frick’s first direct-connected electric dc motor-
driven compressor was built in the early 1900s. These
adaptable machines paved the way for the wide acceptance
continued on page 63
DECEMBER 2014 64 COMPRESSORtech2
‘Breaking The Ice’ For Mechanical
Refrigeration > Frick compressors pioneered ice making,
refrigeration and air conditioningBY NORM SHADE
n This 13.5 in. (343 mm) bore x 28 in. (711 mm) stroke
Frick refrigerating compressor, driven by a 20 in. (508 mm)
Corliss steam engine, was installed for the Rock Island Ice
Co. at Fort Worth, Texas, in 1891. It operated for 60 years.
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Toshiba International Corporation is proud to be a single-sourcesolution for your application demands, offering a complete product
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With an extensive list of engines already mapped,even more are on the way. Install Murphy’s turnkeyEngine Integration Control System on your engine
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KTA19 G8.3
G5.9 – (Coming Soon)
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