GE COMPLETES

METEM ACQUISITION

EMERGING MARKETS
EYE LNG

MAY 2016

WWW.COMPRESSORTECH2.COM/SUBSCRIBE/

SULLAIR ROTARY
SCREW COMPRESSORS

Customer:

Challenge:

Result:

Vertically integrated global

petrochemical company, Texas.
Build a world-scale olefin plant to
process plentiful, low-cost shale gas.

Three trains of reliable, efficient

Elliott steam turbines and compressors
ensure the customers competitive
advantage in world markets.

They turned to Elliott

for a long-term partnership and long-term service.

World-scale olefin processors turn to Elliott for steam turbines and compressors
that 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

T U R B I N E S

G L O B A L

S E R V I C E

The world turns to Elliott.

www.elliott-turbo.com

ARIELS TORQUE REFERENCES

AT YOUR FINGERTIPS
With the all new Ariel Torque Guide App

May 2016

COMPRESSORtech2 is the premier resource for gas compression news and information.

Featured Articles
12 GE Completes Metem Acquisition
14 Test Facilities Improve Compressor Reliability, Performance Predictability
24 Active Magnetic Bearing System For Large Machines
30 GE Tested, REP Approved
Cover Designed By
Alyssa Loope
COMPRESSORtech2 (ISSN 1085-2468)
Volume 21, No. 4 Published 10 issues/year
(January-February, March, April, May, June,
July, August-September, October, November,
December) by Diesel & Gas Turbine Publications,
20855 Watertown Road, Waukesha, WI 531861873, USA Subscription rates are $85.00 per
year/$10.00 per copy worldwide. Periodicals
postage paid at Waukesha, WI 53186 and at additional mailing offices. Copyright 2016 Diesel &
Gas Turbine Publications. All Rights Reserved.
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copyright laws and treaties. Unauthorized duplication and publication is expressly prohibited.
Printed in the USA.
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Return Undeliverable Canadian Addresses to:
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220, Waukesha, WI 53186-1873 USA.

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34 RMS Expands Its Footprint

42 Analysis: Valve Performance On Booster Primary Compressor For LDPE
48 Inlet Cooling For Gas Turbines Driving Gas-Gathering Compressors

Departments
4 Page 4 Australia Leads The LNG Export Race
6 Global Perspective Emerging Markets Eye LNG
8 About The Business Domestic Oil & Gas Downturn Continues
While Political Stances Threaten Its Survival
10 Events & Meetings
26 Featured Products
41 Literature
46 Prime Movers
52 Scheduled Downtime
53 Marketplace
54 Advertisers Index

MEMBER OF

56 Cornerstones Of Compression Sullair Rotary Screw Compressors

THINK GERMAN,
ACT LOCAL.
LOOKING FOR AN ALL-IN-ONE
COMPRESSION PROVIDER?
OVER 30 YEARS OF EXPERIENCE IN BRAZIL FROM CONCEPT TO SERVICE, ANY APPLICATION.
NEUMAN & ESSER Amrica do Sul is the expert for
any compression needs in Central and South America.
Located in Brazil, NEA's team works as the single-contact
provider for: Sales, Engineering, Packaging and Service.
This includes care for the entire reciprocating compressor
system - from the initial drawings to complete life-cycle
service. Hydrogen, technical and natural gases, LNG, air
and more, we are here to serve you.

NEUMAN & ESSER

Amrica do Sul Ltda

Located in Belo Horizonte, Brazil

www.neuman-esser.com
Contact me for Central and South America:
Marcos Rihan
Sales Manager
marcos.rihan@neuman-esser.com.br
Direct line: +55 (31) 2126-9503

NEA GROUP Headquarters in Germany

BLUESTROKE
COMPRESSOR
SYSTEMS

Page

CT2 Founder .......................... Joseph M. Kane

COMPRESSOR

A Member of the Diesel & Gas Turbine Publications Group

PUBLICATION STAFF

Australia Leads The

LNG Export Race

Associate Publisher ................... Mark Thayer

Associate Publisher ..............Roberto Chellini
Senior Editor ................................... DJ Slater
Senior Editor ................. Michael J. Brezonick
Associate Editor ............................... Jack Burke
Associate Editor ............................Chad Elmore
Associate Editor ...................................Art Aiello
Copy Editor ............................... Jerry Karpowicz

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

Advertising Manager .................. Katie Bivens
Circulation Manager ............. Margaret Pieper
Production Manager ................ Marisa Roberts
Graphic Artist ...........................Brenda Burbach
Graphic Artist .................................Carla Lemke
Graphic Artist ............................... Alyssa Loope

PUBLICATION HEADQUARTERS
20855 Watertown Road, Suite 220
Waukesha, Wisconsin 53186-1873
Telephone: (262) 754-4100 Fax: (262) 754-4175

CONTRIBUTING EDITORS
Norm Shade Cambridge, Ohio
Mauro Belo Schneider Rio Grande du Sul, Brazil

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Telephone: (281) 890-5310

GERMANY
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UNITED KINGDOM
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ITALY
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Telephone: +39 0464 014421 Fax: +39 0464 244529

SWEDEN
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JAPAN
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Telephone: +81 45 624 3502 Fax: +81 45 624 3503

KOREA
D.S. Chai, Sales Manager
Dongmyung Communications Inc.
82 Pyeongchangmunhwa-ro, Jongno-gu
Seoul, 03011 Korea
Telephone: +82 2 391 4254

DIESEL & GAS TURBINE PUBLICATIONS

President & CEO .................... Michael J. Osenga
Executive Vice President ....Michael J. Brezonick

he country that introduced latex

gloves, vegemite and Crocodile
Dundee is now home to one
the largest LNG projects in the world.
Australias Gorgon project, located on
Barrow Island off the coast of northwestern Australia, shipped its first
cargo this spring, strengthening the
lead of the Land Down Under in the
global LNG export race.
The U.S. made headlines in February
when Cheniere Energy dispatched the
first shipment of LNG from its facility
at Sabine Pass, Louisiana, bound for
Brazil. But the sheer size and scope
of the Gorgon Project quickly negated
any strides gained by Sabine Pass.
The Gorgon project includes a domestic natural gas plant, a carbon
dioxide injection project and an LNG
export facility. Its three liquefaction
trains have a combined capacity of
2.1 Bcfd (59 x 106 m3/d). The first train
was commissioned in March, with
the second and third trains to follow
at six- to nine-month intervals. The
Gorgon project, taking more than six
years to develop at a cost of US$54
billion, is the worlds most expensive
LNG project to date.
Ultimately, Asia is the LNG prize.
The U.S. will benefit from the US$5.3
billion Panama Canal expansion set
to open this year, cutting costs and
travel time from the U.S. Gulf Coast to
Asia by 11 days (See November 2014
CT, LNG Vessels Will Run Through It,
p. 38). But the infrastructure required
to meet Asias thirst for LNG is lacking
in the U.S.
Including the first train from Gorgon,
Australias LNG export capacity currently stands at 6.2 Bcfd (157 x 106 m3/d).
If the additional LNG capacity currently
under development is fully operational
as planned by 2019, the countrys LNG

exports capacity would likely increase

to the largest in the world, at 11.5 Bcfd
(325 x 106 m3/d), equivalent of one-third
of global LNG trade in 2014.
Three projects in eastern Australia
have been fully or partially commissioned since 2014. Queensland Curtis
commissioned its two trains in 201415, Gladstone commissioned its first
train in October 2015 and Australia
Pacific sent its first cargo in January
of this year. All three projects process
coal bed methane into LNG and have
a current combined capacity of 2.3 Bcfd
(65 x 106 m3/d). Once fully completed,
they will have a combined capacity of
3.4 Bcfd (96 x 106 m3/d).
Gorgon LNG is the first of the four
new projects off the northern coast of
Western Australia to be partially commissioned. Three other projects in the
northwest Prelude, Wheatstone and
Ichthys are still under construction.
These three projects have a combined
capacity of 2.8 Bcfd (79 x 106 m3/d)
and are expected to come online between 2016 and 2018.
Most new Australian liquefaction
capacity is already contracted on a
long-term basis to countries in the Asia
Pacific region. Among destinations for
Australian LNG, Japan accounts for the
largest share of contracted liquefaction
output, with contracts for 79% of output
from the existing liquefaction projects
(in operation prior to 2014) and 35%
from the new projects, according to the
U.S. Energy Information Administration
(EIA). China is the second-largest destination, with 15% of contracted LNG
from the existing liquefaction projects
and 23% from the new projects.
The U.S., mired in red tape and facility delays, is quickly losing ground
to Australia in the race to become a
global LNG supplier. CT2

WHAT IS THE POWER OF ONE?

The power of one is what happens when many individuals join forces toward
a common goal. Its the greatness that can be achieved through a shared
purpose. For Compressor Products International, its the global footprint,
manufacturing efficiencies and product innovations that arise from the
unification of the 16 companies weve acquired since 2007. For our customers,
its the power of a single phone call for all of your oil & gas compressor needs.
Together, we are stronger. Together, we are CPI.

CPIstrong.com | 1-800-675-6646

CPIstrong.com/us | 1-800-675-6646

an EnPro Industries company

Global Perspective

BY ROBERTO CHELLINI
ASSOCIATE PUBLISHER

Emerging Markets
and cost-competitive LNG
Eye LNG > Flexible
terminals provide regasification to
emerging Asia-Pacific markets

generation module and berthing platforms, based on need

and investment plans.
Its lower cost structure increases its attractiveness relative to a conventional onshore import terminal, especially
as firms operate with smaller capex budgets amid the current low oil price environment. Furthermore, Gravifloats
flexibility to cater to a wide range of market sizes offers it a
competitive edge over standard floating facilities, as oversupply in the regional LNG market drives investors away
from large-scale LNG projects.
Some countries have already moved to explore the possibility of installing Gravifloat terminals to meet rising demand
from the power sector. For instance, Thailand is currently
mulling over plans for a US$45 million LNG-based power
plant in Ben Dam Bay, Con Dao, which will include an LNG
depot, a port and an 18 MW LNG power plant. Myanmar is
also reviewing a proposal from Gravifloat to construct a 127
MW LNG-fueled power plant offshore the Thilawa Special
Economic Zone.
A sustained period of weak LNG prices will create an environment whereby countries and companies that perhaps did
not have sufficient financial resources are able to consider
investing in LNG for the long term. BMI forecasts the price
of Asian benchmark Japan Korea Marker (JKM) to remain
below US$5/MMBtu over the period from 2016 to 2020,
lower than the US$13/MMBtu average over 2013 to 2015.
The low prices will place buyers in a strong bargaining position to secure favorable long-term contracts.
Furthermore, floating storage regasification units will
be cheap as shipyards are looking for business amid
a slowdown in the shipbuilding industry. Lower costs of
LNG supply and infrastructure support the view that more
regasification projects will move forward on top of those
under construction, benefitting LNG suppliers who are
looking for export markets. CT2

roliferation of innovative and cost-competitive liquefied natural gas (LNG) terminal solutions within the
Asia-Pacific region will facilitate more-efficient LNG
deliveries to its emerging markets. Many of those markets
are forecast to see substantial growth in LNG import requirements over the coming years.
Singapores marine and offshore engineering firm SembCorp
Marine has increased its stake in near-shore LNG terminal
specialist Gravifloat AS to 56%, or US$27.5 million. In addition, it secured the right to raise its share by an additional
44% to take full ownership through an equity purchase at
the same price.
The acquisition places SembCorp in a good position to
capitalize on the growing need for flexible LNG solutions
in the Asia-Pacific region. Many of the emerging markets
are projected to see considerable growth in gas demand
and have proposed plans to increase LNG imports over the
coming years.
Nontraditional LNG import markets in Asia such as
Bangladesh, Myanmar, Pakistan, the Philippines, Thailand
and Vietnam could add in excess of 15 new LNG regasification facilities, or at least 1.3 Tcf (36.8 x 109 m3) of annual import capacity. Weak LNG prices for at least the next
five years and robust demand for gas will support long-term
investments in LNG, which in turn will create opportunities
for suppliers to sell into these markets. Given that many of
these projects are either in the proposed phase or pending final investment decision, BMI Research (BMI) believes
there are opportunities for Gravifloat to offer a cost-efficient
alternative to procuring LNG.
Gravifloats near-shore terminal can be situated at water
depths as shallow as 50 to 65 ft. (15 to 20 m), and be
constructed in two to three years. The design utilizes a
modular concept, which allows for flexible adjustment of
capacity, as well as stepwise expansion of storage, power
MAY 2016

COMPRESSORtech2

About The Business

BY NORM SHADE

Domestic Oil & Gas

Downturn Continues While
Political Stances Threaten
grass roots conversation is
Its Survival > Informative
needed to counter the negative oil & gas
messaging from environmental advocates

and strategically friendly as generally portrayed. Solar cells,

batteries, and turbine generators rely on components that
contain rare earth metals found outside North America. Not
only is that a strategic concern, significant environmental
issues have been reported from mining and manufacturing
them, especially in China.
For example, solar, thought to be the greenest of energy
sources, has some serious baggage. A November 2014
National Geographic article, How Green Are Those Solar
Panels, Really? pointed out that the fabrication of solar panels requires toxic chemicals and uses large amounts of water
and electricity. The Silicon Valley Toxics Coalition (SVTC),
a San Francisco-based nonprofit that has tracked the environmental impact of the high-tech industry since 1982, reported that the solar industry is focused more on survival and
growth than on tackling the dirtier side of an otherwise clean
energy source. These problems undercut solars benefits.
Well-organized opponents of oil and gas are energetic,
passionate and increasingly effective at influencing public
opinion and politicians. Yet we, as individuals in the oil and
gas industry, do little to counter their messaging and make
our story heard. Talking only among our business associates is not enough. And, although some of the nastier environmental facts associated with green energy should be
more widely publicized, negative messaging risks turning
most of the public off from listening to us.
Instead, we should concentrate on constantly educating
the public on the positives of fracking and domestic oil and
gas production to sustain the U.S. and North America energy needs for the foreseeable future. The benefits jobs,
low costs and security are obvious to all of us, but the
average citizen rarely hears that message except in some
paid advertisements.
As this column has advocated, its up to us to direct
our friends, relatives and neighbors to factual information
that favors our industry, encouraging positive conversation. There are many good information sources including
the American Petroleum Institutes (API) Energy Nation
(www.energynation.org) and the Interstate Natural Gas
Association of Americas (INGAA) new Energy Link (www.
ingaa.org/energylink). Make yourself and your extended
network familiar with them! CT2

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

new development. In the first week of April, Baker
Hughes reported that U.S. rigs drilling for oil and natural gas reached a new low of 443 (354 oil and 89 gas). U.S.
Energy Information Administration (EIA) data shows that
after a 23% decline from 2010 to 2014, crude oil imports actually started increasing again in late 2015. Total 2015 imports
were slightly higher than 2014, and January 2016 imports
soared to 20% higher than the same period last year.
But natural gas production continues to climb due to the
large inventory of drilled wells yet to enter production and to
the amazing productivity of new Marcellus and Utica Shale
wells. The EIA reports that gas storage at the traditional end
of the heating season was 54% higher than the five-year
average, highest ever for that point in the season. This has
kept the Henry Hub price below $1.90/MMBtu.
In the midst of the worst U.S. oil and gas downturn in
decades, environmental advocates, government agencies
and politicians continue to push agendas that endanger the
very survival of the industry that drives the gas compression market. Uninformed, misinformed or misguided presidential candidates are proposing severe restrictions, and
even bans, on fracking.
In March, an EIA report said that over half of the energy
production in the U.S. comes from fracking, pointing out
that the industry has allowed the United States to increase
its oil production faster than at any time in its history. Yet,
some politicians and environmental activists ignore this
fact and push to essentially destroy the U.S. oil and gas
industry. Although green energy development should not
be discouraged, the practical matter is that it cannot meet
demand for decades. And even green energy has environmental consequences, a fact rarely reported by the press
and ignored by the anti-hydrocarbon lobby.
Speaking at the Gas Compressor Associations Expo
in March, Dr. Ken Morgan, director of the TCU Energy
Institute, explained that solar and winds arent as green

Norm Shade is senior consultant and president emeritus of ACI

Services Inc. of Cambridge, Ohio. A 46-year veteran of the
gas compression industry, he has written numerous papers
and is active in the major industry associations.

MAY 2016

COMPRESSORtech2

DISCOVER OUR NEW WEBSITE!

www.burckhardtcompression.com

PUSH THE LIMITS!

FORMING THE WINNING TEAM OF RINGS REDURA SEALING SYSTEMS
REDURA REliable, DURable and Advanced sealing systems for
reciprocating compressors. The product line includes standard rings,
packings as well as specifically in-house developed, designed and
patented products.

REDURA
Longest MTBO at lowest leakage
Highest availability
Lowest life cycle costs

The heterogeneous design of Redura Piston and Rod Sealing

Systems stands for a unique selection of rings, provides optimized
distribution of the dynamic and static pressure differences, reduces
wear on each element and increases the overall sealing performance. The Redura Oil Sealing Systems consist of a combination
of different ring types, ensuring enhanced sealing efficiency while
fulfilling the requirements of dynamic tightness.

UPGRADE YOUR RECIPROCATING

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Tel. +41 52 262 55 00
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REDURA
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Dont replace.
Events & Meetings

Altronic_HHsprd_Mar16_CT2.indd All Pages

Boldface indicates shows and conferences in which COMPRESSORtech2 is participating

MAY

May 24-26
Eastern Gas Compression
Roundtable
Pittsburgh
+1 (412) 372-4301
www.egcr.org
May 31-June 1
Gas Africa
Sandton, Gauteng, South Africa
+27 11 234 1196
www.ingadaevents.co.za

JUNE

June 1-4
Caspian Oil & Gas
Baku, Azerbaijan
+44 207 596 5147
www.caspianoil-gas.com
June 7-9
Global Petroleum Show
Calgary, Alberta, Canada
+1 (403) 209-3555
www.globalpetroleumshow.com
June 13-16
Nigeria Oil & Gas Conference

MAY 2016

Abuja, Nigeria
+234 706 911 7347
www.cwcnog.com
June 13-17
ASME Turbo Expo
Seoul, South Korea
+1 (800) 843-2763
www.asme.org/events/turbo-expo
June 21-23
Power-Gen Europe
Milan, Italy
+44 1992 656 637
www.powergeneurope.com
June 21-23
Sensors Expo & Conference
San Jose, California
+1 (617) 219-8300
www.sensorsmag.com/sensors-expo
June 21-23
Developing Unconventional Gas (DUG)
East Conference & Exhibition
Pittsburgh
+1 (713) 260-6492
www.dugeast.com

10

JULY

July 25-27
SGA Operating Conference
Houston
+1 (972) 620-8505
www.southerngas.org

AUGUST

Aug. 23-25
Power-Gen Natural Gas
Columbus, Ohio
+1 (918) 831-9160
www.power-gennaturalgas.com

SEPTEMBER

Sept. 12-15
Turbomachinery Symposium/
Pump Users Symposium
Houston
+1 (979) 845-7417
http://turbolab.tamu.edu
Sept. 13-15
Gas Compressor Short
Course Conference
Norman, Oklahoma
+1 (405) 325-3136
www.ou.edu/outreach/engr/
gascompressor_home.html

COMPRESSORtech2

Rebuild.

The Altronic Flashguard 2.0 Secondary Spark Plug Lead System

gives you the ability to fully rebuild spark plug leads in the field.
Incorporating custom Teflon extensions, including special
extensions for the Caterpillar 3300 and 3400 engines, multiple
wire styles, a range of primary and secondary connections, and
an assortment of lead accessories, you can cost-effectively
specify a lead for manufacture by your local Distributor, or
locally by your own personnel. In either case, leads can be
serviced/rebuilt when necessary with moderately priced, easily
installed replacement components, including new O-rings, wires,

boots, or grommets/terminal pins acquired directly from your

Distributors inventory or your own.
This system offers accessibility, reliability, and the performance
that are critical to minimize downtime, while driving the
necessary cost-control and serviceability that are so crucial to
twenty-first century operation.
Contact your Altronic Distributor for all the details.

HOERBIGER Engine Solutions

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

2/17/16 9:44 AM

For a complete listing of upcoming events, please visit our website at www.compressortech2.com/events/
Oct. 17-19
Saudi Arabia International Oil & Gas
Exhibition (SAOGE)
Dammam, Saudi Arabia
+39 06 3088 3030
www.saoge.org

Sept. 13-15
Wyoming Natural Gas Fair
Casper, Wyoming
+1 (307) 258-4708
https://wyogasfair.org

Sept. 20-23
InnoTrans 2016
Berlin
+49 30 30 38 2376
www.innotrans.de

Sept. 14-15
International Rotating Equipment
Conference
Duesseldorf, Germany
+49 69 66 03 12 82
www.introequipcon.com

OCTOBER
Oct. 2-5
Gas Machinery Conference
Denver
+1 (972) 620-4026
www.gmrc.org

Oct. 24-27
Rio Oil & Gas
Rio de Janeiro
+55 21 2112 9079
www.ibp.org.br

Sept. 14-15
European Forum for Reciprocating
Compressors (EFRC)
Hofburg, Vienna, Austria
+49 69 6603 1286
www.recip.org

Oct. 10-13
International Seminar Rotor Dynamics
& Bearings
Cologne, Germany
+ 49 2267 6585-0
www.arla-online.com

NOVEMBER

Sept. 20-22
Power-Gen Asia
Seoul, South Korea
+44 1992 656 656
www.powergenasia.com

Oct. 11-13
HHP Summit 2016
Chicago
+1 (888) 993-0302
www.hhpsummit.com

Nov. 7-10
ADIPEC
Abu Dhabi, United Arab Emirates
+971 2 6970 518
www.adipec.com

MAY 2016

11

Nov. 2-4
EP Shanghai 2016
Shanghai
+ 852 2811 8897
www.epchinashow.com

COMPRESSORtech2

n This closed-loop at Solars gas compressor test facility is powered by a dedicated

Titan 130 gas turbine driver on a universal driven-equipment skid that enables full load
testing in a hydrocarbon or inert gas closed-loop.

Test Facilities Improve Compressor

Reliability, Performance
Turbines investment in extensive test
Predictability > Solar
facilities advances compressor development
BY NORM SHADE

Solar continues to invest in its product development efforts through its two ISO 9001:2008 certified campuses in
San Diego. Its gas compressor test facility (GCTF), which
began operation in 2009, is part of a substantial investment in new product development, as well as providing
customers with expanded options for shop testing.
The three-bay GCTF facility at Solars Kearny Mesa
continued on page 16

ince the introduction of its first centrifugal compressor in the early 1960s, Solar Turbines has steadily
developed its compressor product line that now
covers a wide range. The compressors are optimized to
match the speed and power ratings of its Saturn, Centaur, Taurus, Mars, Titan (all registered names of Solar
Turbines) gas turbines. They can be matched with electric
motor drives as well.

MAY 2016

14

COMPRESSORtech2

INNOVATION STANDARD
IS

THE TRUSTED LEADER IN

N AT U R A L G A S C O M P R E S S I O N C O N T R O L S
Murphy by Enovation Controls continues to
invest in products that help you get the
most our of your business and reduce
unscheduled downtime.

We are creating new ways

to help you grow by:
Continuing
to innovate

Developing
fit-for-purpose
products
Bundling end devices that you need
to save you more
By continuing to add diagnostic capability, performance
improvements and unrivaled support, we will work diligently
to make the Murphy choice the easy choice. With more than
75 years in the industry, Murphy is the smart choice, too.

FIND OUT HOW WE CAN HELP YOU GROW YOUR BUSINESS

Contact us for solutions and services.
Phone: 918-317-2641

www.fwmurphy.com/newstandard

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

place at Solars closed-loop test facilities, which accommodate ASME PTC-10 Type I and
II testing. One of the closed-loop facilities is driven by a dedicated 8 MW variable speed
electric motor (top). The extensive data gathered during these tests (bottom) is fed into
the companys prediction database to improve analytical models and to improve compressor durability and reliability.

MAY 2016

16

complex is used for research, development and production, including new

and aftermarket testing of compressors in accordance with ASME PTC10 Type I and II.
In the first two bays, a dedicated
Titan 130 gas turbine engine and an
8 MW variable speed electric motor
drive (VFD) equipped with universal driven-equipment skids enable
full load testing in a hydrocarbon or
inert gas closed-loop up to 3500 psig
(241 bar).
The third test bay can accommodate full compressor package closedloop string testing up to 30,000 hp
(22.3 MW). Testing of Solar compressors at the GCTF facility provides
mechanical integrity, accurate measurements and aerodynamic performance. It also ensures rotordynamic
stability and low vibration that meet
or exceed API requirements.
In addition to testing new compressors, the GCTF facility is available to
test customers gas compressors after overhaul or restage. At its Harbor
Drive complex, Solar has an additional closed-loop test facility, which
is also used for Type II compressor
testing, with a dedicated Centaur 40
gas turbine driver.
In the closed-loop facilities, production or aftermarket compressors can
be shop tested under load to reproduce the aerodynamic design point.
Field gas properties can be simulated
through a variety of gas mixtures. Performance verification with shop tests
before site commissioning is critical
to many customers.
Solar is aware of customer requirements for availability and durability of
compression equipment, which is why
the company emphasizes significant
development testing prior to compressor qualification.
At development, the compressors
are run on natural gas to their speed
and pressure limits, pushing beyond
their normal operation in the field. A
magnetic exciter is used to directly
measure damping in the rotor-bearing
system. This allows verification of rotordynamic stability under actual operating conditions at high speeds and
continued on page 18
COMPRESSORtech2

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COMPRESSORtech2

operate the unit being tested, while measuring and evaluating its performance.
The system establishes specified test conditions, constants and operating
limits. Test data are monitored by video displays as instructed by the test
agenda, selecting various parameters for display, checking values and limits,
and generating reports as needed. When acceptable performance levels are
achieved, the test technician initiates a command to a computerized realtime data acquisition system that captures all instrumented points, initiates
automatic performance computations and prints the results for review for a
permanent test record.
Closed-loop testing is used for development purposes and is often specified by
customers of mission-critical compressor applications. These applications justify the
higher cost of more extensive closed-loop factory validation of compressor aero-

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dynamic and mechanical performance.

Product development advances from
equipment tested in Solar Turbines
production test facilities.
In addition to the closed-loop facilities, two open-loop test facilities
are used to test every Solar Turbines
compressor prior to shipment to evaluate mechanical and aerodynamic
performance in accordance with test
procedures and acceptance criteria as
outlined in applicable test specifications. The suction and discharge nozzles are connected to an open-loop
configuration that uses atmospheric
air. The two open-loop test facilities
have dedicated drivers a Centaur
50 and a Saturn 20 gas turbine.
Mechanical testing is performed first.
The dry gas seals are tested statically
with nitrogen. After preliminary checks
and static seal testing, the unit is operated at break-in speed, then at maximum
continuous speed. Key mechanical parameters such as seal gas leakage and
separation seal air flow, oil flow, and vibration levels are measured and evaluated against established limits.
continued on page 22

20

COMPRESSORtech2
2/22/16 3:56 PM

n Every gas compressor that Solar builds is tested at one of its open-loop test
facilities, which have dedicated drivers a Centaur 50 and a Saturn 20 (right)
gas turbine. Larger compressors can also be tested open-loop on a (normally)
closed-loop test facility driven by a Titan 130 gas turbine (left).

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MAY
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21

2
COMPRESSORtech
1/6/15 1:37 PM

n Solars aero test facility (ATF) enables

testing of scaled single centrifigal compressor stages while making detailed
measurements in order to improve prediction capability and help understand
component performance.

evaluate and understand stage component (impeller, return

vane, etc.) losses, establish guidelines for aerodynamic parameters, and gather data to help design the next generation
of compressors.
The objective of the facility is not only to design and test
stages with the best efficiency for direct application to a production stage, but also to extend our knowledge of critical
parameters, Schor said. For example, a stage can be designed deliberately with a sub-optimal surge margin and, by
analyzing test data and predicted data, correlations can be
derived as to what critical parameters, such as diffusion or
flow angle, are responsible for the adverse effect on component stability.
This extends the prediction capabilities of the design
software and improves the ability to design stages with the
best compromise between head, efficiency and flow range.
Throughout its compressor line, Solar Turbines makes use
of pre-designed, pre-engineered and pretested components
rather than customized stages. Since standardized aero
components are used in Solar compressors rather than a
completely customized design, far more effort can be spent
in careful optimization. The impellers for Solar pipeline compressors have complex 3-D blades with inducer inlet sections. The optimization process makes extensive use of 3-D
modeling components, using computational fluid dynamics
(CFD) tools, scaled model testing at Solars ATF, and full size
testing in its closed-loop test facilities.
These modern computational tools, together with the
expanded test capabilities, have been used to design
compressor stages with high efficiency and a wide operating range, said Manoj X. Dutt, manager, marketing &
product strategy. CT2

After the mechanical tests, aerodynamic testing on air occurs. The primary objective of the test is to confirm the accuracy of the individual stage characteristics used for predicting
compressor aerodynamic performance at the air-equivalent
design speed.
Accuracy is determined by comparing the overall head
vs. flow speed line from choke to surge and the surge line
position against prediction when operating at a speed
equivalent to the specified site design speed. Surge points
are determined at various speed points to validate the
surge flow estimate for the entire operating speed range.
Extensive instrumentation, together with the facility data
acquisition and reduction system, validates mechanical
and aerodynamic performance.
A separate aero test facility (ATF) allows for testing
scaled single stages while making detailed measurements
in order to improve prediction capability and help understand component performance. In this facility, exclusively
dedicated to development testing, Solars engineers can
test entire compressor stage impellers, diffusers, return
vanes and volutes.
Many different types of compressor stage components
can be tested in the ATF. These stages can either be
scales of existing production stages or experimental stages. For each test article, flange-to-flange performance is
determined. Static and total pressures are measured at
various locations throughout the stage to determine overall stage performance as well as the performance of each
individual component.
This process extends our aerodynamic design knowledge, Schor said, adding that the ATF tests are used to
validate and establish limits of 1-D and 3-D design codes,
MAY 2016

22

COMPRESSORtech2

2016 EDITION

XX

WWW.CTSSNET.NET CTSS

Active Magnetic
Bearing System For
Introduces Simotics Active Magnetic
Large Machines > Siemens
Bearing technology for wear-free operation in
large-machine applications

BY ROBERTO CHELLINI

n Simotics Active Magnetic Bearing (AMB) technology for wear-free operation in large-machine
applications. The system is built around standard
controller and converter units from the Sinamics
family of products from Siemens. The illustration
shows a special split bearing as used in a feedpump drive turbine at the Jnschwalde power
plant in Germany.

precisely in the bearing center. Even rotors weighing several tons, spinning at maximum speed, can be held in a
position window that has the diameter of a human hair.
The Simotics AMB technology allows the use of standard
components from the Siemens portfolio, such as Sinamics
and Simotion control and converter units. In the context of
Totally Integrated Automation (TIA) and Integrated Drive
Systems (IDS), Simotics AMB technology is a highly efficient and matched solution for large machine applications,
the company said. Simotics AMB technology seamlessly
integrates into the Siemens TIA concept, as all components in it are mutually compatible and system tested. The
Sinamics standard control components are used both in
the IDS in the drive train to control the magnetic bearings
as well as in the main converter. The PC-based Simotion
P320-4 controller forms a customer-specific, configurable
human machine interface for system monitoring, communication with the higher-level plant controller and for auxiliary
commissioning functionalities.
Simotics AMB technology is already in use. At NAM/Shell,
two 23 MW high-speed compressor drive trains running at
6300 rpm in the Netherlands Groningen gas field utilize Simotics AMBs; as well as at Germanys Jnschwalde power
plant in a 10 MW steam turbine running at 5700 rpm. CT2

n order to limit the wear of moving components, covering

their surfaces with an oil film is a conventional practice.
For more than a century, this has been the only way to
avoid friction between moving metal components. Oil consumption can be expensive and, in some cases, pollute the
environment or the fluid used by the machine.
An alternative system, applicable to all rotating machines
(specifically high-speed and large-dimension machinery) is
active magnetic bearings. While not new, this systems biggest drawback was its control system. The analog tuning
procedure could take several weeks, sometimes months.
With the advent of digital control systems, this procedure
has been reduced to a few hours and has created new opportunities in the design and implementation of all types of
rotating equipment, such as compressors, electric motors/
generators, gas and steam turbines.
With its Simotics Active Magnetic Bearing (AMB) technology, Siemens has introduced an AMB system for large
machines, such as high-speed, high-voltage motors or industrial turbines and compressors. The rotors for such applications are held suspended in the center of the bearing
without any friction or wear. To achieve this, sensors record
the position of the shaft 16,000 times a second and a regulator adjusts the magnetic field to keep the rotor hovering

MAY 2016

24

COMPRESSORtech2

Intelligence on Duty

From here, you see greater uptime.

PROGNOST is your portal to the worlds most comprehensive and effective machinery
diagnostics expertise.
With PROGNOST, maintenance decisions become clear and fact-based.
Critical assets from rotating equipment to gear boxes and bearings achieve true reliability.
Best of all, machinery and people are protected from the unexpected.
See for yourself how machinery uptime grows with the systems, services and lifecycle support
of the leader in online monitoring at your disposal.
reply@prognost.com www.prognost.com

FEATURED
PRODUCTS
Protection Relays
Woodwards new HighPROTEC-2 protection relays are
designed to protect electrical buses and equipment. These
medium-voltage protection relays for generators and
power distribution applications monitor the electrical condition of equipment and disconnect the power source quickly
when a problem or potential problem is detected.
Nine separate HighPROTEC-2
products target different electrical
applications, including electrical
feeders, mains decoupling and
line protection, as well as electrical generators, transformers and
motors. Users can configure each
product to address the specific
aspects of a given application.
This flexibility reduces the number of product variations that occurs when matching a solution to
unique application requirements. Broad voltage and current inputs (0-800V ac and 1A/5A), wide range input power,
parameter configuration, and communication protocols
(DNP3.0, IEC 61850, Modbus, Profibus) provide application

flexibility. Using the expanded communications capabilities,

the HighPROTEC-2 interfaces with Woodwards engine
and turbine controls and generator set controllers to form
a complete control and protection solution for generator
systems. Programming and operation menus, available in
seven different languages,
reside in each unit.
A graphic display shows
the HighPROTEC-2 connection architecture along
with real-time operating values and messages, alarms,
and fault data. A PC-based
service tool simplifies configuration and includes parameter plausibility checks
and an ANSI menu structure. It includes a display
screen editor and event,
trends, and disturbance recorders and counters to aid
operation and troubleshooting. The HighPROTEC-2 has
worldwide certifications including CE, UL, CSA, EAC and
marine certifications.
www.woodward.com/hpt-2

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a failure is always possible. And a plant operation shutdown is never a good thing.
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n GE Oil & Gas completed a full-load engine test

of its 16 MW industrial gas turbine last September.

MW gas turbine slated for

GE Tested, REP Approved > 16
Russian installation
BY ROBERTO CHELLINI

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

& Gas completed the full-load engine test of its 16
MW industrial gas turbine for mechanical drive compressors and power generation.
The test confirmed turbine efficiency, power output and
emissions levels, GE said. Efficiency and power were higher than analytical forecasts, while emissions came in lower
than expected, according to the test results.

MAY 2016

Russian licensee REP Holding assisted with the engine

development, which involved validating the engine requirements and main design parameters. REP Holding also contributed to the preliminary and detail design, as well as the
crafting the low-pressure turbine, and designing the engine
package for the Russian market.
A gas generator full-load test also took place before GE
shipped the module to REP Holdings Nevsky facility in
30

COMPRESSORtech2

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

secondary flows.
The measurements will be used to finalize the digital engine model, as well
as fully characterize the performance of each machine component and define a
baseline thermodynamic cycle. The latter will constitute the starting point to further
increase the turbine power output and efficiency, while also improving emissions.
In order to test the complete GE train configuration, a dedicated test stand was
constructed with a gearbox from GE Lufkin and an electric generator from GE
Power Conversion.
The instrumented unit will remain on its test stand in Florence for research and
development purposes throughout 2016, the company said.
continued on page 32

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St. Petersburg, Russia. At the facility,

the licensee performed further joint
testing on the gas turbine as well as
subsequent field installation at a combined heat and power plant.
Two months later in Florence, GE
Oil & Gas finished the assembly of
a fully instrumented unit, which went
through its validation and characterization test campaign. The engine was
heavily instrumented with research
and development strain gauges, temperature probes and pressure probes
MAY 2016

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31

COMPRESSORtech2

n GEs 16 MW industrial gas turbine was

heavily instrumented with research and
development strain gauges, temperature
probes and pressure probes (among
other equipment) to map performance,
temperatures and secondary flows.

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GE Oil & Gas is working on the production of three gas generators for
REP Holding, which will be used in
St. Petersburg. REP Holding will complete the manufacturing of the lowpressure turbine modules and engine
packages to create the T16 gas turbine engine; it is called the NovaLT16
for the Russian oil and gas market.
The three units will be used to drive
REP Holding centrifugal compressors
as part of the modernization of Russian pipeline infrastructure. The job,
which will see industrial gas turbines
replacing aged turbo-compressors,
requires more than 4000 GT units.
The modernization is expected
to improve transportation efficiency
(amount of natural gas consumed vs.
transported gas and availability) with
longer maintenance intervals and a
smaller environmental impact, GE Oil
& Gas said.
In 2014, GE Oil & Gas announced
an all-GE pipeline configuration of
its 16 MW unit, with a dedicated GE
Oil & Gas designed package and
BOP, developed in collaboration with
TransCanada Corp. and launched as
NovaLT16.
GE Oil & Gas is working to produce
one complete turbo compression train
for installation along a Canadian pipeline in Alberta. CT2
COMPRESSORtech2

FEATURED
PRODUCTS

repaired motors prior to their installation. Split rings come in mating halves that
simplify field installation around the shafts of in-service/coupled motors.
The Aegis Pro SLR Ring is specially designed with O-ring barriers that prevent
the ingress of dust, debris, and excessive contamination that could lessen contact of the rings conductive microfibers with the motor shaft. The Aegis Pro-MR
combines a PRO Bearing Protection Ring with a shaft voltage-monitoring ring in
a single unit.
Specially designed universal mounting brackets allow installation of Aegis Pro
Series Rings on large motors. These brackets attach to Pro Series Rings with
screws and have slotted legs that allow mounting to the motor with a bolt circle
of 2.64 to 7.79 in. (67.05 to 197.8 mm) greater than the shaft diameter. They are
provided with 0.5, 1.0 and 1.5 in. (12.7, 25.4 and 38.1 mm) standoff spacers to
provide sufficient clearance for shaft shoulders, slingers, or other end bell protrusions. Mounting bolts, flat washers and lock washers are also included.
www.est-aegis.com

The Sensor Connection

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

has expanded its line of measurement and control instrumentation

with the addition of the model TCAMS-K-1. This Single Channel Type K
Thermocouple Amplifier Module converts the low output voltage signal
from a Type K thermocouple probe
to a single independent linearized 0
to 5 Vdc output voltage. According to
the company, this output is ideal for
interfacing to instrumentation equipment including data loggers, temperature indicators, chart recorders
and controllers.
Product features include a Type K
thermocouple input; temperature
measuring range from 32 to 2282F
(0 to 1250C); analog output of 0 to
5 Vdc; and a response time of 1 ms.
http://thesensorconnection.com

RMS Expands
Machinery Services Inc. provides full range
Its Footprint > Rotating
of turbomachinery repair and upgrade services
BY NORM SHADE

n The RMS service facility consists of three 10,000 sq.ft. (929 m2) bays that include a rotor assembly shop (left), large-capacity machine
shop with quality control room, and an assembly shop (right) with a full range of lifting, moving and storage equipment.

equipment manufacturer), said Jerry Hallman, company

president and co-founder. We have a total focus on existing
compressor equipment, as opposed to OEMs, which have
their resources focused on new equipment. We can provide
superior engineered solutions to long-standing problems
that the OEM is unwilling or unable to solve. We also focus
on orphaned equipment that is no longer fully supported
by an OEM. And we provide customers with open access
to RMS experts.
Types of projects include rerates for improved performance;
engineered overhauls of rotors and complete machines;
mechanical redesigns and upgrades; reapplication of surplus equipment trains; component repairs; new parts supply including rotor blading, disks, shafts, stators, casings,
bearings and seals; and field service that ranges from inspection and turnaround support to providing supervisors
to full turnkey responsibility.
We take pride in our ability to refurbish turbomachinery
to a condition that ensures long-term trouble-free operation
for our customers, Hallman said. Our assemblers, inspectors, machinists and field service supervisors have an average of 25 years of experience in their respective fields and
continued on page 36

n 1998, a group of experienced turbomachinery engineers with a strong aftermarket engineering background
founded Rotating Machinery Services Inc. (RMS) in
Bethlehem, Pennsylvania. Now in its 18th year, the company has steadily grown its business, becoming a major force
in providing turbomachinery aftermarket engineering and
repair services to the refining, chemical, gas transmission,
power generation and steel industries. Earlier this year,
RMS opened a satellite engineering office in Appleton,
Wisconsin, specializing in the support of the former A-C
Compressor line of centrifugal compressors.
RMS performs a wide range of services on turbomachinery, including reliability improvements, performance optimization, repair, component replacement and the supply of
upgraded/overhauled surplus equipment. The company
has experience with repowering turbomachinery packages and has also supplied new custom-designed equipment skids and lube oil systems. Its experience includes
axial and centrifugal compressors, fluid catalytic converter
(FCC) and nitric acid expanders, gas turbines, aeroderivative power turbines and steam turbines.
RMS provides a full range of turbomachinery services,
giving users a complete alternative to the OEM (original
MAY 2016

34

COMPRESSORtech2

Everywhere.
Providing solutions for oil and gas applications upstream, downstream and in-between.
We are where you need us.

Welcome to a new era of innovation and technology.

As you have come to expect, Dresser-Rand provides
safe, reliable and efficient rotating equipment for nearly
every application in the oil and gas market.
But theres more.
The new Dresser-Rand business now has expanded
resources and more experience as a member of the
global Siemens family. The Dresser-Rand business

combines one of the industrys most extensive

portfolios of rotating equipment with a universe of intelligent
solutions and one of the worlds largest technical support
and service center networks. We offer more choiceswhere
you need usall from a single supplier.
So what can you expect from us? High-quality products
and services, combined with local support around the
clock, wherever you are, for the applications that matter
to you.

dresser-rand.com

Experience, Reliability, Integrity...

The AXH manufacturing complex consists of

six plants, totaling 559,100 SF on 67 acres.

(918) 283-9200

MAY 2016

Fax (918) 283-9229

www.axh.com

36

take great pride in our facility and our

ability to handle our customers property with the greatest efficiency and
attention to detail.
Hallman said that RMS is affiliated
with respected millwright service organizations throughout the country, and
RMS supplies field supervision for
each crew to ensure proper execution
of every project.
Our organization is made up of
uniquely experienced engineers and
technicians, said Robert J. Klova, PE,
vice president, chief engineer and cofounder. We leverage our experience
with the latest engineering technology.
Experience in all types of custom-engineered turbomachinery separates
the optimum solution from the run-ofthe mill. Strong design and analytical
engineering form the backbone of everything we do. Engineering makes
the difference, and we focus on continuous development of the next generation of turbomachinery engineers
to serve customers future needs.
RMS has analytical capabilities in
structural analysis, aerodynamics,
rotor dynamics and metallurgy using
the latest analytical tools.
The RMS service facility consists
COMPRESSORtech2

...
MAY 2016

rotary table inspection stations. The

machine shop is equipped with 25
and 15 ton (22.5 and 13.5 tonnes)
overhead cranes.
The assembly shop has six large
assembly cells, a weld shop, nondestructive test (NDT) area with magnetic particle and wet magnetic particle
booths, an abrasive blast room and
multiple abrasive blast cleaning cabinets. This shop is supported by a 35/15
ton (31.5/13.5 tonnes) crane with 27
ft. (8.2 m) hook height and multiple jib
cranes. Also in this area, RMS field service operations maintain a 20 ft. (6.1 m)
fully equipped sea container/shop and
gang boxes, ready for immediate dispatch to customer sites.
RMS capabilities are evidenced
by its list of successful turbomachinery projects. A recent major project
was an ammonia/water turbine generator set, developed from a surplus
steam turbine for a process customer in Pakistan. RMS provided the
complete train of equipment, with
new controls and auxiliaries, including the application of dry gas seals
for ammonia containment. To support the project, RMS had to develop
continued on page 38
37

low-rating.hoerbiger.com

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

include a rotor assembly shop, machine
shop with quality control room, and an
assembly shop. The rotor shop, which
is serviced by a 25 ton (22.5 tonnes)
overhead crane, houses multiple indicating stands and stacking pits, two
Schenck balancing machines with
respective capacities of 40,000 and
17,000 lb. (18,140 and 7710 kg), an
electrical runout (glitch) system, a variety of hydraulic coupling and tie-bolt
stretching equipment, and a Bracker
hydraulic rotor tenon peening system.
The machine shop houses multiple
large machine tools including a 5 in.
(127 mm) bar CNC horizontal boring
mill, a 60 in. (1524 mm) swing CNC
vertical boring mill, a Mazak 300M
CNC turning-milling center, a 52 in.
(1321 mm) swing by 236 in. (5994
mm) between centers engine lathe,
and a 90 in. (2286 mm) swing vertical
boring mill, as well as a variety of small
manual lathes, knee mills and grinders. The temperature-controlled, quality control room houses a number of
granite tables, coordinate measuring
equipment with scanning capabilities,
positive material identification equipment and two precision air bearing

LOW... ...RATING

n The capabilities of RMS experienced engineering staff include expertise in all major
types of custom-engineered turbomachinery
and a full range of analytical expertise with the
latest analytical tools in rotordynamics, structural analysis (e.g., turbine disk, left), aerodynamics (e.g., centrifugal stage flow path,
center) and performance (e.g., steam turbine
blade erosion, right).

n RMS provided this complete ammonia/water turbine gen-set for a process customer in Pakistan. Developed from a surplus steam
turbine, it provided the complete train of equipment, including controls and auxiliaries and the application of dry gas seals for ammonia
containment. To support the project, RMS had to develop performance analysis capability for ammonia and steam mixtures.

n RMS provided this complete machinery

train for a nitric acid plant in 2008. Starting with a surplus train, RMS completely
designed the axial compressor and rerated
the turbine, providing a new lube oil console as well. It also rerated the customers
existing expander during a turnaround.

performance analysis capability for

ammonia and steam mixtures.
The company has special expertise
in fluid catalytic cracker (FCC) and nitric acid expanders. Nitric acid is the
basic material for the production of
fertilizers, explosives and chemicals.
In 2014, an I-R E520 nitric acid tail
gas expander experienced a highpressure seal failure. RMS engineering supervised the change-out of the
damaged expander with a spare unit
that had been sitting idle following a
multiyear run. The spare expander
had experienced high of 2 to 3 mils
(51 to 76 m) and unstable shaft vibrations during its prior run. Improved
cold alignment, bearing changes, and
careful setup resulted in low and
stable vibration of less than 1.06 mils
(27 m), the lowest historical level for
this expander.
MAY 2016

38

COMPRESSORtech2

n An axial compressor rotor is ready for

return to a customer after an engineered
overhaul in RMS shop.

In 2008, RMS provided a complete

machinery train for a nitric acid plant.
Starting with a surplus train, RMS
completely designed the axial compressor and rerated the turbine, providing a new lube oil console as well.
It also rerated the customers existing
expander during a turnaround.
In 2012, RMS was contracted to
support the emergency breakdown
of a European refinerys FCC power
recovery train. A failed Elliott hot gas
expander was at the heart of the
breakdown. RMS was able to restore
the main axial compressor to service
on motor only within a 10-day period.
The company then received another
contract for a root cause analysis
of the failure and for rebuilding the
damaged expander using an existing
spare rotor. During the inspection process, RMS determined that the entire
intake casing assembly was no longer
suitable for service. It was able to deliver a new intake casing assembly, including first- and second-stage stator
housings in an expedited 16 weeks
from date of order. RMS field service
team travelled to Europe to support
the installation of the intake casing

and expander assemblies, enabling

an early startup.
Last year, RMS was offered a
unique challenge to urgently replace a
Cooper-Bessemer RC20 compressor
rotor that suffered a heavy rub failure
caused by impellers contacting the
diaphragms. The impellers were reverse engineered through mechanical
and FaroArm inspection methods in
four weeks. RMS engineers analyzed
the inspection information, and new
CAD models were created. Utilizing
forged material from in-house stock,
RMS was able to complete five-axis
machining of the impellers and a finished product, including overspeed
testing, in less than eight weeks. The
engineering and manufacture of a
new shaft, balance piston and shaft
sleeves were completed in 12 weeks,
so that the entire replacement rotor
assembly was assembled, balanced
and shipped in 13 weeks, one week
ahead of the agreed-upon 14 weeks.
RMS also performed a rotordynamics
analysis and developed performance
curves for the design.
In addition to service and repair,
continued on page 40

n RMS provides engineering and support to users

with older power turbines, such as Cooper RT65, I-R
GT51 and GT61, Dresser-Rand DR61 and DresserClark DJ125. Projects have included remaining life
predictions for rotors and stationary components,
casing redesigns, replacement of major stationary
and rotating parts including outer casings and rotor
disks, field service, and rotor and complete power
turbine overhauls.

MAY 2016

39

n RMS refurbishes and upgrades process (left) and pipeline centrifugal compressors including new custom-engineered
aerodynamic assemblies (right).
solving turbomachinery problems with engineering analyses and improved designs
has always been an RMS focus. For example, a 1968 vintage GHH horizontally
split centrifugal compressor in a toxic gas service had experienced chronic joint
leakage over many years. The end user tried various fixes including purchasing
a spare compressor with a thicker casing; yet the sealing problem could not be
consistently eliminated. Finally, the end user was faced with the need to replace the
machines entirely. However new compressors would not match the existing layout

MAY 2016

40

and pipe locations, and lead time was

over 30 months. RMS custom designed
and manufactured two new 300 series
stainless-steel drop-in replacement
compressors with upgraded barrel type
casings to solve the split line leakage
problem. The complete units utilized
new RMS casings and diaphragms with
the customers existing rotors, bearings and inner seals. Dry gas seals and
a new common oil system were also
included as part of the upgrade. The
new compressors were installed in the
spring of 2014, completely eliminating
the chronic leakage problems.
FCC expanders can experience significant erosive wear due to catalyst
particles entrained in the flue gas.
Using computer fluid dynamics (CFD)aided state-of-the-art aerodynamic
design, RMS developed a number of
unique features that have significantly
improved blade and disk lives. These
include low-erosion rotor and stator
airfoils, blade platform seals, and a
unique overlapping platform design
upgrade that shields the rotor disk
from the harmful effects of catalyst
laden flue gas. The low erosion design
doubled the life of the rotor disk and
blades to six years at one customer
site. RMS significant experience in all
aspects of FCC expander design, service and support has earned it a strong
and growing place in the FCC expander aftermarket, where numerous refineries rely on us to support their FCC
power recovery trains, Klova said. CT2
COMPRESSORtech2

LITERATURE
Compressed
Technical Services

Cooling
Solutions

Gemini
Upgrade Parts

Preservation
Coatings

Stark Industries brochure

outlines its Compressed
Technical Services offering.
CTS designs and manufactures compresor system
packages for industrial gas.
Compressors, oil-removal
systems and air-storage
solutions are enumerated
along side the companys
services offering.
www.starkindustries.com

The Fuzzys Radiator brochure lays out the products,

services and technologies
used by the Texas panhandle company. Fuzzys cooling solutions include radiator
packages, heat exchangers,
fin fan packages, radiator
cores, charge air coolers,
gaskets, cooling coils, hydro
blasting, soda blasting and
repair services.
www.fuzzysradiator.com

TrueRock released brochures to highlight the features and benefits of its line
replacement/upgrade parts
for Gemini compressors.
The brochures feature the
H Series aluminum piston rod (pictured) and the
M/H Series variable volume
clearance pockets.
www.truerocksupply.com

A-76 Technologies supplies

the A-76 line of preservation coatings and lubricants,
offering corrosion prevention
and lubrication in highhumidity, high-salinity environments. A green variation
contains no volatile organic
compounds, helping customers reduce emissions.
www.a76tech.com

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

Analysis: Valve Performance On Booster

Primary Compressor For LDPE >
Production of critical parts, maintenance strategies
help to optimize availability, minimize costs
BY JIMMY SALMON AND ENZO GIACOMELLI

n Booster primary compressor.

he production of low-density polyethylene (LDPE)

requires special compressors to obtain the pressure necessary for the product.
The booster primary compressor brings the pressure
from low value up to the suction of the hyper compressor
that feeds the reactor.
Great attention is paid to all details of the plant in order to
achieve maximum operating time. The valves represent an
important component that strongly influences the reliability
of compressors and the plant.
The booster primary compressor requires stringent capacity control, further increasing its complexity.
An analysis of the design, production and performance
aspects of the booster primary compressor follow.

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

56,000 lb./hr (25,000 kg/hr) for the primary.
The boosters suction pressure is slightly above the atmospheric one, collecting the gas from the plant recovery
system. The discharge of the primary reaches 3600 psi
(25 MPa) to feed the hyper compressor. The hyper compressor, designed and manufactured by GE Oil & Gas, is
an eight-cylinder machine that raises the pressure to full
reactor pressure. The three cylinders are double acting on
the booster, which reaches a pressure of 3278 psi (22.6
MPa). The compressor has 24 Nuovo Pignone-designed
valves manufactured by Cozzani.
The primary compressor operates up to 3771 psi (26 MPa)
and has two cylinders with a tandem arrangement (secondstage inboard and third-stage outboard). Additionally, the primarys first stage is double acting with 2+2 valves, while the
two second and third stages are single acting and positioned
on the same cylinder with a tandem arrangement. The second stages have one suction valve and one discharge valve
per cylinder, while the third stages have one combined suction and discharge valve per cylinder. All the cylinders are
equipped with plastic piston and packing rings.
The cylinder lubrication is made with a mineral oil with
lubricity additives. It is the same one that is applied for the
booster/primary and hyper compressor.

Plant features
The booster primary machine is a six-cylinder, multiservice compressor, which combines the function of
the booster and primary on one frame manufactured by
Nuovo Pignone (now GE Oil & Gas). The motor operates at 4000 hp (2983 kW) at 327 rpm. The machine has
Jimmy Salmon is a senior principal engineer with 40 years of continuous service in LDPE maintenance, reliability and production.
Enzo Giacomelli is a consultant for Dott.Ing.Mario Cozzani Srl.

MAY 2016

42

COMPRESSORtech2

Valve applications
The set of 30 valves is equipped
with metal rings in all stages of booster and primary. The capacity control
requires the use of finger-type, onestep unloading systems as well as
continuous bypass control. Because
the gas involved is not corrosive, the
material of the seat and guards is
alloy steel AISI 4140.
The valve bolts for the seat/guard
system were provided with a threaded
connection, including a surface treatment for longer life. Castle-type locknuts were used to prevent the assembly
from loosening in service. These nuts
also include an anti-friction surface layer
to reduce damage during maintenance.
Simulation programs have realized the design on the full operating range. The machines have been
manufactured to meet quality control
procedures. The critical parts, such
as springs and rings, are designed to
withstand fatigue stress.

(temperatures, pressures and vibration). In operation, we monitor process

and oil temperature and pressure, as
well as machine vibration.
Valve performance
The valves are critical compressor
components. Their performance has
been checked by pressure and temperature analysis. The attention to any
deviation from the design parameters
and homogeneity of the valves of the

same cylinder is essential to assess

performance and keep operations running until a failure can be predicted.
Following the 1996 valve change,
the next change occurred in 2002 for
all of the valves. In 2006, the primary
third-stage valves were changed during re-ringing of the third-stage cylinders, as the cylinders were already
largely dismantled. All other valves
remained in service.
continued on page 44

Maintenance strategies
In the years following the 1983 commissioning, the decision was made to
use predictive maintenance for determining when the valves should be
changed. Changes in gas temperature and interstage pressure were the
signals to indicate failing valves. In
the first 13 years, however, there were
no issues.
A lengthy turnaround in 1996 provided an opportunity to change out all
valves on a proactive basis. A detailed
inspection showed no problems. After
this shutdown, a preventative, timebased maintenance program was developed for the valves, which followed
the standards elsewhere on site.
Today, bearings and valves are replaced on a time-based schedule.
During the scheduled shutdowns,
we also check bearing clearances
and rider band wear. We crack detect critical bolts by ultrasonic means.
One throw per shutdown is checked
for web deflection. These inspections
(nearly every two years) also include
a rider band wear check. Other work
includes oil and filter change, lubricator
box inspection, and functional checks
on compressor alarms and shutdowns
MAY 2016

43

COMPRESSORtech2

Most valves have lives of six to 13

years. The primary third-stage valves
were removed with lives of four to 13
years. The last valves placed in service now have nine years and are
still operating. The valves were
in good condition during each
inspection. While slight wear occurred to some seating surfaces,
it wasnt enough to cause performance issues. There was also
slight wear in the bottom of some
spring recesses.
The rings were in good condition, with
no cracks or broken pieces. The springs
were intact, with none of them broken or misshaped. Every reconditioning was made according to the recommended procedure.
n Ring valves after disassembly.
Conclusions
The original valves installed in a booster primary compressor have performed well from one proactive switch to
the next during the 32-year window. All replacement parts
have been designed to the original more than 30-year-old
design. Although potential design improvements could be
made, such as plastic rings, the original work suited this
application. CT2

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

booster and first-stage primary valves were reconditioned.
The final reconditioning efforts took place in Cozzanis
service center in Magnolia, Texas, with the coordination
of the compressor manufacturer and supervision from the
valve manufacturer.

MAY
2016
EGCR_May16CT_HalfHorizNonBld.indd

44

2
COMPRESSORtech
4/14/16 2:24 PM

COMPRESSOR

ECT

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PRIME
MOVERS

them gain local market reach in new market segments,

expands its product portfolio to cover market requirements
and gives them direct access to a well-established local
supply chain.

Gasmet Technologies
BP

Gasmet Technologies has acquired Quantitech Ltd.

Headquartered in Finland, Gasmet Technologies is a
global manufacturer of gas monitoring instruments and
systems for industrial and environmental applications including continuous emissions monitoring, process control,
engine exhaust gas, greenhouse gas monitoring and carbon capture.
Quantitech Ltd. provides advanced environmental and
process monitoring instrumentation in the U.K. and Ireland.
Following the acquisition, Quantitech will remain at its
Milton Keynes, U.K., location, trading under the same name
and continuing to supply the same range of products.

BP and China National Petroleum Corp. (CNPC) have

signed a production sharing contract for shale gas exploration, development and production in the Neijiang-Dazu
block in the Sichuan Basin, China. The contract is BPs first
shale gas production sharing contract in China and covers
an area of approximately 579 sq.mi. (1500 km2). CNPC will
be the operator for this project.
This production-sharing contract is the first achievement
from BP and CNPCs framework agreement on strategic
cooperation that was signed last October during the visit
to the U.K. by Xi Jinping, president of The Peoples Republic of China. In addition to unconventional resources,
the framework agreement covers possible future fuel retailing ventures in China, exploration of oil and LNG trading opportunities globally, and carbon emissions trading
as well as sharing of knowledge around low carbon energy
and management practices.

Burckhardt Compression
Burckhardt Compression will acquire a 60% stake in
Shenyang Yuanda Compressor Co. Ltd., a Chinese reciprocating compressor manufacturer. Shenyang Yuanda reportedly had sales of about US$111 million in 2015 with
650 employees.
Shenyang Yuanda, established in 1997, is focused on
the development, manufacturing and service of reciprocating compressors. Burckhardt said the acquisition helps

Wasco Engineering Services Singapore

Wasco Engineering Services Singapore (WESS) has
signed an agreement to serve as LeROI Gas Compressors
authorized packager and distributor.
As a LeROI packager and distributor, WESS will have
product and service offerings that include vapor recovery,
well unloading, fuel gas compression, flare gas capture and
wellhead compression.
WESS network includes the Middle East, South East
Asia and Australia. LeROI controls more than 60% of the
U.S. compression market, the company said.

Enerflex Ltd.
Enerflex Ltd., a supplier of products and services to the
global energy industry, opened its new service facility in
Adelaide, Australia. The facility is the latest addition to
Enerflexs global branch network and the seventh location in Australia.
The 21,528 sq.ft. (2000 m2) facility, located at Gilman, will
provide Enerflexs complete product and service offerings
including compression, process and electric power equipment sales, aftermarket service and support, and integrated
asset management for the Southern Australia region.
The facility includes a workshop focused on equipment
overhauls, project optimization, upgrades, retrofits, and
general asset management, as well as a regional training
facility and a parts warehouse.

Correction
The minimum suction pressure for MAN Diesel & Turbo barrel compressors was incorrectly stated in Standardized Refinery Compressor Packages in the March 2016 issue (page
75). The correct minimum pressure is 50 psig (3.5 bara).
MAY 2016

46

COMPRESSORtech2

Now established and manufacturing

in the US German Experts in Sealing
Technology for Reciprocating
Compressors, Rotary Systems and
Renewable Energies

Exclusive Sealings
Exclusive Materials
Exclusively OEM
We proudly present the
SD50 Sealing Ring a contacting
segmented ring for rotating equipment,
such as blowers, dryers, mixers and other
rotating applications.
This ring provides a high sealing efficiency
against the rotating shaft through
overlapping sealing elements even at
high shaft speeds up to 45 m/sec.
The gas tight design reduces the loss of
buffer gas and split housings are
enabling an easier maintenance of the
SD50 Sealing Ring.
info@stasskol.com
www.stasskol.com
STASSKOL GmbH
Maybachstrasse 2
39418 Stassfurt
Germany

+49 3925 288100

STASSKOL Inc.
Suite 100,
19911 Morton Road
Katy, Texas 77449
USA

+1 713 2445050

Inlet Cooling For Gas Turbines

Driving Gas-Gathering
indirect evaporative chilling
Compressors > Hybrid
systems help optimize performance
BY GARY HILBERG

n Hybrid indirect evaporative chilling systems are efficient due to their use of
indirect evaporative cooling operating in series with mechanical chilling.

s natural gas usage continues to grow, due to its

clean, cost-competitive and efficient nature, the
demand for larger capacity compressors has increased. Many operators use gas turbines to drive their
compressors due to their power density, ease of operations and low emissions.
One challenge with modern gas
turbines is that they lose signifiChilled Turbine
cant output and efficiency as air
temperatures rise, forcing users
to accept lower capacity or add
Titan 130 19802S
incremental equipment to comMars 100 15000S
pensate for this loss. Figure 1
shows the performance of sevMars 90 T1300
eral leading gas turbines used to
Taurus 70 10300
drive compressors.
For one integrated oil and gas
Taurus 60 7800S
firm, Petrleos Mexicanos S.A.
Centaur T6200
de C.V. (Pemex), the opportunity

Gary Hilberg is president of Everest

Sciences. Contact him at: ghilberg@
everestsciences.com.

MAY 2016

to gain significant incremental gas flow from its existing facilities was very compelling. Pemex worked with
Everest Sciences of Tulsa, Oklahoma to evaluate the
potential benefits of providing inlet chilling the existing Solar Taurus 60 gas turbines at its Pardon facility.
continued on page 50

Chilled
Output
(HP)Turbine Output (HP)

5000

10,000

Chilled 47F (8.3C)

48

15,000

20,000

25,000

Ambient 100F (37.8C)

COMPRESSORtech2

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Metallic Plates|Thermoplastics|Springs|Buttons|Poppets|Kits|Center Bolts|Pins|Lift Washers|O-Rings

www.kbdelta.com
800-632-3994
Torrance, California USA

KB Delta Inc. is an aftermarket and OEM supplier of compressor valve parts. KB Delta makes no representation that all of
the parts it manufactures are OEM parts, however to the best of its knowledge, OEM specifications are adhered to on all of
the parts manufactured.

n Inlet cooling optimizes gas turbine performance by cooling the

gas turbine inlet air and providing more mass flow for combustion and increasing the efficiency of the gas turbine compressor.

Unit 5 Performance & Reliability Test January 2016

Unit 5 Performance & Reliability Test Jan 2016

400

70

160

60

120

50

80

40

40

30

0
:0

:0
30

00

:0

18

29

29

12

:0

:0

06

29

00

:0

29

28

18

:0

28

12

:0

0
28

06

:0

28

00

:0

0
27

18

:0

0
27

12

:0

27

27

06

:0

00

:0

0
26

18

:0
12

26

200

80

240

90

280

100

320

110

360

Temperature / F

120

Power / kW

130

Date & Time

TI-01
Ambient Air

XI-02
Relative Humidity

TI-05
Air Leaving ESID
(primary air) T1

TI-06
Final Leaving
Air Temperature T2

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MAY
2016
Modulift_JanFeb16_CT.indd

50

2
COMPRESSORtech
1/13/16 5:23 PM

ability to gain 15 to 25% incremental

power continuously over a 12-month
period is a key advantage of modular
inlet chilling solutions. Future projects
with Pemex are expected to complete
quickly now that all parties are familiar with the technology.
A key benefit of hybrid indirect
evaporative chilling is the automated
and reliable operations of the chilling
solution, providing a consistent inlet
temperature and system gas flow

This evaluation showed a significant

value proposition, and Pemex issued an international request for
proposals in 2014. Everest and its
local partner Equipos Industriales del
Golfo (EIGSA) received the contract
to supply three hybrid indirect evaporative chilling systems to Pemex in
November of 2014, with operations
starting in early 2015.
The hybrid indirect evaporative chilling systems tsolution is highly efficient
due to its use of indirect evaporative
cooling operating in series with mechanical chilling. For most applications,
this solution provides the efficiency of
evaporative cooling without using incremental water, while still providing
the consistent inlet air temperature of
mechanical chilling.
Inlet cooling optimizes gas turbine
performance by cooling the gas turbine inlet air and providing more mass
flow for combustion and increasing
the efficiency of the gas turbine compressor. Increased output from existing equipment optimizes the overall
facility, leveraging the existing staff,
and reduces the overall operating
cost on a US$/hp-hour basis.
For the Pemex Pardon project, the
modular equipment was factory packaged and tested and then delivered to
the site for installation by EIGSA. The
two hybrid indirect evaporative chilling
systems were installed in late 2015
and commissioned in early 2016. The
MAY 2016

even as the ambient temperature

varies, as shown in Figure 2. Gas
flow is a key metric for all gas transportation companies. For the Pemex
Pardon plant, this reduction in inlet
temperature increased the per unit
gas flow from 30.0 MMcfd (8.5 x 105
m3/d) to 33.4 MMcfd (946 m3/d) in
the coldest month of the year; in the
summer it is expected that the perunit gas flow will increase by an additional 10%. CT2

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Synthetic
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Come See Us at the

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field tested to eliminate many of your serious gas compressor
problems. Each gas compressor application has its own unique
set of operating parameters and issues. Summit offers a variety
of synthetic lubricant base stocks to solve these issues. Summit
Synthetic gas compressor lubricants will increase productivity with
minimal downtime. Call Summit today and reduce your lubricantrelated operating and maintenance costs.

Free technical support. Call us we can help!

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Quality Service Expertise

800.749.5823
www.klsummit.com
51

www.sublimedescaler.com

903.534.8021
COMPRESSORtech2

Scheduled Downtime

3
4
6

Visit www.compressortech2.com/scheduled-downtime/ for answers

I Before E, Except

D T V D Z C O U N T E R F E
D R H E C N A L L

E A S

Y P E G
I

P S T E

N R B E

B C F E

N G E N

C Y O D E S O E F O R F E

G P T E U E S N E E Z

W R H D R N R
N E E A
I

E D

E Z E E

U N N

S G S G R E G

T S

N O

D E

E D L R H

T Y T E R L

E T F S R R Y P U O R

G M H O G T G O S R E

R T U D

S E E T M P E W H

Y N C G T E

O G S

T R N

V E
I

W N Y G E E N T O S H M L
E H

P T Z B E C R O F N

E L
I

R O L G E

R E E D S N W
I

L E T

L G E E R T

O Y E T T O G B H L

F P S E D P M L R A T

E R S F S E

E O B E V G H E S L A T G E U
I

S T Y

S N U O L E E R F Y

R E F

E D O C

O S E Z N B E H H F C

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E N M E H
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SWITCHES CLASS I, DIV. 1&2, GROUP D
UNITED STATES ENERGY CORPORATION
1600 MISSILE WAY, ANAHEIM, CA 92801

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Order your books, catalogs and more at

STOREFRONT.DIESELPUB.COM

CT_Storefront_1cx2in.indd 1

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Custom Reprints Available

Articles in COMPRESSORtech2 can be reprinted at a
very reasonable cost and used for effective direct mail
purposes, answering inquiries, trade show distribution
and many other sales development activities. These reprints can be produced to your specifications in one or
multi-color formats on selected paper in standard 8 x 10
1/2 or DIN A4 sizes. Layout and production services are
also available. Contact Reprint Manager for information.
Mary Graesing mgraesing@dieselpub.com
Phone: 262-754-4147 Fax: 262-754-4177

2016 CLASSIFIED
AD RATES
Display or non-display classified
advertising accepted.
Rate is $130.00 per column inch, one inch minimum.
No charge for typesetting.
Payment must accompany order.
For an immediate price quote
email your ad copy to:
Katie Bivens
Email: kbivens@dieselpub.com
Phone: (262) 754-4140

MAY 2016

53

Page 1

Advertisers Index
*Further information on this companys products can be found in the 2015 Edition of the Diesel & Gas Turbine Sourcing Guide
(at www.Dieselandgasturbineguide.net) and/or 2016 Compression Technology Sourcing Supplement (at CTSSnet.net).

ACI Services Inc. ...................................................................41

* KB Delta Compressor Valve Parts, Mfg. ...................28-29, 49

ADIPEC 2016 ..........................................................................53

Modulift ...................................................................................50

Air-Cooled Heat Exchangers ................................................36

MOTORTECH GmbH ..............................................................18

Altronic, LLC .....................................................................10-11

* ARIEL CORPORATION ............................................................1

Murphy by Enovation Controls ................... 15, Fourth Cover

Armco Compressor Products Corp. ....................Third Cover

Neuman & Esser Group ..........................................................3

BG Service Co., Inc., The ......................................................43

PROGNOST Systems GmbH ................................................25

* Burckhardt Compression AG .................................................9

Shinkawa Electric Co., Ltd. ...................................................40

Compressor Products International ......................................5

Sloan Lubrication Systems ..................................................20

Cook Compression ................................................................13

* Cozzani, Dott.Ing. Mario Cozzani S.r.l. ...................................7

STASSKOL GmbH .................................................................47

DCL International Inc. ...........................................................26

Sullair ......................................................................................39

* Dresser-Rand .........................................................................35

Summit Industrial Products ..................................................51

E Instruments International ..................................................46

Sumy NPO PJSC ................................................................33

Eastern Gas Compression Roundtable ...............................44

SYNTHOSOL ..........................................................................27

* Elliott Group .......................................................Second Cover

Exline, Inc. ..............................................................................19

* Testo, Inc. ...............................................................................32

Girtz ........................................................................................21

Tulco Oils ...............................................................................31

HOERBIGER ...........................................................................37

Zahroof Valves Inc. ................................................................17

Cornerstones Of Compression story continued from page 56

Rotor Diameter

Max. Discharge Pressure

Full Load Capacity Range

Series

in.

mm

psig

bar

cfm

m3/min

PDX10

4.01

102.0

200

13.8

72 to 176

2.0 to 4.0

PDX12

5.02

127.5

200

13.8

163 to 295

4.6 to 8.4

PDH12

5.02

127.5

400 or 500

27.5 or 34.5

108 to 385

3.1 to 10.9

PDX16

6.43

163.2

200

13.8

258 to 555

7.3 to 15.7

PCC16

6.43

163.2

400

27.5

223

6.3

PDX20

8.03

204.0

200

13.8

423 to 996

12.0 to 28.2

PDR20

8.03

204.0

200

13.8

547 to 1289

15.5 to 36.5

PCC20

8.03

204.0

400

27.5

298 to 441

8.4 to 12.5

PDR25

10.04

255.0

200

13.8

554 to 1674

15.7 to 47.4

PCC25

10.04

255.0

400

27.5

583 to 857

16.5 to 24.3

PDX32

12.65

321.3

200

13.8

962 to 2329

27.2 to 66.0

PDR32

12.65

321.3

200

13.8

1732 to 3292

49.0 to 92.2

PCC40

16.06

408.0

300

20.7

3527

100.0

n In addition to being a leader in portable and industrial air compression markets, Sullair provides the widest range of rotary screw
compressors available for natural gas applications.
thousands in operation and with some units running for well
over 20 years.
The PD series offers a range of geared and direct drive
options to deliver flows up to 3292 cfm (93.2 m3/min) and
pressures up to 600 psi (41.4 bar) as well as spiral and slide
valve options for capacity control. The PC series are direct
drive units capable of flows up to 3527 cfm (99.9 m3/min)
and pressures up to 400 psi (27.6 bar), featuring an economizer port and slide valves for capacity control.
An oil-free dry screw compressor line was introduced in
1979, and a full line of pneumatic air tools was introduced in
1985 to complement the companys portable air compressor
line. Sullair has remained a pioneer of air compressor technology, delivering the first 500 psig (34.5 bar) two-stage portable
compressor in 2003, as well as encapsulated compressors
and vacuum systems. Today, the Sullair line of portable compressors ranges from 185 to 1600 cfm (5.2 to 45.3 m3/min)
with output pressures from 100 to 500 psi (6.7 to 34.5 bar),
being designed for years of use in extreme field conditions. Its
line of single-stage air compressors ranges from 5 to 450 hp
(3.7 to 335 kW) and two-stage compressors range from 100
to 600 hp (75 to 447 kW).
Operating behind the scenes in many cases, Sullair compressors are used in thousands of common applications as
well as many unique applications that most wouldnt expect
like fountains in Las Vegas and parades in New York City.
In 1984, Sullair was purchased by Sundstrand Corp.,
which became part of the United Technologies Hamilton
Sundstrand business unit in 1999. In 2012, it became part
of Accudyne Industries Inc. In 2015, Sullair celebrated its
50th anniversary, noting that it has manufactured well over
300,000 rotary screw compressors since its beginning. CT2

in 1966. The new Sullivan Machinery Co. was the first in the
U.S. market to completely rely on rotary screw compressor
technology. By 1968, after Sullivan had established itself in
markets that use portable compressors, the company introduced stationary rotary screw compressors to the industrial
air market. Later that year it changed its name to Sullair,
which became a public corporation in 1972.
Responding to market demand for clean and dry air in
specialized applications, Sullair developed air treatment
systems for its compressors and, in response to customer
needs, developed a line of proprietary compressor fluids
and related products that enabled it to become a dominant
supplier in the air compression market. Over the next two
decades, rotary screw compressors would almost completely displace reciprocating compressors in portable and
industrial air compression applications.
In the early 1970s, the Sullair C series was developed
for refrigeration applications, being offered in a complete
turnkey package. This made Sullair one of the very few
companies with full lines of screw compressors optimized
for both air and refrigeration applications.
In 1971, Sullair screw compressors were first adapted for
natural gas compression, making it one of the first manufacturers to enter this new market. Over the ensuing decades,
Sullair gas compressors have been commonly applied for
vapor recovery, gas gathering, landfill gas recovery, coal
bed methane, wellhead compression, sweet and sour process gas and fuel gas boosting.
Sullair OEM gas compressor models, commonly called
gas ends, are the PDR, PDX and C series. Together, they
represent the broadest range of natural gas screw compressor types and options of any manufacturer in the market, with
MAY 2016

55

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C ornerstones Of Compression

n The Sullivan Machinery Co., which became Sullair Corp. in 1968, was the first in the U.S. market to completely rely
on rotary screw compressor technology. Founded in 1965 by former employees of Joy Manufacturing Co., Sullivan
moved quickly to introduce its first portable rotary screw air compressor in 1966. Over the succeeding 50 years, Sullair
has manufactured well over 300,000 rotary screw compressors.

Sullair Rotary Screw

pioneered screw compressors
Compressors > Company
to domination of portable and industrial air
compression markets

BY NORM SHADE

n 1965, Donald C. Hoodes departed Joy Manufacturing

Co., a Pittsburgh-based manufacturer of mining and
reciprocating compressor equipment. In Michigan City,
Indiana, he founded a privately held company, taking the
name of Sullivan Machinery Co. As president, Hoodes
brought with him Roger Gustafson, Borje Vagenius and
C.J. Joseph as vice presidents. Their shared interest was
the relatively new rotary screw compressor technology that
was emerging for air compressor applications. That same
year, the new company acquired a license from Svenska
Rotor Maskiner AB (SRM) of Sweden to market rotary
screw compressor technology.
Starting with Ingersoll Rand in 1958, Joy in 1960 and
Gardner Denver in 1963, interest in screw compressor
technology was rapidly growing in the U.S. Interestingly, of
those three well-established air compressor companies, Joy
ultimately elected to stick with reciprocating and later centrifugal compressor technology for its air compressors, which
opened the door for Hoodes new enterprise.
The Sullivan Machinery Co. name was previously connected with Joy. In fact, Sullivan Machinery dates back
to 1868 when the New England company was formed to

MAY 2016

manufacture a newly invented diamond-channeling machine

for quarrying stone, especially marble. In 1901 it purchased
another company in Chicago that expanded its products
and services in prospecting, mining, oil field exploration and
industrial construction. In 1923, Sullivans rapidly expanding
business completed a new factory in Michigan City.
Through the years, many innovations in machinery for
the basic industries were attributable to the dedication of
Sullivan engineers. Early in the 1900s, Sullivan rock drills
and channeling machines dug 185 ft. (56.4 m) deep wheel
pits at Niagara Falls, New York, excavated 15 mi. (24 km) of
rock for the Chicago Drainage Canal and countless Sullivan
rock drills helped carve out the Panama Canal. In 1928,
Sullivan reciprocating compressors supplied high-pressure
air for rock drills penetrating the backbone of the Cascades
for the Great Northern Railway tunnel. And during World
War II, Sullivan Machinery Co. was cited for its contribution in war production equipment and services. In 1946, Joy
Manufacturing acquired Sullivan.
Hoodes and his team moved quickly to produce its first
150 cfm (4.25 m3/min) portable rotary screw air compressor
continued on page 55
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