2009 April

New Stationary Engine
Emission Regulations
Proposed
Attenuating Noise
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April 2009
CT April Cover.qxp 3/25/09 9:13 AM Page 1
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I Volume XIV: Issue III ................................................................................4
I Global Perspective LNG Spot Contracts are Gaining Ground ..................6
I Market Talk Compression Equipment Business
Feeling Effects of Economic Developments ..............................................10
I Flowserve Signs Valve Manufacturing Joint Venture
with S&A Abahsain Co. Ltd. ....................................................................11
I GE's Power Crystal Technology Debuts ..................................................12
I TECHCorner Loose Piston Detection for Reciprocating Compressors ....14
I VetcoGray to Supply Equipment for
OGX Drilling Campaign Offshore Brazil ..................................................30
I Water to Make the Sahara Flourish ........................................................34
I Stimulating Canada's Energy Sector ......................................................36
I The P-51 Goes On-Stream in the Campos Basin......................................38
I New SWT Series of Speed Switches from Dynalco ..................................39
I When Operating Equipment Has to Meet
Noise Abatement and Emission Standards ..............................................40
I Custom Control Installation for Gas Plant ................................................46
I SBCO Celebrates 86-Year Anniversary with Move to New Facility ............50
I Optimizing Power Load on Hydrogen Makeup Compressor ......................54
I EPA Proposes New Emissions Regs For Stationary Diesel, Gas Engines....59
I Black Powder Removal ..........................................................................60
I About The Business Burckhardt Compression Selltech Cook
Compression Ariel Hoerbiger Tritech JAG flowcomponents........64
I Dateline ..................................................................................................8
I Literature Library ..................................................................................29
I Products................................................................................................31
I Scheduled Downtime..............................................................................44
I Industry News........................................................................................45
I Advertisers Index ..................................................................................56
I Marketplace ..........................................................................................58
p. 12
p. 34
APRIL 2009
p. 46
p. 50
APRIL 2009 3 COMPRESSORTech
Two
COMPRESSORTech
Two
(ISSN 1085-2468) Volume 14, No. 3 Published 10 issues/year (January-February, March, April, May, June, July,
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April TOC.qxp 3/25/09 9:21 AM Page 1
PUBLICATION STAFF
CT
Two
Founder.......................Joseph M. Kane
Editor and Publisher ........D. Phillip Burnside
Associate Publisher ............Roberto Chellini
Managing Editor....................Brent D. Haight
Senior Editor .................Michael J. Brezonick
Senior Editor .......................Sheila Gailloreto
Senior Editor .....................Michael J. Mercer
Regional Manager/Editor .........Ian Cameron
Feature Editor.......................Dawn M. Geske
Field Editor/
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Joe Kane
Volume - XIV: Issue - III
tionable substances to our environ-
ment than the gasoline it replaces. In
addition, ethanol does not contain
nearly the energy potential of gaso-
line, so a given trip requires greater
fuel consumption.
Now, for renewable energy sources
the total kilowatt hours generated
by wind and solar energy (some
45,493,000 MW) was approximately
1.1% of the total U.S. consumption in
2008. The administration wants to
double this amount in the next three
years. You do the math. One barrel of
oil contains the energy equivalent of
1.64 MW. So, wind and solar energy
displaces approximately 76,000 barrels
of oil per day. This is equivalent to the
raw energy extracted from one aver-
age coal mine. This pales before the
4,118,198,000 megawatt hours con-
sumed in the U.S.A. in 2008. Con-
sequently, we can double renewables
over and over and not significantly
displace hydrocarbon-based energy re-
quired to drive our economy. So, our
present primary energy source will be
with us for quite some time.
Incidentally, Im not sure of the
drinking age in Ireland for beverages
with alcohol. However, I dont think
many Irishmen worried about it dur-
ing St. Patricks Day. Also, a flagon
or two of Guinness is often con-
sumed for its medicinal properties.
With that thought, may the Lord con-
tinue to hold you in the hollow of
His hand. I
A cartoon attracted my attention the
other day. It showed a mugger hold-
ing up at gun point what looked like
an average citizen. The victim, with
his hands held high said, Youre too
late. This is somewhat how many of
us feel as we watch whatever paltry
wealth we were able to accumulate
evaporate. Is there anyone out there
that knows whats going on? If so, I
would appreciate a short note. I
havent a foggiest notion where things
are headed.
Not all is gloom and doom. I un-
derstand France will boost the lawful
age for consuming certain alcoholic
beverages from 16 to 18. That means
that more of the nectar emanating
from that country will be available for
the rest of us. So my recommendation
is that when you go home after a
hard days work, relax in your favorite
easy chair and hit the sauce.
Next, the ethanol industry is ex-
pected to supply some 36 billion gal-
lons (136.2 billion liters) by 2022.
With gasoline consumption down
about 7% and expected to drop more,
and because ethanol production is ar-
bitrarily mandated and ratchets up
each year, does anyone wonder what
we will do with the surplus? Ethanol?
Production is heavily subsidized and
does not measure up to its intended
benefit. Thats because the whole
supply chain of ethanol from growing
fertilized corn to actual production
and transportation adds more objec-
The Muddle We
Live In
4 COMPRESSORTech
Two
MEMBER OF BPA WORLDWIDE
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Two
are
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Tel: 262-754-4137 Fax: 262-754-4176
CT225.qxp 3/24/09 4:11 PM Page 1
imagination at work
GE Oil & Gas
What goes higher and
deeper at the same time?
A N S W E R : O u r o f f s h o r e a n d s u b s e a r o t a t i n g e q u i p m e n t i s b a s e d
o n p r o v e n t e c h n o l o g i e s t o d e l i v e r h i g h r e l i a b i l i t y a n d a v a i l a b i l i t y
a s t h e i n d u s t r y m o v e s i n t o h a r s h e r e n v i r o n m e n t s . B l u e C
T M
i s o n e
e x a m p l e t h e i n d u s t r y s r s t s u b s e a c o m p r e s s o r m o d u l e
c u r r e n t l y o p e r a t i n g w i t h a 2 0 - M W c a p a c i t y a t 9 0 0 m .
The ocean is full of questions.
We create the answers.
Learn more at booth 1117
May 4-7, Houston, Texas
and at geoilandgas.com/OTC
GEoil&gas.qxp 3/18/09 4:23 PM Page 1

The LNG market is relatively young;
the first production of LNG on an in-
dustrial scale was back in the late
1960s. At the start of the business,
long-term contracts (typically 20
years) were signed to guarantee all
partners a return on investment in:
liquefaction plants, regasification ter-
minals and LNG carriers transporting
the product from production to con-
sumer markets.
With the growth of this business,
the increased number of players and
the need for more flexibility on both
sides, the spot market has been devel-
oped in parallel to that governed by
long-term contracts.
The majority of LNG activities are
concentrated in the Asiatic Pacific
area. The size of this market is fore-
cast to be around 5.3 Tcf (150 x 10
9
m
3
) in 2009. Major import countries
are Japan, 3.2 Tcf (92 x 10
9
m
3
); fol-
lowed by South Korea, 1.3 Tcf (38 x
10
9
m
3
); Taiwan, 424 Bcf (12 x 10
9
m
3
); and India and China with 282 Bcf
(8 x 10
9
m
3
) each.
Major export countries in the area
are Malaysia with 1.13 Tcf (32 x 10
9
m
3
); followed by Indonesia 1.12 Tcf
(31.7 x 10
9
m
3
); and Australia with
812 Bcf (23 x 10
9
m
3
). Qatar in the
Middle East, with 1.5 Tcf (43 x 10
9
m
3
) production capacity, also is ex-
porting a large share of its LNG to
Asia Pacific, while minor supplies
come from elsewhere.
The spot LNG market is highly re-
munerative when demand is high and
long-term contracts fail to meet de-
mand forcing LNG importers to
buy spot cargos. However, if spot
prices tied to the actual demand
drops, remuneration will suffer. With
the global economy slowdown poten-
tially reducing demand for energy in
2009, the Asian LNG market is likely
to order fewer LNG cargos.
In the longer term, the market will
recover with India and China re-
quiring substantially more energy to
support t hei r economi c growt h.
However, recent findings of substan-
tial natural gas reserves both in India
and China suggest that most of the
additional demand will be covered
by the distribution of gas locally
t hrough newl y bui l t domest i c
pipelines, limiting growth of LNG im-
ports. LNG prices that in 2008 have
exhibited peaks over US$10 per mil-
lion Btu, could fall to US$5 or even
less in 2009.
Marketing strategy adopted by the
major players goes both ways. While
major international oil companies
such as Shell, BP and Total have
based their sales on long-term con-
tracts, the BG Group has preferred to
keep a large share of its LNG capacity
to cover spot market requests. This
strategy proved highly profitable dur-
ing 2008, but is showing its weakness
in 2009. Apparently BG expects oper-
ating profits from their global LNG
business to fall 7% in 2009, to 1.3
billion, from 1.4 billion in 2008.
Imports from the Atlantic Ocean
basin (where the majority of BGs
LNG production assets are located) to
Japan, South Korea, India and Taiwan
slowed at the end of 2008, lowering
the spot price of LNG.
While falling spot prices have a neg-
ative impact on BG, the largest sup-
plier of spot LNG cargos to Asia, major
LNG importers such as Korea Gas and
Tokyo Electric Power are benefiting
substantially. It is said that these utili-
ties will save more than US$5 billion a
year for every US$1 per million Btu
decline in LNG prices.
BG stands to lose out as utilities
cover gas demand from existing long-
term contracts and avoid the spot
market. I
Two
IRoberto Chellini
LNG SPOT CONTRACTS ARE GAINING GROUND
A Risky But Potentially Profitable Possibility
Raising Some Doubts in the Present Environment
By Roberto Chellini, Associate Publisher
CT226.qxp 3/24/09 8:47 AM Page 1
LMF_HighOutput.qxp 3/19/09 8:41 AM Page 1
Two
APRIL
Apr 7-9 NEFTEGASEXPO - 11
th
Interna-
tional Specialized Exhibition Oil and Gas
Exploration and Development Know-How
Technologies and Equipment, Lenexpo, St.
Petersburg, Russia; Contact: Elena Rytova,
Restec Exhibition Company, P.O. Box 268,
St. Petersburg 197110, Russia.
Tel: 0812 320 9660
Fax: 0812 320 8090
E-mail: oilgas@restec.ru
Web: www.restec.ru
*Apr 21-22 Gas Compressor Institute
- Seward Community College, Liberal,
Kansas, U.S.A; Business and Industry,
Seward County Community College, P.O.
Box 1137, 810 Stadium Road, Liberal,
Kansas 67905-1137, U.S.A.
Tel: (620) 629-2653
Fax: (620) 629-2689
Web: http://www.liberalgasinstitute.com/
GCI/GCI.html
*Apr 21-22 Texas Energy Alliance
Expo & Annual Meeting - Multi-Purpose
Event Center (MPEC), Wichita Falls, Texas,
U.S.A.; Texas Alliance of Energy Producers
719 Scott Avenue, Suite 930, Wichita Falls,
Texas 76301, U.S.A.
Tel: (940) 723-4131/(800) 299-2998
Fax: (940) 723-4132
E-mail: alliance@wf.net
Web: www.texasalliance.org
MAY
*May 4-7 Offshore Technology
Conference - Reliant Center at Reliant
Park, Houston, Texas, U.S.A.; OTC
Headquarters, 222 Palisades Creek Drive,
P.O. Box: 833868, Richardson, Texas
75083-3868, U.S.A.
Tel: (972) 952-9494
Fax: (972) 952-9435
Web: www.otcnet.org
*May 11-15 ACHEMA 2009 - Frankfurt
am Main, Germany; Dechema e.V.,
Postfach 15 01 04 60061, Frankfurt/Main,
Germany.
Tel: +49 69 7564-230 / -238
Fax: +49 69 7564-0
E-mail: achema@dechema.de
Web: www.achema.de
*May 12-14 Eastern Gas Compression
Roundtable - Robert Morris University,
Moon Township, Pennsylvania, U.S.A.;
West Virginia University, P.O. Box 6070
Morgantown, West Virginia 26506-6070,
U.S.A.
Tel: (304) 293-3745 or (304) 293-3745
Fax: (304) 293-6751
E-mail: angela.durham@mail.wvu.edu
Web: www.egcr.org
May 19-21 AGA Operations Conference
& Biennial Exhibition - David L. Lawrence
Convention Center, Pittsburgh, Pennsylvania,
U.S.A.; American Gas Association, P.O. Box
79580, Baltimore, Maryland 21279-0580,
U.S.A.
Tel: (410) 997-0763
Fax: (202) 824-9184
E-mail: exhibit@epponline.com
Web: www.epponline.com
*May 25-28 Gastech 2009 - Abu Dhabi
National Exhibition Center, U.A.E; Contact:
Tony Stephenson, Event Director, DMG
World Media (UK) Ltd., Westgate House,
120/130 Station Rd., Redhill, Surrey, RH1
1ET, United Kingdom.
Tel: +44 (0) 1737 855000
Fax: +44 (0) 1737 855482
E-mail: info@gastech.co.uk
Web: www.gastech.co.uk
Dateline
*Indicates shows and conferences in
which COMPRESSORTech
Two
is participating.
For a complete listing of upcoming events, please visit our website at www.compressortech2.com
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CT April Dateline.qxp 3/24/09 8:56 AM Page 1

Two
*May 26-28 Sensor + Test 2009 -
Nuremberg Messe, Nuremberg, Germany;
AMA Service GmbH, Contact: Ms.
Christiane Schild, Won-Muenchhausen-Str.
49, 31515 Wunstorf, Germany.
Tel: +49 5033 9639-0
Fax: +49 5033 1056
E-mail: info@sensorfairs.de
Web: www.sensor-test.com
*May 26-28 Power-Gen Europe 2009
Koelnmesse, Cologne, Germany, Contact:
Kevin Marlow, PennWell Global Energy
Group, Pennwell House, Upshire, EN9
3RS, United Kingdom.
Tel: +44 1992 656 610
Fax: +44 1992 656 700
E-mail: kelvinm@pennwell.com
Web: www.powergeneurope.com
May 31-Jun 5 OMAE 2009 28
th
International Conference on Ocean,
Offshore and Arctic Engineering - Honolulu,
Hawaii, U.S.A.; Sea to Sky Meeting
Management, Suite 206, 201 Bewicke Ave.,
North Vancouver, British Columbia, Canada,
V7M 3M7.
Tel: (604) 984 6455
E-mail: info@omae2009.com
Web: www.omae2009.com
JUNE
*June 3-4 Energy Exposition - Cam-
Plex Convention, Gillette, Wyoming,
U.S.A.; Bulldog Industries LLC, P.O. Box
51151, Casper, Wyoming 82605, U.S.A.
Tel: (307) 234- 1868
Fax: (307) 234-1868
Web: www.energyexposition.com
*June 8-12 ASME Turbo Expo - World
Center Marriott Resort & Convention
Center, Orlando, Florida, U.S.A.; ASME
International Gas Turbine Institute (IGTI),
6525 The Corners Pkwy, Suite 115,
Norcross, Georgia 30092, U.S.A.
Tel: +1-404-847-0072
Fax: +1-404-847-0151
E-mail: igtiexpo@asme.org
Web: www.turboexpo.org
*June 9-11 GO-EXPO : Gas and Oil
Exposition 2009 - Roundup Centre,
Stampede Park, Calgary, AB, Canada; DMG
World Media, #605, 99-8th Street SW,
Calgary, AB, Canada T2R 1J5.
Tel: (403) 209 3555 or (888) 799 2545
Fax: (403) 245 8649
E-mail:
Web: http://www.petroleumshow.com
*June 16-19 SGA Offshore
Conference - Moody Gardens, Galveston,
Texas, U.S.A.; Southern Gas Association
3030 LBJ Freeway, Suite 1300, Dallas,
Texas 75234, U.S.A.
Tel: 972-620-8505
Fax: 972-620-1613
Web: www.southerngas.org
*June 23-26 MIOGE 2009 - Moscow
International Oil & Gas Exhibition,
Expocentre, Moscow, Russia; Contact: Irian
Gorshkova, Project Director, ITE Group Plc
(London), 105 Salusbury Road, London,
NW6 6RG, United Kingdom.
Tel: +44 (0) 207 596 501
Fax: +44 (0) 207 596 5106
E-mail: irina.gorshkova@ite-exhibitions.com
Web: www.mioge.com
Dateline
*Indicates shows and conferences in which COMPRESSORTech
Two
is participating.
For a complete listing of upcoming events, please visit our website at www.compressortech2.com
The World Standard In Gas Compression Coolers.
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CT April Dateline.qxp 3/24/09 8:58 AM Page 2
The turmoil in the commodity
and credit market is showing signs
of affecting gas compression re-
quirements. Fourth quarter results
from compression packagers reflect
lowering demand as producers con-
tinue to cut back on planned capital
expenditures pending recovery in de-
mand and pricing. While Exterran re-
ported an increase in its backlog at
the end of 2008, it also called atten-
tion to the likelihood of order cancel-
lation and request for delayed deliv-
ery that could adversely affect this
backlog. One could conclude that the
impact has already been felt in its
contract compression that saw its uti-
lization rate decline to 76% from 80%
the previous year.
Similar reports were seen from
Canadian packagers. Toromont re-
ported a 30% decline in booking in
the fourth quarter and Enerflex re-
ported a 6% decline in its backlog.
These impacts shouldnt be sur-
prising. Future commodity prices
continue to hold in a US$4 to $4.35
range for April delivery, with the 12-
month strip now averaging $5.12.
Continuing concern regarding de-
mand and oversupply seem to be de-
pressing the markets outlook. Cur-
rently EIA is expecting Henry Hub
spot price to average $5.01 per Mcf in
2009 and $5.93 per Mcf in 2010. They
do not foresee a rebound until 2010.
Recognizing the suppressed state of
the natural gas market, drilling activ-
ity has dramatically declined. In
the most recent report from Baker
Hughes, for the week ending Feb. 27,
rigs drilling for natural gas have de-
clined to 970. These levels have not
been seen since the spring of 2004.
Average natural gas rig activity in
February 2009 was 1037 in compari-
son to 1426 a year ago.
An interesting analysis by Spears
and Associates calls attention to the
parallel in rig activity decline in
2008/2009 to that of the previous cy-
cle in 2001/2002. If this analysis holds
true, it is likely that the bottom will
occur sometime midyear, with
small incremental increases thereafter.
This is assuming that economic activ-
ity in the U.S. market stabilizes as is
currently projected, which at this time
remains in question.
As we prepare to exit the with-
drawal season, it is likely that we
will do so with elevated levels of
natural gas in storage. As of the most
recent report, current gas in storage is
running 218 Bcf (6.17 x 10
9
m
3
) ahead
of the five-year average and 270 Bcf
(7.65 x 10
9
m
3
) over levels in storage a
year ago. Assuming a rate of draw
comparable to that of the five-year av-
erage, we will exit the storage with-
drawal season with 1596 Bcf (45.2 x
10
9
m
3
) in storage 317 Bcf (8.98 x 10
9
m
3
) ahead of that in storage in 2008.
Entering the injection season with
likely lower industrial demand could
lead to substantial build-up ahead, fur-
ther complicating future pricing. The
current long-range forecast from the
National Weather Service does not in-
dicate abnormally warm temperatures
in the Midwest and Northeast, which
could weaken demand for cooling
load and lessen the demand from nat-
ural gas-powered generation.
It is difficult at this time to
clearly project when prices for
natural gas will stabilize. Producers
continue to be cautious, awaiting
some signs of recovery. In reporting
their capex budget, many do so with
a caveat of built-in flexibility of re-
sponse dependent on market condi-
tions. It is apparent that current future
prices leave little in the way of incen-
tive for producers to expedite capital.
Hedging, which in the past has pro-
vided a means to manage risk associ-
ated with new production, is currently
not providing much value.
As the economy continues to strug-
gle to find footing, each day seems
to bring more questions than an-
swers. Hopefully the coming months
will bring some clarity but unfortu-
nately one had hoped that we would
have had the clarity by now. The
global implications of this downturn
only complicate the recovery and it
will likely be a long recovery, but at
this time one could only hope for
some stability in the market as a posi-
tive sign. I
Two
IHarold Lampe
Harold Lampe is the principal of
Energy Research Services of Tulsa,
Oklahoma, U.S.A., which provides
market research, customer satisfac-
tion analysis, competitive and mar-
ket intelligence and business develop-
ment strategies for the energy
industry, on which he has focused for
over half of his 30 years conducting
market research projects. He can be
reached at hlampe@hotmail.com.
COMPRESSION EQUIPMENT BUSINESS FEELING
EFFECTS OF ECONOMIC DEVELOPMENTS
Analysis of Current Parallels in Rig Activity Decline in 2008/2009
to that of 2001/2002 Cycle Predicts Bottom by Midyear
By Harold Lampe
CT223.qxp 3/25/09 8:49 AM Page 1
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Global flow control products and
services provider Flowserve Corp. has
signed a joint venture agreement with
S&A Abahsain Co. Ltd., a diverse
Saudi Arabian business entity.
Building on existing joint ventures
with the Flowserve Pump and Seal di-
visions, Abahsain and Flowserve have
expanded their relationship to include
the manufacturing of control valves,
ball valves, plug valves, butterfly
valves, and electric and pneumatic ac-
tuators for the oil and gas, petrochem-
ical, power and water industries.
We are pleased with this new
joint venture with Abahsain Group,
said Lewis Kling, Flowserve president
and chief executive officer. This
new agreement and partnership posi-
tions us well to continue to serve our
val uabl e cust omers i n t he Saudi
Arabian market.
The j oi nt venture, cal l ed
Flowserve/Abahsain Flow Control Co.
Ltd., will begin initial manufacturing
from a temporary faci l i ty i n Al
Khobar, Saudi Arabia. A new facility
capable of manufacturing the full line
of valve products is planned to be
constructed in Dammam in 2009, and
is expected to be operational by
January 2010.
Flowserve has existing Pump and
Seal operations in Saudi Arabia, said
Tom Pajonas, president of the Flow-
serve Flow Control Division. By
signing this agreement with Abahsain,
we are increasing Flowserves pres-
ence in the Kingdom by adding local
valve and actuator manufacturing ca-
pabilities. This underscores our com-
mitment to Saudization and to the
needs of our customers in the Saudi
Arabian market.
This agreement substantially ex-
pands our existing relationship with
Flowserve, said Shaukat Sheikh, di-
rector of Abahsain Group. We are es-
pecially pleased to be associated with
the prestigious Flowserve line of flow
control products. Abahsain is already
a local manufacturer of commodity
valves, and with this new joint ven-
ture agreement we expect to become
a major player in the critical engi-
neered valve segment.
Operating in more than 55 coun-
tries, Flowserve produces engineered
and industrial pumps, seals and valves
as well as a range of related flow
management services.
S&A Abahsain Co. Ltd. was founded
in 1947 by brothers Saleh and Ab-
dulaziz Abahsain as an electrical con-
t ract i ng company and has si nce
grown into a diverse business entity
spanning industry, trading, construc-
tion, real estate and services mar-
kets. The company was recentl y
named one of the top 50 companies
in Saudi Arabia in recognition of its
contributions to the development of
the Saudi economy. n
SEE DIRECTLINK AT
WWW.COMPRESSORTECH2.COM
FLOWSERVE SIGNS VALVE MANUFACTURING JOINT
VENTURE WITH S&A ABAHSAIN CO. LTD.
Agreement Expands Relationship Between Flowserve and S&A Abahsain Co.
CT210.qxp 3/23/09 10:31 AM Page 1
The announcement last fall that GE
would upgrade gas turbines and spare
modules at the Egyptian Operating
Co. for Natural Gas Liquefaction
Projects (Egyptian LNG) LNG facility
located in Idku, Egypt, was significant
on two fronts. The agreement was
valued at more than US$60 million,
but more importantly, signifies the in-
troduction and first use of GEs Power
Crystal technology on power turbines
in the oil and gas industry. The tech-
nology is designed to help operators
meet future power output or durabil-
ity requirements of their gas turbines.
Egyptian LNG is a joint venture of
local shareholders including EGPC and
EGAS, and foreign shareholders such
as BG Group plc, PETRONAS and Gaz
de France. At the time of writing, there
were two LNG trains running at the
Idku plant, each with a capacity of 3.6
million tons of LNG per year.
Under the agreement, GE is to sup-
ply Power Crystal parts retrofit kits to
upgrade 12 GE MS5002D gas turbines
and four spare modules that are used
at the LNG facility. Parts for Phase I
(upgrade of spare modules) will be
shipped this year and shipment for
Phase II will take place in 2010 to
2012. The upgrade will be carried out
during the next major overhaul of the
gas turbines (Phase II) and it will be
based on a modular replacement basis
with no impact in terms of the origi-
nal time schedule, according to GE.
The Power Crystal kits are based on
single-crystal technology that was
originally developed for GEs aircraft
engines and adapted for use on its ad-
vanced, heavy-duty gas turbines. The
technology has been used in almost
all of the companys aviation engines
since 1990. In addition, GE has expe-
rience with single-crystal materials in
its LM2500+, LM2500+G4, LM6000PD
aeroderivative gas turbines as well as
its LMS100 and all FB and H class in-
dustrial turbines.
The kits use single-crystal advanced
GES POWER CRYSTAL TECHNOLOGY DEBUTS
Upgrades Designed to Boost Performance or Extend Life of MS5002
Gas Turbines in Oil and Gas Applications
I The Power Crystal kit is a program devel-
oped to safely enhance the output power
and/or availability of GEs MS5002C and D
gas turbines. The first application of this
technology in the oil and gas market will be
used at the Egyptian LNG-owned LNG facility
located in Idku, Egypt.
Two
I The Power Crystal technology retrofit kit for MS5002C and D GE gas turbines includes
first-stage buckets that are manufactured in single-crystal material. All grain boundaries are
eliminated, and the single crystal with controlled orientation is produced in an airfoil shape
to improve high-temperature strength, transverse creep and fatigue strength.
CT219.qxp 3/23/09 12:03 PM Page 1
Since 1972 our custom-engineered impellers
have solved high-performance cooling problems.
Multi-Wings twisted airfoil profile maximizes
each fans efficiency, so we can create the ideal
solution to reduce your compressors power
consumption and noise. Multi-Wing airfoil
impellers will help you get the job done at a
price you can afford.
www.multi-wing.net
Low Noise High Efficiency
Custom fan solutions for diameters up to nine feet
alloys for high-performance turbine
blades that enable turbine firing temper-
atures to be raised at least 72F (22C)
(designed for 91F [33C]). This, accord-
ing to GE, leads to a 4% increase in tur-
bine power output with no increase in
NO
x
emissions for the MS5002D and a
potential power increase of 6% for the
MS5002C gas turbine.
This power output increase can be
kept independent of the ambient tem-
peratures at the site, said Filippe
Cinelli, new product introduction
leader for global services at GE.
Alternatively, if the firing tempera-
tures are left unchanged, the Power
Crystal technology can enable longer
mean time between maintenance in-
spections. So, the Power Crystal tech-
nology allows operators to choose be-
tween a power increase or availability
increase option.
With the Extendor technology, the
mean time between maintenance of
Power Crystal-equipped units with ei-
ther standard or LHE combustors is
24,000 equivalent running hours. This
allows operators to skip the traditional
12,000 equivalent running hour in-
spections. According to GE, the base-
line for the maintenance plan of a
Power Crystal unit running on the
availability increase option includes a
liner and transition piece inspection at
24,000 hours and a major inspection
at 48,000 hours. If the firing tempera-
tures of the turbine are not increased,
GE said operators can postpone the
maj or inspection to 72,000 hours
based on the improved materials and
design of the Power Crystal kit. This,
according to GE, can allow customers
to gain up to 10 days of production
over a full maintenance cycle.
The kit features an improved design
of the first-stage hot gas path compo-
nents and the latest in GEs combus-
tion Extendor technology. This up-
grade is similar to the evolution that
was made between the MS5002B and
MS5002C models.
The kit for GEs MS5002C and D gas
turbines touches three areas of the en-
gine. These are the first-stage nozzles,
first-stage buckets and other flow-path
components. The first-stage nozzles in-
clude a new and improved cooling pat-
tern, but no aero change. The first-stage
buckets feature a material change from
a directionally solidified GTD111 to the
proven single-crystal material to en-
hance creep resistance. The combustion
chamber transition pieces and liners,
fuel nozzles and cross fire tubes, and
cross fire tube retainers now feature the
Extendor Kit modifications. These con-
sist of the latest hard coating material
and the redesign of parts to optimize
clearances to reduce wear. The first-
stage shroud material has been changed
from AISI410 to AISI310, and the inner
nozzle ring has been redesigned to in-
clude additional cooling holes.
With the single-crystal material, all
the grain boundaries are eliminated
from the structure and a single crystal
with controlled orientation is pro-
duced in an airfoil shape. The elimina-
tion of all grain boundaries and the as-
sociated grain boundary strengthening
additives allow a substantial increase
in the melting point of the alloy
providing a corresponding increase in
high-temperature strength. According
to GE, creep and fatigue strength are
also increased compared to equiaxed
or directionally solidified structures of
previous generation turbines.
This retrofit kit has been developed
with the aim to be the least invasive
possible in the existing hardware, and
the control system will not be part of
this kit, said Cinelli. The customer
can keep his controls, and a light
modification of the software could be
required only if the customer selects
the power increase option. I
SEE DIRECTLINK AT
Two
CT219.qxp 3/23/09 12:03 PM Page 2
Reciprocating compressors frequently play a critical role
in hydrocarbon processing plants, particularly in providing
makeup and recycle hydrogen compression service. In re-
cent years, so-called de-bottlenecking projects have seen
many of these machines move into more prominent roles
where they have a larger impact on process throughput. As
a result, the need for reliable mechanical condition moni-
toring has escalated because of the significant impact on
production that total or partial loss of a machine entails.
While valve failures typically account for the majority of un-
planned outages
1
, failures of bolted joints on the running
gear (connecting rod, crosshead, piston rod and piston) can
lead to long and extensive outages. This article explains
how reciprocating compressor condition monitoring sys-
tems can detect mechanical looseness and provides an ex-
ample of how to detect a loose piston.
Application
Three, six-throw, balanced-opposed horizontal reciprocat-
ing compressors provide makeup hydrogen for the catalytic
cracker unit at a large refinery. In order for the unit to run at
full capacity, all three compressors must operate in parallel
loss of one machine results in a 20% reduction in pro-
duction, which can have enormous economic repercussions.
Each compressor has two distinct services, based on process
stream requirements; each of these services has three com-
pression stages. Each compression stage consists of one
double-acting compressor cylinder. Suction valve plug type
unloaders provide capacity control for second- and third-
stage cylinders. The first-stage cylinder capacity control in-
cludes a head end (HE) variable clearance pocket as well as
valve unloaders.
Instrumentation
Because of the crucial role these machines play in the re-
finerys production, the customer embarked on an ongoing
reciprocating compressor equipment health management
program. An online instrumentation system, consisting of
GE Energys Bently Nevada 3500 Series, transducers and GE
Energys System 1 diagnostic and optimization software,
monitors and trends critical management parameters. Table
1 summarizes the parameters monitored by the system.
This article focuses on the combined application of the
online cylinder pressure and crosshead acceleration.
While it has long been understood that cylinder pressure
has value for thermodynamic measurements and P-V
Two
LOOSE PISTON DETECTION FOR
RECIPROCATING COMPRESSORS
Reciprocating Compressor Condition Monitoring Systems Provide
Sufficient Data To Detect Loose Components
By Brian Howard, P.E.
Brian Howard is a senior engineer/technologist, GE Energy. For
additional information, contact the author by e-mail:
brian.howard@ge.com.
Table 1 Monitored Parameters
Temperature Cylinder valves
Main bearings
Cylinder suction
Cylinder discharge
Valve covers
Packing
Vibration/ Force Frame (velocity)
Crosshead (acceleration)
Piston rod (displacement)
Maximum rod load (compression)
Minimum rod load (tension)
Degrees of rod reversal
Pressure Cylinder pressure vs. volume (PV)
Peak cylinder pressure
Minimum cylinder pressure
Discharge pressure
Suction pressure
Compression ratio
curves, the ability to correlate events in the crosshead ac-
celeration signal (and cylinder or valve cover acceleration
signal, if available) with known events in the pressure
and/or rod load curves proves to have great value in de-
tecting mechanical looseness in the running gear. Using
online cylinder pressure data in this manner provides tim-
ing information in a manner analogous to a Keyphasor
signal on rotating equipment.
Impact/Knock Monitoring Methodology
While not necessarily a new measurement, online cross-
head acceleration has really gained broad acceptance in
only the last 10 or so years. As a result, industry has little
experience in applying and analyzing this measurement.
The signal generated by an accelerometer on a crosshead
shows different frequencies with different amplitudes at dif-
ferent points in the revolution. In contrast, transducers
monitoring rotating machinery generate signals with rela-
tively constant frequency content over the shaft revolution
with few harmonics. For this reason, most descriptions
characterize signals from rotating equipment as sinu-
soidal. But how to characterize the rich, complex signal
generated by a crosshead accelerometer?
continued on page 16
CT171.qxp 3/25/09 9:46 AM Page 1
www.arielcorp.com
World Standard Compressors
C
A
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E
H
IS
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O
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A
riel serial No. 494
In service June 1977
Parts available 24/7

Ariel.indd 1 12/15/08 11:21:14 AM
Figure 1 shows an unfiltered crosshead acceleration sig-
nal sampled synchronously with crankshaft rotation plotted
on a crank angle domain plot. (The term unfiltered means
that no filters have been applied to the accelerometer sig-
nal. Only the response corners of the transducer, 10 Hz and
30 kHz, limit the frequency content of the accelerometer
output signal.)
The peaks and valleys of the signal frequently draw the
most attention of analysts. Interestingly, these portions of the
signal resemble the idealized response of a first order system
to a sudden change. For example, consider a cantilevered
beam struck by a sledgehammer. Initially, the beam displaces
under the hammer motion, then, as the hammer moves past
the beam, the beam vibrates freely. Figure 2 shows this ex-
ample and the oscilloscope output for a proximity probe
viewing the beam during the event.
The shapes shown in Figure 1 and the right pane of
Figure 2 occur often in mechanical engineering, electrical
engineering and signal processing applications. Qualita-
tively, this shape represents the system response to an im-
pulse input. By definition, the accelerometer measures the
response of the crosshead guide to internal forces; there-
fore, these shapes correspond to impulse inputs, or events,
within the compressor
i
. Although the accelerometer signal
represents the response to impulse events, these signatures
on the curve are often referred to as impulse events, rather
than impulse response events for the sake of brevity.
Not all impulse response events within the crosshead ac-
celerometer signal convey the same information. Referring
to Figure 1, two impulse events have been labeled. Impulse
#1 has high frequency content compared to Impulse #2.
Mechanical knocks or bangs excite resonances of the recip-
rocating compressor components such as crosshead guides,
distance pieces, etc. Typically, these frequencies lie below
2000 Hz
ii
. In contrast, impulse events originating in gas flow
noise, valve opening or valve closing events express a
much higher frequency. Therefore, the high frequency
Impulse #1 likely relates to a valve opening or closing
event and the lower frequency Impulse #2 relates to a me-
chanical knock or impact.
Mechanical impacts represent the greatest potential
threat to machine health. Filtering ensures the protection
system alarms on only signal content related to mechanical
problems. In addition, comparing an unfiltered to a filtered
signal has diagnostic value. Bandpass filtering the signal
from the crosshead accelerometer with a 3 Hz high pass
and 2000 Hz low pass results in a waveform that repre-
sents only those impulse events associated with mechani-
cal impacts. Applying this filter to data sampled synchro-
nous wi th crankshaft rotati on resul ts i n a fi l tered
synchronous waveform.
The unfiltered signal has value too; however, separating
out the mechanical events from the valve noise presents a
challenge. For example, a loose valve has significant
mechanical content, but occurs at very nearly the same time
as the valve opening. The impulse event generated by the
gas flowing through the valve completely covers the im-
pulse event generated by the collision of the valve with the
cage or valve seat. Since whistles, pops and other noises
can completely obscure impulse events associated with me-
chanical knocks, shutdown on the unfiltered crosshead ac-
celerometer signal is not recommended.
One final note on crosshead acceleration concerns units
of measurement. Three distinct sets of standards address vi-
bration measurements on reciprocating compressors. API-
618 recommends frame vibration, but has nothing on
crosshead acceleration. However, section 7.9.4.2.5.2.4 pro-
vides vibration criteria for pipe in units of displacement
peak-to-peak (pk-pk) and velocity peak-to-peak. API-670 in-
cludes a discussion on accelerometers, but nothing on ve-
locity transducers or accelerometers on the crosshead.
Section 5.4.5.5 of API-670 recommends acceleration in units
Two
Impulse #1 Impulse #2
I Figure 1. Unfiltered synchronous crosshead acceleration versus
crank angle.
IFigure 2. Hammer impacting a cantilevered beam resulting in an impulse signal.
i
Throughout GE Energy Reciprocating Compressor literature, prod-
uct descriptions and case histories, the term impulse event refers
to a signal shaped as shown in the right hand pane of Figure 2. In
this context, impulse event does not have the same definition as
when the term applies to physics or dynamics. Within these subjects,
impulse refers to the strength and duration of a collision force.
ii
This is an empirically derived value for large API-618 style recip-
rocating compressors mounted on block type foundations. It does
not represent an absolute value grounded in a rigorous first prin-
ciples analysis.
CT171.qxp 3/23/09 10:33 AM Page 2
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CPI.indd 1 3/13/09 1:34:05 PM
Two
of true peak (0-pk) and velocity in root mean square (RMS).
ISO-10816-6 generically covers displacement, velocity and
acceleration all in units of RMS. What is the best representa-
tion of the amplitude of crosshead acceleration?
RMS can be addressed first. For pure waveforms (i.e.,
sinusoidal, square, etc.) simple conversions exist to con-
vert amplitudes in 0-pk or pk-pk to RMS. However, as
shown in Figure 1, the crosshead accelerometer signal is
not a pure waveform. Therefore, the value has to be cal-
culated numerically as:
For the data shown in Figure 1, the calculation results in
a value of 0.57 gs RMS. The value does not correlate well
with the critical features of the signal. RMS proves to have
little value in quantifying the amplitude of a rich signal like
those coming from crosshead accelerometers.
That leaves the choice of either 0-pk or pk-pk for
crosshead acceleration. Many power and other electrical
engineering calculations use a 0-pk value to represent the
amplitude of a signal. To be consistent with this practice,
both crosshead acceleration and frame vibration preferred
units are 0-pk
(2)
. All acceleration data presented in this pa-
per will be in units of gs 0-pk.
Even with filtered and unfiltered crosshead acceleration sig-
nals and meaningful units of measurement, the many moving
parts of a typical reciprocating compressor cylinder present a
real challenge for those attempting to determine the source of
a knock. Not only does the compressor have many moving
parts, but the forces acting across the parts change constantly
throughout the revolution. For example, consider the
piston in a double-acting cylinder, as shown in
Figure 3. (For the pur-
poses of the
following qualitative discussion, the difference in areas of the
piston face created by a piston/tail rod will be neglected).
With the piston at bottom dead center, the crank end cham-
ber has completed the discharge of gas and is at discharge
pressure. In contrast, the head end chamber has completed
the intake of gas from the suction manifold and is at suction
pressure. The higher pressure in the crank end chamber re-
sults in a net force that tries to move the piston toward the
head end head. The piston rod resists this force and is placed
in tension.
The gas pressure acts not only on the piston assembly,
but also on the cylinder. Again, neglecting the piston rod
area, note that the higher pressure in the crank end cham-
ber compared to the head end chamber results in a net
force on the cylinder that tries to move it toward the com-
pressor frame. The distance piece and frame extension re-
sist this force and come into compression.
As the piston begins to move toward the head-end head,
the pressure in the crank end falls to suction pressure and
the pressure in the head end rises to discharge pressure. At
some point during this transition the forces on either side of
the piston (and therefore the cylinder) will be equal. With
the piston at top dead center, as shown in Figure 3, the pres-
sure in the head end chamber is higher than the pressure in
the crank end chamber. This places the rod in compression
and the distance piece and frame extension in tension.
In practice, within the 3500 monitoring system, the cylin-
der pressure measurement at each 0.5 of revolution is mul-
tiplied by the area of each piston face minus the area of the
piston/tail rod. The monitor then sums the forces acting on
each piston face to obtain the resultant gas load curve. The
blue line in Figure 4 shows the gas rod load for an operat-
ing cylinder on a makeup compressor.
Forces also transition from tension to compression at the
crosshead pin, piston to crosshead connection and connect-
ing rod to main bearing. As these parts move, the inertia
forces (the mass of the moving parts times the acceleration
expression given in the Appendix) must be added to the gas
forces. The red line in Figure 4 shows the inertia force.
Summation of the inertia and gas force at each point in the
plot results in the combined rod load curve. Since the calcu-
lation of the inertia load includes the mass of the piston
assembly, rod and crosshead assembly, the combi-
nation of this inertia force and gas force, rep-
resented by the green line, is the
crosshead pin load
3
. Within the
scope of this presentation, the
=
=
n
i
i RMS
x
n
Amp
1
2
1
I Figure 3. Cross-section of a typical double-
acting cylinder, piston at top dead center (TDC).
CT171.qxp 3/23/09 10:34 AM Page 3
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terms combined rod load or combined force always indicate
crosshead pin load.
While the loading curves have intrinsic value in assessing
the stress on the machine, they also have value in localizing
knocks and impacts on reciprocating compressors. For ex-
ample, consider the case in which excessive clearance devel-
ops between the crosshead pin and crosshead bushing. As
the combined rod load forces at the crosshead pin transition
from compression to tension, and vice versa (shown by the
green dots on Figure 4), the pin moves from one side of the
bushing to the other. Excessive clearance enables a rapid
build-up of velocity that must be absorbed by the bushing.
This results in a knock at the point where the combined rod
load crosses the neutral axis. Therefore, knocks that occur
near the point of combined rod load reversal typically indi-
cate looseness or problems within the crosshead assembly.
What about a knock that occurs at gas rod load reversal
points (shown by the blue dots on Figure 4)? Such a knock
must not have much influence from the reciprocating mass.
Therefore, the connection or joint with the least mass must
be suspected of being the cause of the knock. For most
reciprocating compressor running gear, this is the piston-to-
piston rod connection (or, in the case of integral piston-rod
assemblies, the piston rod-to-crosshead connection).
Case History
Analysis During a routine audit, plant personnel ob-
served an impulse event on the crosshead accelerometer
of the LP Stage 2 cylinder. Although the filtered synchro-
nous waveform amplitude had not yet crossed the alarm
limit, the level of the impulse event was close enough to
warrant a detailed analysis.
The large impulse event in the unfiltered synchronous
waveform, highlighted by the red ellipse in Figure 5, drew
the attention of the analyst. This event begins approximately
211 after top dead center (ATDC) near the pressure curve
crossover point and 4 before the crank end suction valve
opens. The format of the data in Figure 5 provides some
valuable insight into the possible causes of this impulse
event. The left vertical axis represents the point at which the
piston moves closest to the head end head. If liquid were
present in the cylinder, it is near this point that an impulse
event would be observed
3
. Likewise, piston-to-head end
head contact would result in an impulse event left vertical
axis. The situation is analogous at the 180 crank angle,
when the piston moves closest to the crank end head.
Mechanical knocks, valve opening/closing events or gas
flow can cause a response in an unfiltered synchronous
waveform. In addition, the event lies close to both the pres-
sure cross over and the suction valve opening events. With
this information, the analyst can construct two hypotheses
about the source of the impulse event:
1. The impact event results from a loose valve or loose
cage on the crank end suction side of the cylinder. In
this case, a corresponding knock should occur when the
pressure inside the cylinder rises above suction pressure.
2. The impact event results from a loose piston or piston
ring slap. In this case, a corresponding knock should
occur for each time the pressure curves cross.
Two
I Figure 4. Gas rod load, inertia rod load and combined rod load
versus crank angle.
I Figure 5. LP stage 2 cylinder
pressure, crosshead acceler-
ation and rod position versus
crank angle
iii
.
CT171.qxp 3/23/09 10:35 AM Page 4
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Observations from
only the unfiltered syn-
chronous waveform
and the cylinder pres-
sure curves do not pro-
vide enough informa-
tion to support or
refute either hypothe-
sis. The analyst requires
additional information
to determine the cause
of the impulse event.
Referring to the fil-
tered crosshead ac-
celerometer signal in
the lower-left pane,
observe that the im-
pul se event at 211
ATDC also appears. In
addition, the filtered
synchronous wave-
form shows another
event occurring at 53
ATDC, between the
crossover of the pres-
sure curves and the
head end sucti on
valve opening. Note
that this impulse event
Two
n Figure 6. LP stage 2 rod load, crosshead acceleration and rod position versus crank angle.
n Figure 7. LP stage 2 rod load, crosshead acceleration and rod position versus crank angle. Zoomed display of rod position waveform.
CT171.qxp 3/23/09 1:57 PM Page 5
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barely could be seen in the unfiltered synchronous wave-
form because of the noise from the valve opening and
closing and the gas flows in the cylinder manifolds. The lo-
cation of this event, long after the crank end cylinder pres-
sure rises above suction pressure, provides enough infor-
mation to refute the first hypothesis of a loose valve.
As the first event does not line up with a valve opening
event and both events contain significant amplitudes related
to mechanical looseness, plant personnel then examined the
rod load curves alongside the crosshead acceleration and
rod position waveforms. As only the second hypothesis re-
mains, the analyst expected that the two events in the fil-
tered synchronous waveform would line up closely with the
gas reversal points.
Referring to Figure 6, note that the first event occurs ap-
proximately 4 after the gas rod load crosses the neutral axis.
Two
IFigure 8. Typical heavy-duty piston assembly.
IFigure 9. As-found condition of the piston and piston nut.
IFigure 10.
LP Stage 1
after return
to service.
The second impulse event occurs approximately 2 after the
gas rod load crosses the neutral axis a second time. The
proximity of the impulse events to these gas reversal points
strongly suggests a loose piston. With this information, the
CT171.qxp 3/23/09 10:36 AM Page 6
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analyst now has sufficient data to support the hypothesis
of a loose piston.
In this case, the rod position probes provide important
supporting evidence for the loose piston hypothesis. System
1 allows users to zoom in on a particular event in a wave-
form, but still keep the cursors synchronized across plots.
Figure 7 shows the same data as in Figure 6; however, the
plot format separates the data into four distinct panes and
the focus of the lower right pane is zoomed in around thee
high-frequency ring-down of the vertical rod position probe.
Aligning the cursor with the beginning of this ring-down
event on the rod position waveform, note that it begins ap-
proximately 4 before the impact appears on either the unfil-
tered or filtered synchronous waveform plots. The proximity
to gas reversals suggests that the loose piston was initially
hard against the piston nut (when the gas forces placed the
assembly in tension) and then forced to the piston rod shoul-
der when the forces transitioned to compression. The motion
of the piston and the impact with piston rod shoulder were
energetic enough to excite vibration on the piston rod.
With the evidence from the filtered synchronous
crosshead acceleration waveform and the rod position
waveform, the analyst felt confident that a loose piston
caused the high-amplitude impulse event.
Inspection Results
With an online monitoring system in place and requests
from operations to continue running the unit, the plant de-
cided to continue running until spares could be obtained
and an outage planned.
Once the plant shut the machine down, the maintenance
team removed the head, expecting to find the piston nut
loose (reference Figure 10 for terminology). In fact, they
found the small stake holding the piston nut to the head
Two
IFigure 1A. Crank slider arrangement.
end postion (shown inside the red circle in Figure 9). The
presence of the stake indicated the nut had not come
loose, with respect to the head end piston half.
Further inspection of the piston assembly revealed that
though the nut had not come loose, sufficient relaxation of
the piston assembly occurred, allowing the piston halves to
be rotated by hand on the piston rod. It appeared that
some event, such as liquid ingestion, had created sufficient
force to plastically deform the threads under the nut and/or
the piston rod between the nut and piston rod shoulder.
The maintenance team removed the piston assembly and
replaced it with a new, spare assembly.
Figure 10 shows the rod load, crosshead acceleration and
rod position data after the compressor returned to service.
Note the absence of significant impulse events on either
crosshead acceleration waveform.
Conclusion
System 1/3500 provided critical insight into the compres-
sor condition, allowing the plant to understand and diagnose
the compressor condition. Without proper pre-load, fatigue
cycles accumulate on the portion of the piston rod under-
neath the piston. Unchecked, this can eventually lead to se-
vere mechanical damage. Even if the failure had progressed
to the level of an audible knock, detection of the loose pis-
ton would have been extremely difficult without quality data
to guide the disassembly and inspection process. I
References
1. Leonard, Stephen M. Increasing the Reliability of
Reciprocating Compressors on Hydrogen Service.
Dresser-Rand: Painted Post, NY. 1995.
2. General Electric. Protecting and Managing API-618
Reciprocating Compressors. Document Number
178896, Revision NC.
3. Atkins, K.E. Martin Hinchliff, and Bruce McCain. A
Discussion of the Various Loads Used to Rate
Reciprocating Compressors. Proceedings of the Gas
Machinery Conference, 2005.
4. Howard, Brian and John Kitchens. On-line Acceleration
and Cylinder Pressure (PV) Measurements for
Reciprocating Compressor Diagnostics. Proceedings of
the Gas Machinery Conference, 2007.
Appendix Crank Slider Applied Mechanics
Given the crank slider arrangement shown in figure 1a,
derive the expression for piston/crosshead linear motion as
a function of crank angle, the expression for piston/
crosshead velocity as a function of crank angle and the ex-
pression for piston/crosshead acceleration as a function of
crank angle.
CT171.qxp 3/23/09 10:37 AM Page 7
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www.axh.com
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A
From inspection of Figure 1, note that:
And l
4
is the crosshead/piston position. Begin by writing
the loop equation for the crank slider:
Acceleration
Beginning with displacement, the loop equation for the
crank-slider can be written as:
Differentiating this expression with respect to time gives
the velocity:
Since the stroke is fixed, the derivative of r is zero.
Likewise, the connecting rod length is also fixed so that the
derivative of l is also zero. Since the crosshead guides
bound the motion of the crosshead, u
4
is a constant and its
derivative is also zero. With these simplifications, the veloc-
ity expression can be written as:
Differentiating the velocity expression with respect to time
and simplifying results in an expression for acceleration:
Using Eulers identity to separating into real and imagi-
nary parts:
Solving for connecting rod angular acceleration:
Substituting the expression for connecting rod angular
acceleration into the real part equation and solving for pis-
ton acceleration and simplifying the expression:
Another common form of the equation for acceleration
can be found by rearranging the numerator:
Further simplification of this expression for hand cal-
culation can be obtained by observing that, for most rec-
iprocating compressors, the radius of stroke divided by
the connecting rod length is usually on the order of 0.2
to 0.25. Because of this, the following simplification can
be made:
Which results in the following simplified expression for
acceleration of the reciprocating mass:
Rewriting in terms of crankshaft rpm and the reaction
force of the crosshead pin gives:
0 = + + BO AB OA
( ) ( ) ( )
( ) ( ) ( ) 0
0
3 3 3
2
3 2
2
2
4 3 3 3
2
3 2
2
2
= +
=
cos l sin l sin r
l sin l cos l cos r
& & & &
& & & & & &
( ) ( ) ( )
( ) ( )
( )
( ) ( )
( )
( )( )
( )

+
=
+ =
3
2
3
2
2 2
3
2
2
3 2
2
2
3
3
2
3 2
2
2
3
3
2
3 2
2
2 3 3
cos
sin
l
r
cos l
sin r sin r
cos l
sin l sin r
sin l sin r cos l
& & & & & &
& &
& & & &
( ) ( ) ( )
( ) ( )
( )( )
( )
( )
3
3
2
3
2
2 2
3
2
3 2
2
2 4
3 3 3
2
3 2
2
2 4
=
=
sin
cos
sin
l
r
l cos l cos r l
sin l cos l cos r l
& &
& & & &
& & & & & &
( )
( ) ( )
( )
+ =
2
3
2
2
2
2
4
3
2
2
2
2 4
1
2
sin
l
r
sin
l
r
cos
l
r
cos r l
& & &
( )
( ) ( )
( )
+ =
2
3
2
2
2
4
4
3 2
2
2
2
2 4
1
1 2
sin
l
r
cos
l
r
l
r
cos
l
r
cos r l
& & &
1 9375 0
16
1
1
4
1
1
2
=
.
0 0984 0
64
1
4
1
3
= =
.
( )
+ =
2 2
2
2 4
2 cos
l
r
cos r l
& & &
( )
( ) ( )
+ = t cos
l
r
t cos r m F
ing reciprocat Inertia
2
2
180
2
4
2
=
=
=
=
t
Length Rod Connecting l
/ Stroke r
0
4 4 3 3 2 2
4 4 4 3 2
= + + + + +
i i i i i i
e i l e l e li e l e ri e r
& & & & &
&
0
4 3 2
4 3 2
= + +
i i i
e l e li e ri
& & &
0
4 3 3 2
4 3
2
3
2
2
= + +
i i i i
e l e li e l e r
& & & & & &
0
4 3 2
4
= + +
i i i
e l le re
CT171.qxp 3/25/09 9:05 AM Page 8
Transmission And
Control Website
Altra Industrial Motion has de-
veloped a new website. The
site is organized in nine cate-
gories, including steam tur-
bines, fans and blowers, gas
turbines, nuclear power
pumps, wind turbines, tidal
power turbines, inclined con-
veyors, cooling towers and
conveyors. Equipment for coal-
fired and ethanol plants is also
included. For products, photos
and features visit www.
altraenergyoilandgas.com.
SEE DIRECTLINK AT
Rubber Gaskets
Topog-E Gasket Co. offers a
technical specification and
usage guide for its molded
rubber handhole and man-
hole gaskets for steam, hot
water boilers, water heaters,
softeners, deaerators, make-
up tanks and other pressure
vessels. The company also
offers a pocket slide rule that
charts steam temperature ver-
sus pressure.
SEE DIRECTLINK AT
Electronic Measure-
ment Product Guide
A product guide is available
from Noshok, a manufacturer
of transmitters, transducers,
switches and indicators. Each
product is listed with a pic-
ture, description, features and
specifications. The guide also
features an environment rat-
ings guide and hazardous lo-
cation classifications in the
back along with a frequently
asked questions section.
SEE DIRECTLINK AT
Multijacket
Tensioners
Superbolt Inc. has brochures
available detailing applica-
tions of its multijacket tension-
ers in gas compression serv-
ice. Tensioners provide a safe,
fast and cost-effective product
for problems with difficult
bolting applications. The
brochures are available online
at www.superbolt.com.
SEE DIRECTLINK AT
Literature Library
COMPRESSORTech
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Lit_029.qxp 3/24/09 11:39 AM Page 1
The new RecipCOM delivers
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and therapy for your
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VetcoGray, a GE Oil & Gas business,
has signed a four-year frame agree-
ment with OGX Petroleo e Gas to sup-
ply subsea wellhead systems and cas-
ing strings for an exploratory drilling
campaign that could include more than
50 wells offshore Brazil. The drilling
campaign has the potential to signifi-
cantly increase Brazils oil discoveries.
Created in 2007, in response to
growing interest in major oil reserve
discoveries off the Brazilian coast,
OGX is the countrys largest indepen-
dent oil company. OGX has already
secured long-term contracts with four
semi-submersible drilling rigs to con-
duct a massive four-year offshore ex-
ploratory drilling campaign that has a
potential for up to 51 wells to be
drilled in several blocks located in
Santos, Campos, Esprito Santo and
Par-Maranho basins offshore Brazil.
OGX has the exploration rights in
22 offshore high-potential blocks,
with 4.8 billion barrels of oil equiva-
lent (boe) of total estimated risked
recoverable resources of oil and nat-
ural gas.
The frame agreement with OGX,
one of the largest agreements
VetcoGray has ever secured in Brazil,
will cover the supply of MS-700 and
MS-800 subsea wellhead systems, in-
cluding large-bore casing strings, as-
sociated rental tools and onshore and
offshore assistance during the entire
drilling campaign.
The order for the initial six wells al-
ready has been placed and first deliv-
ery is planned for July 2009. The well-
heads will be manufactured at
VetcoGrays Jandira Plant located in
So Paulo state, Brazil, and the casing
strings package will be fabricated at
the service center located in Maca,
Rio de Janeiro state.
VetcoGray has been providing sub-
sea wellheads and subsea tree sys-
tems in Brazil for more than 30 years,
with over 1200 subsea wellheads and
180 subsea trees produced and in-
stalled there.
GE Oil & Gas continues to expand
its presence across Latin Americas oil
and gas sector, with more than 1000
units of gas turbines and compressors
installed throughout the region and
over 31,068 mi. (50,000 km) of oil, gas,
water and refined product pipelines
successfully inspected to date. With the
acquisition of VetcoGray, the business
now has key regional offices in
Argentina, Bolivia, Brazil, Ecuador,
Peru, Mexico and Venezuela, providing
customers with local manufacturing,
sales and services capabilities. I
VETCOGRAY TO SUPPLY EQUIPMENT FOR OGX DRILLING
CAMPAIGN OFFSHORE BRAZIL
Program Could Include up to 51 Wells and Significantly Increase Countrys Discoveries
CT213andProducts.qxp 3/23/09 1:54 PM Page 1
V
isit
u
s
a
t
th
e
A
c
h
e
m
a
2
0
0
9
,
Fra
n
k
fu
rt
G
e
rm
a
n
y
H
a
ll
8
.0
,
B
o
o
th
P
3
4
P
3
7
For more information please contact compressor-mechatronics@hoerbiger.com
w
w
w
.
h
o
e
r
b
i
g
e
r
.
c
o
m
Two
Measurement And
Alignment Software
Pinpoint Laser Systems has introduced
Pinpoint Capture software for use with the
companys Microgage line of measuring
and alignment products. Capture is a
Windows-based application for recording
and monitoring measuring and alignment
results. Its designed to view readings from
one Microgage display and up to four re-
mote receivers on a computer at a time.
The data can then be uploaded to other
spreadsheet and statistical packages for
analysis. Pinpoint Capture was pro-
grammed with a large screen format with
easy-to-read measuring values and a choice
of plots and graphs to follow measuring re-
sults. The Laser Microgage 2-D is a laser
transmitter that projects a compact, focused
laser bean that is detected by a portable re-
ceiver. Measurements can be made over a
range of 180 ft. (54.86 m) with precision of
less than 0.0001 in. (0.000254 cm) in a fac-
tory environment, said the company.
SEE DIRECTLINK AT
Vibration Switch
Metrix now offers Hardy Instruments
HI 5800 vibration switch, along with
other Hardy vibration monitoring prod-
ucts. The HI 5800 is designed to provide
machine protection for rugged working
environments in a compact package. It
is self-contained and can be mounted to
any location on rotating or reciprocating
equipment, said Metrix. If excessive vi-
bration levels are reached, the unit is
equipped to provide alarm or shutdown.
All sensing and electric components
along with an LED alarm display are en-
gineered into a stand-alone switch box,
making installation easy, said Metrix. The
switch also incorporates an integral relay
to provide operation with both normally
open and normally closed contacts in
rugged installations.
SEE DIRECTLINK AT
Control Valve Asset Manager
Flowserve Corp., a manufacturer of
flow control products, has launched the
Flowserve ValveSight, an asset manage-
ment system for integrated control valves
and automated quarter-turn valve pack-
ages. ValveSight is designed to predict
potential failure modes and prioritize
condition-based maintenance before
process downtime and to identify critical
issues before they occur.
The diagnostic software captures data
from the valve, actuator, position and con-
trol signal while the process is running, then
displays the data in a graphical user inter-
face. The interface allows the user to trans-
late different alarms and data point into at-
a-glance color-coded health indicators. The
system runs on FDT/DTM and can be con-
nected to a host DCS, workstations or any
system that supports the FDT/DTM format.
SEE DIRECTLINK AT
Products COMPRESSORTech
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CT213andProducts.qxp 3/24/09 11:40 AM Page 2
Cameron.qxp 6/19/08 11:09 AM Page 1
Cameron.qxp 6/19/08 11:07 AM Page 2
The Algerian government has been
well aware of the need for develop-
ment of water systems in its commu-
nities and over the years has imple-
mented extensive water supply
programs. However, the water min-
istry of Algeria is now extending wa-
ter supply programs into the deep
Sahara Desert. The establishment of
the ministry ADE, LAlgrienne des
Eaux, has launched an ambitious proj-
ect, a potable water supply to
Tamanrasset from In Salah.
Construction of the pipeline is al-
ready under way and the project has
been given considerable priority in
Algeria. Initially, water from this proj-
ect will be supplied to 100,000 inhabi-
tants of Tamanrasset, but eventually
half a million inhabitants may get wa-
ter from this pipeline.
In the future, the development will
include enhancing communication
and energy connections, providing
crucial support to agriculture and the
travel industry in the area. The supply
system starts from the water aquifer
north of In Salah. The groundwater is
gathered up from several wells to
flow lines, down to the reservoirs of
the first pump station.
Wrtsil is delivering 18 engine-
driven pump sets and their ancillary
equipment to the Tamanrasset potable
water supply project in the Sahara,
said Pekka Laine, application man-
ager, Oil Pump & Power, Power
Plants, Wrtsil. The water supply is
a vital part of the development of
Tamanrasset and of the whole area in
the Ahaggar Mountains. Huge ground
water reserves have been found in
connection with oil and gas explo-
ration providing new chances and
visions to the host countries.
The contract received by Wrtsil
calls for both pump sets and ancillary
equipment to be installed at six
pumping stations, with each station
having three pump sets. Each pump
set will include a six-cylinder, Wrtsil
32GD dual-fuel engine, a speed-in-
creasing gearbox and a centrifugal
pump. For the first few years the en-
gines will run on diesel fuel oil. Once
a supply of natural gas becomes avail-
able, they will operate in gas mode.
Light fuel oil (LFO) will then be used
for pilot injection and as the backup
fuel. The gearbox is a single-stage,
parallel-shaft, double-helical gear unit
with a ratio of 2.288. It is manufac-
tured by BHS, Germany. It drives the
single-stage pump, made by Sulzer,
Brazil, at a speed of 1716 rpm.
The main contractor for the pipeline
pump stations for ADE is the construc-
tion company China Petroleum En-
gineering and Construction Corp.
(CPECC), which is a daughter com-
pany of China National Petroleum
Corp. The equipment will be delivered
to the pumping stations during the sec-
ond half of 2009, and the pipeline will
be fully operational and tested in early
I For the Tamanrasset
pump project, a six-
cylinder Wrtsil 32GD
dual-fuel engine will
drive each centrifugal
pump via a speed-in-
creasing gearbox. In-
itially, the engines will
run on diesel fuel oil.
Once a supply of nat-
ural gas becomes avail-
able, they will operate
in gas mode.
Two
WATER TO MAKE THE SAHARA FLOURISH
Algerian Pipeline Project Designed to Support,
Among Other Things, Future Energy Projects
By Bo Svensson
CT216.qxp 3/23/09 10:22 AM Page 1
2011. At the moment, the project implementation is in the in-
tensive design stage at Wrtsil. The requirement for just
2.5 MW [3353 hp] of pumping power was too low for our
portfolio of DF and SG gas engines, but very suitable for the
32GD, said Laine.
Once full daily capacity is reached, two of the engines in
each pumping station will run, with one on standby. In the
early stages, when the volumes being pumped are lower,
one engine will run and two will be idle.
Because CPECC wanted the pumping houses to be as
small as possible, the project team borrowed the principles
employed by Wrtsil Ship Power for designing machine
rooms on vessels. The layout of the pumping units, there-
fore, corresponds to the configuration used onboard re-
ducing total pump house volume by 50%.
The pipeline will extend 456 mi. (740 km) from In Salah
aquifer at an elevation of 1444 ft. (440 m) to Tamanrasset at
the elevation of 4593 ft. (1400 m) above the sea level. The
water conduit will be two 31.5 in. (80 cm) parallel pipes,
and the total design capacity of the supply system is 3.5
MMcfd (100,000 m
3
/day).
The reservoir tanks at each pumping station have a vol-
ume of 141,260 cu.ft. (4000 m
3
), which corresponds to just
one hours supply, said Laine. The flow control will be
according to signals from the water level of the water reser-
voir tanks, and by varying the speed of the pumps the cor-
rect level will be maintained.
The project has some challenging aspects. One is that the
pumping stations are located in remote areas of the Sahara
Desert in very harsh site conditions. The Sahara is huge
covering some 3.47 million sq.mi. (9 million km
2
), the area
almost equal to China or Canada, and extending 3728 mi.
(6000 km) east to west and 1243 mi. (2000 km) north to
south. It includes sand, rocks, mountains and more sand. I
IThe pipeline will extend 456 mi. (740 km)
from In Salah at an elevation of 1444 ft.
(440 m) to Tamanrasset at an elevation of
4593 ft. (1400 m) above sea level. The wa-
ter conduit will consist of two 31.5 in. (80
cm) parallel pipes, and the total design ca-
pacity of the supply system is 3.5 MMcfd
(100,000 m
3
/day). The supply system starts
from the water aquifer north of In Salah,
where the groundwater is gathered up from several wells, to flow lines
down to the reservoirs of the first pump station (SP1).
CT216.qxp 3/23/09 10:23 AM Page 2
As 2009 unfolds, the realities of the
global economic slowdowns effect on
the oil and gas industry in Western
Canada are becoming more pro-
found. The Petroleum Services
Association of Canada (PSAC)
recently revisited its 2009
drilling forecast and arrived at a
startling realization drilling
activity in Western Canada will
most likely be at its lowest point
in 10 years. This year the pre-
dicted number of wells drilled in
Canada will drop by 21% to
13,500 (see Table 1) because of
low commodity prices.
Alberta
Alberta, where the bulk of
Canadas oil and gas is pro-
duced, will feel the most im-
pact with drilling activity ex-
pected to drop by 28.6% to
8455 wells its lowest total
since 1998. Some industry an-
alysts predict that the PSAC
forecast may be on the high
side, particularly in light of
the 12-month natural gas strip
price currently being around
US$5.00 per MMbtu. Some
also forecast that when the
winter heating season winds
down, gas prices could fall
even more and further
curtail drilling. Drilling
rigs in Western Canada
are currently operating at
about 50% capacity.
The other bellwether
indicator for oil and gas
activity is land sales. The
sale of conventional oil
and gas drilling rights in
Alberta is off to its slowest
start since at least 1996
(the earliest year Alberta
Energy has statistics on its
website). At a recent land
sale, Alberta received
CAD$8.4 million for an
average price of $42.59
per acre ($105.24 per
hectare) both record lows.
Land sale activity in Alberta is
expected to remain low for
most of 2009.
On March 3, 2009, the Gov-
ernment of Alberta announced
a new three-point incentive
plan to help keep the energy
sector active while the current
economic slowdown contin-
ues. The stimulus plan is ex-
pected to cost the province
about CAD$1.5 billion in roy-
alty payments over the life of
the plan. The three programs
are the Drilling Royalty
Credit, the New Well In-
centive Program and the
Orphan Well Fund.
Drilling Royalty Credit
The Drilling Royalty Credit
is a one-year program that
applies to new conven-
tional oil and natural gas
wells drilled between April
1, 2009, and March 31, 2010. It pro-
vides a CAD$61-per-foot-drilled ($200-
per-meter-drilled) royalty credit on a
sliding scale and uses the companys
2008 level of production as its base.
(see Table 2).
The amount of the credit is deter-
mined by the depth of the wells
drilled, with the highest benefit going
to companies with the smallest pro-
duction rates in the previous year. For
example, the total value of available
credits would be based on a com-
panys cumulative measured depth of
new drilling in the fiscal 2009-10 pe-
riod. If the company produced an av-
erage of 8000 BOE/day in 2008, then
it would receive a credit of up to 50%
of the total royalties it owed in 2009-
10. The program is intended to maxi-
mize the benefits of small to midsized
producers and free up capital for all
producing companies.
New Well Incentive Program
The New Well Incentive Program is
STIMULATING CANADAS ENERGY SECTOR
Provincial Governments in Western Canada Announce
Stimulus Programs to Offset Drilling Slowdown
By Neil Purslow
Two
2008 Production Levels Maximum Credit as a Percentage
(BOE/day)* of Royalties Owed for Fiscal Year 2009-10
Less than 10,000 50%
10,001 to 15,000 40%
15,001 to 20,000 30%
20,001 to 25,000 20%
Greater than 25,000 10%
* BOE (barrels of oil equivalent) is a measurement used by industry that is based on the amount of energy con-
tained in a barrel of crude oil.
Table 2. Sliding Scale Table.
Province 2009 2008 Percentage
(Wells) (Wells) Change
Alberta 8455 11,844 (28.6%)
British Columbia 905 844 7.2%
Saskatchewan 3805 3986 (4.5%)
Manitoba 250 287 (12.9%)
Other Provinces 85 82 3.7%
Canada 13,500 17,043 (20.8%)
2009 revised drilling forecast based on crude oil prices of US$50.00 per barrel and natural gas prices of US$5.50
per thousand cubic feet.
Table 1. Wells drilled in 2009 versus 2008.
CT217.qxp 3/23/09 10:27 AM Page 1
a one-year program that offers a
maximum royalty rate of 5% for the
first year of oil and gas production
from new conventional wells com-
mencing production between April 1,
2009, and March 31, 2010. The 5%
rate applies to the first 12 months of
production, up to a maximum of
50,000 bbl for oil and 500 MMscf
(14.2 x 10
6
m
3
) for natural gas. As an
example, a well commencing pro-
duction on Aug. 15, 2009, would be
eligible for the reduced royalty rate
through to Aug. 15, 2010, or until its
production cap is reached. The pro-
gram is intended to free up cash
flow, which will in turn provide pro-
ducers with capital to reinvest in the
oil and gas industry in Alberta.
Orphan Well Fund
When an oil or gas well has no
party legally responsible or financially
able to handle its abandonment and
reclamation, it is called an orphan.
To encourage the clean-up of inactive
wells, an Orphan Well Fund was de-
veloped as part of the stimulus plan.
The province is providing CAD$30 mil-
lion to the Orphan Well Association,
whose purpose is to manage aban-
donment and reclamation projects for
orphaned sites. The Association will
focus on high-priority and very old
sites, and on the final reclamation of
abandoned locations all of which
pre-date the creation of the Orphan
Well Association and the establish-
ment of modern industry practices
and regulatory standards regarding
well abandonments. There are esti-
mated to be more than 600 sites that
are orphans. The purpose of this fund
is to reduce the environmental foot-
print of the energy sector by returning
well sites to their former states, while
at the same time keeping the service
industry busy.
British Columbia
The one bright spot on the drilling
scene is British Columbia (BC), where
PSAC forecasts a 7% increase in drilling
to a total of 905 wells this year. This is
largely the result of shale gas opportu-
nities in the provinces northeastern
fields, which have attracted numerous
producing companies to the area. That
attraction was evident in 2008 when
BC raised CAD$2.66 billion in land
sales, in contrast to Alberta and
Saskatchewan at CAD$937 million and
CAD$1.12 billion, respectively. But
even the hot spots Montney and
Horn River plays are cooling these
days because of capital limitations and
access problems in the areas.
To ensure the province remains
competitive and drilling activity con-
ti nues, the BC government an-
nounced changes to its Deep Royalty
Program on Feb. 3, 2009. First, it relo-
cated the east/west line to reflect up-
dated geol ogi cal , reservoi r and
drilling data. The east/west line di-
vides the province into two regions
based on the cost of drilling in each
region. Wells drilled on the west side
(less access to infrastructure and
more complex geology) are awarded
a higher royalty credit than wells on
the east side.
Next, the horizontal length factor
for deep horizontal wells was recalcu-
lated. The factor determines the al-
lowable horizontal well depth that is
used to calculate royalty credits. The
factor was changed to recognize the
increased technical challenges and
higher costs associated with drilling
horizontal wells in BC.
And lastly, well qualification criteria
were changed for horizontal and ver-
tical wells. The top of pay rule was
replaced with a measured depth to
the completion point concept, which
reduces uncertainty in depth calcula-
tions. The new concept measures
depth along the wellbore from the in-
tersection with the completion point
to the kelly bushing used when the
well was drilled.
In addition to the deep royalty
changes, the BC government has im-
plemented infrastructure and road-
building programs that reflect the chal-
lenges of developing high-cost
resources in remote areas. Royalty
breaks for 2009 total CAD$120 million.
Saskatchewan
Saskatchewan, which saw an in-
crease in activity with the Bakken oil
play and heavy oil regions in 2008,
will see drilling fall by about 5% to
3805 wells in 2009. Although these ar-
eas remain active, they have recently
cooled somewhat because of low
commodity prices and infrastructure
limitations. The Saskatchewan govern-
ment does not plan to make royalty
changes at this time because it feels
its present structure is well suited for
developing energy plays now and
into the future.
Conclusion
Prices for oil and gas have crashed
by about 70% from record highs in
2008. This has led to billions of dollars
in spending cuts by producers, as they
try to match their spending levels with
the dramatic deterioration of cash flow.
At this point, low commodity prices
appear to be the main deterrent to
drilling, rather than provincial con-
straints. The various provincial govern-
ments in Western Canada recognize
that the industry is facing a tight-
money situation, and it is doing its part
by reducing royalty payments to stimu-
late activity within its jurisdictions. n
APRIL 2009 37
HOSS Gas Field Compressor.
When it comes to gathering, storing,
processing, or transporting large
volumes of gas (including CO
2
),
you need the muscle to handle the job.
The Dresser-Rand HOSS or SuperHOS
compressor is bigyet can still be
conventionally packaged. Its engineered
to be strongfor applications up to
8,700 horsepower (6,488 kW) at 1,200
rpm, and its an excellent match with
todays high horsepower gas engine
drivers...not to mention that it can be
delivered fastleaving others in the dust.
The Americas: (Intl +1) 713-354-6100
ESA: (Intl +33) 2-35-25-5225
Asia-Pacic: (Intl +60) 3-2093-6633
info@dresser-rand.com
www.dresser-rand.com
SEE DIRECTLINK AT
CT217.qxp 3/23/09 10:29 AM Page 2
The P-51, the first semi-submersible platform built en-
tirely in Brazil, went on-stream, beginning the production
of well MLS-99, in the Marlim Sul field in the Campos
Basin. Installed at a water depth of 4117 ft. (1255 m) and
93 mi. (150 km) off the coast of Maca, the new unit is ca-
pable of producing up to 180,000 barrels of oil per day
and is considered strategic for the maintenance of Brazils
oil self-sufficiency.
The new platform is part of the Brazilian Federal
Governments Growth Acceleration Program (GAP) and
generated 4000 direct and 12,000 indirect jobs during its
construction. The total investment made in this production
unit neared US$1 billion. The FSTP (Keepel Fells Technip)
consortium, Nuovo Pignone (gas compression module),
Rolls-Royce (power generation module), and Nuclep (hull)
were in charge of construction.
The P-51 is capable of compressing 211 MMscfd (6 x 10
6
m
3
/d) of gas. This production is part of the Natural Gas
Production Anticipation Plan (Plangs), created to reduce
Brazils foreign dependence on this fuel. Its four turbines
are able to generate 100 MW of energy, enough to supply a
city of 300,000 inhabitants.
The new unit will be interconnected to 19 wells (10 oil
and gas producers and nine water injectors, and to 85
pipelines, which together add up to 208 mi. [335 km]).
Measuring 410 ft. (125 m) in length, 360 ft. (110 m) wide,
and weighing a total of 48,000 tons (43,544 tonnes), the P-
51 will lodge up to 200 people.
The platform is one of four expected to enter production
in coming months. The Cidade de Niteroi floating produc-
tion, storage and offloading vessel, or FPSO, will produce
at the Marlim Leste field.
In the Espirito Santo Basin, Petrobras expects to install
the FPSO Cidade de Sao Mateus. The FPSO BW Peace
was scheduled to start pilot production at the deepwater
subsalt Tupi field in the Santos Basin in March. n
THE P-51 GOES ON-STREAM
IN THE CAMPOS BASIN
The P-51 is Capable of Compressing
211 MMscf (6 x 10
6
m
3
) of Gas
Two
From major equipment
overhauls to minor
inspections, the Exline
Field Services Division
offers comprehensive
on-site maintenance
and service to keep
your machines rolling.
We specialize in reciprocating
engines, compressors, generators,
rotating equipment, and other industrial
equipment.
CALL ON EXLINE
2006I Exline, Inc. EXLI-2033
Call 800-255-0111 Fax 785-826-4425
Visit our website at www.exline-inc.com
3256 East Country Club Road, P.O. Box 1487
Salina, Kansas 67402-1487 E-mail: salesandservice@exline-inc.com
Your Single-Source
Field Services Solution
FOR ALL YOUR
MAINTENANCE NEEDS
CT214.qxp 3/25/09 10:16 AM Page 1
Dynalco has introduced a new SWT
series of speed switches for the moni-
toring and protection of rotating and
reciprocating machinery. The SWT se-
ries of speed switches are DIN rail
mountable for easy installation and are
fully isolated for compatibility with ex-
isting systems, the company said.
The SWT-2000, a Two-Channel
Speed Switch/Transmitter, contains
two isolated speed switches in one
package. The SWT-2000 is able to
monitor and protect two separate ma-
chines or processes simultaneously,
with separate 4 to 20 mA proportional
outputs. It also contains four relay set-
points and two open collector outputs
with a variety of configuration op-
tions. Applications would include dual
turbocharger protection and redun-
dant protection for critical operations.
Programming is done via an Ethernet
connection.
The SWT-1000 Speed Swi t ch/
Transmitter has a single relay set-
point for overspeed protection and
provides 4 to 20 mA isolated output.
Thi s product i s confi gurabl e vi a
Windows software.
The SWTD-1000 Speed Switch/
Transmitter has the same functionality
as the SWT-1000 and includes an inte-
grated backlit display. This product is
software programmable and utilizes a
1/8 DIN package for easy installation.
The SW-100 is a DIN rail mountable
speed switch that uses a single set-
point for over/underspeed protection.
According to the company, the SW-
100 is simple to configure with no test
equipment or computer needed.
Dynalco, a Crane company, pro-
vides intrinsically safe instruments,
sensors, controls and gauges, portable
analyzers, intelligent real-time predic-
tive analysis systems, asset manage-
ment software and comprehensive
services for the oil and gas produc-
tion, natural gas pipeline, marine,
power generation and processing in-
dustry. The SWT series enhances the
current Dynalco line of speed
switches and transmitters, allowing a
wide range of solutions for machine
monitoring and protection, the com-
pany said. I
SEE DIRECTLINK AT
NEW SWT SERIES OF SPEED
SWITCHES FROM DYNALCO
Designed to Monitor and Protect Rotating
and Reciprocating Machinery
I The SWT-1000 Speed Switch/
Transmitter has a single relay set-
point for overspeed protection and
provides 4 to 20 mA isolated output.
APRIL 2009 39
THE
PERFECT
FIT FOR
PARTS.
Expertise. Properly designed
parts maximize the performance
of your rotating equipment. At
Dresser-Rand, we have extensive
knowledge about parts materials,
dimensions, surface nishes,
and coatings. And we use that
knowledge to manufacture parts
that will help keep your equipment
running longer and more reliably.
So dont settle for generic parts.
Protect your equipment investment
with genuine Dresser-Rand
brand parts.
www.dresser-rand.com
The Americas: (Intl +1) 713-354-6100
ESA: (Intl +33) 2-35-25-5225
Asia-Pacic: (Intl +60) 3-2093-6633
info@dresser-rand.com
SEE DIRECTLINK AT
CT211.qxp 3/24/09 10:18 AM Page 1
The recent economic downturn has
had many far-reaching effects. One
casualty of the slowdown has been
commodity prices, including crude oil
and natural gas, which are now at lev-
els that have not been seen in almost
a decade. These low prices have
caused a significant decrease in ex-
ploration and drilling activity in
Canada, with energy companies
choosing instead to concentrate on
their producing assets. Working with
existing assets has created some
bright spots. Stealth Acoustical &
Emission Control Inc. (Stealth) of
Calgary, Alberta, Canada, is one.
Stealth designs, manufactures, as-
sembles and installs advanced and
complete noise abatement and emis-
sion reduction products on new and
existing equipment and facilities. The
company uses the most advanced ma-
terials available to create modular de-
signs for quick on-site installation. Ease
of construction results in minimal or
no operational downtime, while pro-
viding excellent performance.
Colin Davison, president of Stealth,
said that he started the company in
2006 with one employee in his base-
ment. Stealths staff has since grown to
65 at the end of 2008. We attribute
our success to delivering excellent
technical advice and high-quality tech-
nology, all of which are used to ensure
the reduction of customers noise and
emission concerns. We guarantee our
products and services and their out-
come and never leave a site until
the noise and/or emission levels that
were promised have been achieved.
We plan on growing to 100 employees
by the end of January 2009.
Stealths acoustical products include
fan silencers, ventilation packages, ex-
haust systems and enclosures/building
packages that are used to encapsulate
noise-generating equipment. Acoustical
products are generally mobile and are
reuseable on other applications.
Emission control products include cat-
alytic silencers and converters, diesel
particulate filters, air-fuel ratio con-
trols, oxygen sensors and other equip-
ment components. Davison said that
their line of emission control products
is one of the most advanced and com-
plete in the industry.
A variety of materials are used in
the manufacturing process to create
Stealths products. Carbon steel, core
ten, metalized coatings, aluminum or
stainless steel, powder coatings and
high-heat paint are some of the mate-
rials used. The type of material and
the configuration of each product de-
pend on the requirements of the ap-
plication where they will be used.
We have developed a range of stan-
dard products that are customized to
each project, said Davison.
The company employs a dedicated
engineering group that is uniquely
qualified in acoustical and emission
technology. Solutions to resolve noise
on a package often require a tremen-
dous amount of engineering and prac-
tical expertise. If it is not designed
right, fixing one item often leads to
other problems, said Davison. Stealth
creates designs that minimize or elimi-
WHEN OPERATING EQUIPMENT HAS TO MEET
NOISE ABATEMENT AND EMISSION STANDARDS
Stealth Acoustical and Emission Control Provides Expertise and Manufactures
High-Quality Products that are Guaranteed to Meet Legislative Requirements
By Neil Purslow
I This is one of three electrical MCC houses being packaged for Suncors Stage 3 Firebag Oilsands Mine project located near Fort McMurray,
Alberta, Canada. The building contains electronic equipment that will be used to control the power generation equipment located on-site. The
building will be split into four separate components for shipping, and then be reassembled on-site.
Two
CT208.qxp 3/24/09 9:54 AM Page 1
nate critical low-fre-
quency and shell
noise, and can be
easily integrated with
operational equip-
ment. All products
are manufactured for
extended life and are
available with quick
lead times.
A large portion of
Stealth s noise and
emission projects in-
volve gas compres-
sion and power gen-
eration. In most
cases, projects begin
with a site-specific
analysis to measure
the current sound
and/or emission lev-
els. Then the levels
required by the client
are determined. The
analysis may be theo-
retical, such as when
a new package is being designed; or
actual, using existing on-site facilities
both before and after the new equip-
ment is installed. For example, when
performing an acoustical study on a
gas compression package, the radiated
noise from each piece of equipment
must be measured. From that data,
Stealth determines the best way to re-
duce the specific sound frequencies.
Depending upon the application, it
may be best to use baffles, or to put
the sound through the walls and have
it travel down to the bottom of the
skid and into the ground. The process
becomes more difficult when more
than one equipment item is operating
simultaneously in a facility.
Most of the analysis re-
ports for gas compres-
sion packages deter-
mine that the exhaust
silencers are too loud
and the ventilation sys-
tems are inadequate.
When Stealth develops
a plan for silencing a
package, the company
considers a number of
factors in the design.
For instance, Stealth
designs ventilation sys-
tems in packages to
operate year round
with the doors and
windows closed. This
is important because if
compressor packages
have to operate with
their doors and win-
dows open during
warm weather,
landowners are an-
noyed by the noise be-
cause they too have their doors and
windows open.
One area that requires significant
engineering is noise abatement for
large cooling fans. Air movement is
critical, so when designing a silencer
to quiet an aerial fan, backpressure
must not be allowed to develop since
I The manufacturing facilities in Calgary, Alberta, are divided into two buildings.
Activities that generate airborne particles, such as cutting, welding and grinding, are lo-
cated in the first building. In the second building, final assembly of products and skids is
performed. Stealth fabricates complete power generation packages using a variety of on-
staff trades, including electricians, welders and sheet metal workers.
Turbine Fuel Gas Conditioning & Filtration
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All equipment manufactured in-house
including heater, controls, vessel, and skid
Extensive fuel gas conditioning expertise
ASME Section VIII, Div. 1
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ElectroClean
CT208.qxp 3/23/09 12:00 PM Page 2
most fans cannot operate with much,
if any, backpressure. Along with air
movement, consideration for sound
dampening includes such factors as
the type of perforation, thickness of
the materials, distance between the
baffles and type of insulation. Often
the result is very large silencers using
special designs and materials. A re-
cently completed project included the
manufacture of a 25 ft. wide x 40 ft.
long x 20 ft. high (7.6 x 12.2 x 6.1 m)
silencer containing baffles and perfo-
rated liner. The silencer was a single
unit that fit over the cooler and was
lifted into place. The air and noise ex-
its the top of the unit.
Producers are beginning to realize
the benefits of putting sound attenua-
tion into their packages when they are
fabricated, stated Davison. A retrofit
costs about 10 times more than
putting the abatement equipment in
place initially. For the same cost as a
single retrofit, producers can install 10
quiet packages and drastically reduce
landowner concerns about noise. In
many cases, we install silencing equip-
ment that far exceeds current regula-
tions. Many believe that since the rules
are continually evolving and getting
tighter all the time, better sound atten-
uation now will significantly save high
retrofit costs later. As an added bonus,
installing sound components during
fabrication eliminates the need to in-
stall oversized equipment that runs
slower to reduce noise.
Stealth works with all major gas
compression packagers to create stan-
dard and acoustic buildings and prod-
ucts that are offered to the packagers
clients. The companys standard build-
ings that do not include acoustics, con-
tain design elements that allow
acoustics to be inexpensively added
later if noise issues arise. We have no
intention of entering the fabrication
business for gas compression, said
Davison. We leave that to the folks
that know how to do that best. We as-
sist them by providing expertise and
high-quality acoustic technology that
works well on their packages its
what we know best.
In power generation, activities
range from designing, manufacturing
and installing sound attenuation and
emission control equipment to fabri-
cating complete power generation
packages. Approximately 35% of the
companys work activity for power
generation is for prime power and
65% is for standby. Packages can in-
clude walk-in, skin-tight or drop-over
enclosures that are acoustic or non-
acoustic, and contain internal UL/ULC
fuel tanks. All packages and retrofit
work meet exacting quality standards.
The company stated that the exper-
tise they have developed with gas
compression and power generation
benefits each other. For power gener-
ation, Stealth designs packages that
are useable and maintainable by oper-
ators and maintenance staff because
of what they learned from gas com-
pression packages. And for gas com-
pression, sound attenuation concepts
and materials, such as using higher
gauges of steel that are typical in
power generation units, have been
employed to create very quiet com-
pressor packages.
Power generation packages are fab-
ricated for various types of facilities,
including hospitals, schools, airports
and telecommunication data centers.
Since many are placed in highly pop-
ulated areas, noise requirements are
very stringent. In one instance, a
standby power generation unit for a
data center was only allowed to pro-
duce 60 dBA at 7 ft. (2.1 m). The
completed unit was placed on the
roof of a high-rise office building in a
major city. For existing standby units,
drop-over enclosures with or without
acoustics are often provided.
Oilfield facilities are a growing
market for power generation, said
Dennis Seitz, U.S. operations man-
ager for St eal t h. Our Denver
[Colorado, U.S.A.] operation is cur-
rently seeing significant growth in
demand for prime power units in
Colorado, Utah, New Mexico and
Wyoming. The company manufac-
tures single power generation skids
up t o mul t i pl e uni t s i n a si ngl e
building. Buildings range from skin-
tight, to 20 x 40 ft. (6.1 x 12.2 m)
walk-around skidded enclosures, to
rigid-frame buildings that house four
or more 2000 hp (1490 kW) engine/
generator combinations.
Engineering services also include
assisting clients in analyzing facilities
and developing proper sound and
emission recommendations. Specific
resolutions may include replacing the
exhaust silencer, eliminating air flow
restrictions or adjusting the speed of
the fan. A report is prepared detailing
the specific outcomes that will be
achieved if the recommendations are
followed. For large projects, changes
are often staged with the results re-
viewed at the completion of each
stage. All results outlined in the report
are guaranteed by Stealth.
For some applications, package
design, faulty equipment or poor
foundations may be the cause of vi-
bration not low-frequency noise.
When thi s occurs, Steal th works
closely with the client to analyze the
package to arrive at an optimum so-
lution. On one particular coalbed
methane (CBM) project, it was deter-
mined that the skid on the package
had been designed and built with
too much vibration in it. To solve
the problem, a very rigid second
skid was built and the existing skid
was mounted onto the new skid us-
ing vibration isolators. Since then,
solving vibration in small horse-
power gas compression and power
Two
IThis sea-can container will
house power generation
equipment when it is fin-
ished. The container will be
deployed in the Caspian Sea.
CT208.qxp 3/23/09 12:01 PM Page 3
generation skids used in CBM has
become somewhat of a niche market
for Stealth, said Davison.
Stealth also assembles electrical sys-
tems. These systems can include
portable buildings, which contain
electronic and electrical components
used to control plant equipment and
facilities. In one key project, Stealth
was contracted by Siemens and
Suncor to package three electrical
MCC houses for Suncor s Stage 3
Firebag Oilsands Mine project located
near Fort McMurray, Alberta. Because
of the size of the houses, they must
be split into four separate compo-
nents for shipment to northern
Alberta, and then be reassembled on-
site. In addition, Stealth provided
heat, lights, platforms and steps for all
the houses.
Stealth also supplies a variety of
other products, such as roof-mounted
hoods and vents, power generation
units built in sea-can containers, and
individualized engine enclosures. In
one plant where an acoustic building
had not been installed, a sound enclo-
sure was installed around the com-
pressor inside the building. Re-
quirements for the enclosure included
maintaining air movement and provid-
ing adequate access for operating and
maintaining the equipment. The com-
pany has also created soundproof
rooms in noisy plants. It is sometimes
easier and less expensive to sound-
proof an existing control room in a fa-
cility than silence the equipment.
Stealth currently has three manufac-
turing plants that fabricate the com-
panys products. The main facility, lo-
cated in Calgary, has 42,000 sq.ft.
(3900 m
2
) of office and shop space.
The Winnipeg, Manitoba, Canada,
plant has 6000 sq.ft. (560 m
2
) and the
Denver plant has 32,000 sq.ft. (2975
m
2
). Each facility contains the neces-
sary overhead lifting capacity and ac-
cess doors to accommodate the fabri-
cation of most packages. The Denver
site also provides complete engineer-
ing services and on-site administration
for its clients.
An internally developed QC pro-
gram is rigorously followed in all ar-
eas of the company, with each power
generation unit undergoing a thor-
ough physical evaluation for noise be-
fore shipment. Noise levels must be
proven before a unit is allowed to
leave the yard. Since a large number
of the power generation units are sold
to Caterpillar, Cummins, Siemens and
Waterous for resale to their customers,
Stealth endeavors to ensure units are
as close to perfect as possible. The
same quality concepts are applied to
all products manufactured by Stealth,
including gas compression.
Researching new materials and
processes to improve sound attenua-
tion and emission control is an ongo-
ing process at Stealth. For instance
with sound, Stealth is continually
evaluating different baffles and mate-
rials; employing a variety of metals
and thicknesses in walls; using differ-
ent combinations of metals, vinyl and
insulation; and trying a range of sizes
and shapes of perforation holes.
Positive results are filed for future use
when subsequent and unusual proj-
ects require new ideas.
Our sales continue to grow in
North America, as well as internation-
ally with recent shipments to Russia,
Peru and other South American loca-
tions, said Davison. But a portion of
our growth must be attributed to the
new regulations regarding acoustic
and emission control. These standards
are continually being refined and are
becoming more stringent, especially
as equipment is located closer to
people. The interesting thing about
the standards is that they are inde-
pendent of commodity prices for
crude oil and natural gas. If existing
equipment is to continue to operate,
i t must meet the new standards.
Achieving this is keeping us very
busy 12 months a year. I
SEE DIRECTLINK AT
CT208.qxp 3/23/09 12:01 PM Page 4
Offshore Challenge
Visit www.compressortech2.com for answers.
Two
BUSINESS GLOBALARITY
Agent
Agreement
Barriers
Bill of Lading
Border
BRIC
CE
Certification
Commerce
Communication
Concession
Consul
Contract
Coordinate
Courtesy
CSA
Customs
Declaration
Destination
Development
Diplomacy
Documentation
Duty
Emigrate
European Union
Exchange Rate
Export
Fair Trade
Fee
Flexibility
Forwarder
Freight
Geopolitics
G Three
Guarantee
Immigrate
Inspection
Insurance
Intermodal
International
Intervention
ISO
Labor
Letter of credit
Localization
Logistics
Longitude
Mercosur
Negotiations
NEMA
Partner
Permit
Pragmatism
Premier
Protectionism
Quota
Regulations
Requirements
Rules
Standards
Teleconference
Translation
Transparency
Travel
Treaty
Visa
AprilPuzzle.qxp 3/24/09 8:47 AM Page 1
Donaldson Co.
Donaldson Co. has recognized Phillip
Johnson, director, Liquid Filtration, new
business development, for his work on
Fuel Filtration Reality Check, a study
that predicts by 2010 diesel injection sys-
tems will require much higher efficiency
filtration and will need to be significantly
cleaner than the technology today.
Johnson presented his study at the 9
th
International Filtration Conference hosted
by Southwest Research Institute and was
awarded the Peter Herman Award for
outstanding technical presentation.
CECO Pipeline Services
David G. Nolan has been named to
the business development team at CECO
Pipeline Services. Nolan will work with
customers in project management, safety
supervision and refining policies and pro-
cedures. He has more than 32 years ex-
perience in the industry, most recently at
Truckline Gas Co., where he worked in
project management, estimating and bud-
get. For his new role, he will be based
near Alexandria, Louisiana, U.S.A.
JAG flocomponents
JAG fl ocomponent s USA Inc. has
added Rick Doughten as product man-
ager and John Stuart as operations
manager. Doughten, with more than 30
years of experience, will provide tech-
nical support to the sales team in addi-
tion to working with customer audit
teams for the companys quality assur-
ance programs. Stuart, in his new role,
will work to enhance sales processes
and inventory management following
more than 20 years of experience with
valve companies.
Cook Compression
Steve Newton has j oi ned Cook
Compression as regional manager for
the Middle East. He will be based in
Bahrain. Newton graduated in 1976
from West Wyt henshawe Techni cal
Col l ege, where he obt ai ned hi s
ONC/HNC in Mechanical Engineering.
He worked for Ingersoll-Rand/Dresser-
Rand in the U.K. and France for over 25
years, including six years in the Middle
East as area sales manager. During his
career, Newton has served in after-
market sales, quality control, machine
t ool s, fi el d servi ce, busi ness de-
velopment and product services.
GE Oil & Gas
GE Oil & Gas has moved into its new
office building in Houston, Texas, U.S.A.
The new GE Oil & Gas building is the
first site to house all GE Oil & Gas busi-
nesses at one location, since the acquisi-
tion of PII Pipeline Solutions in 2002,
VetcoGray in 2007 and Hydril Pressure
Control in 2008. The move signifies a sig-
nificant step in GE Oil & Gas commit-
ment to long-term growth in the oil and
gas industry.
Almost 500 employees from sales, en-
gineering, commercial operations and
other supporting functions have co-
located to the new office building. This
regional headquarters will support all
segments of the oil and gas industry
from drilling and completion to produc-
tion, LNG, pipeline, refining and petro-
chemicals. In addition to the new office
building, GE Oil & Gas also has three
manufacturing plants and two service
centers in the Houston area. In total, GE
Oil & Gas employs more than 2000 peo-
ple in the Houston area.
Building facilities include an audito-
rium, training and meeting rooms, caf
and a TelePresence room that uses the
latest technology to enable virtual meet-
ings around the globe.
Two
Industry News COMPRESSORTech
Two

IndustryNewss045.qxp 3/24/09 8:52 AM Page 1
DCP Midstream has five Fairbanks
Morse MEP 6G engines at their
Giddings Gas Plant in LaGrange,
Texas, U.S.A. They were acquired in
2000 and were in use until 2005, but
had been idle until, in 2008, DCP des-
ignated the first of these power plants
for use in a dual-purpose separable
package powering a four-throw, two-
stage Ingersoll Rand reciprocating
compressor, providing both inlet and
residue service.
Originally manufactured as diesel
submarine engines in the 1940s or
50s, the natural gas-fueled, spark-
ignited engines were converted from
Fairbanks Morse naturally aspirated
model 38 D 8 1/8 opposed piston,
two-cycle engines with an output of
1350 hp (1.01 MW) at 900 rpm. Their
cylinder bore is 8.125 in. (20.6 cm),
with a 10 in. (25.4 cm) stroke.
The Ingersoll Rand compressors are
four-throw, two-stage units, with two
9.5 in. (24.1 cm) cylinders for the first
stage and two 6 in. (15.2 cm) cylin-
ders for the second stage. Stroke is
5.5 in. (14 cm) and rated 1000 rpm. In
this application, compressor suction is
235 psi (16.2 bar) for residue service
and 295 psi (20.3 bar) for inlet service
with discharge typically around 950
psi (65.5 bar).
At the time, DCP was operating two
turbines with a combined throughput
capacity of 100 MMcfd (2.83 x 10
6
m
3
/d) of natural gas. That capability
exceeded demand, so DCP decided to
use the MEP in conjunction with one
of the turbines. The turbine/MEP
combination can provide throughput
of 62 MMcfd (1.76 x 10
6
m
3
/d) and re-
sults in increased efficiency. It also al-
lows for a significant reduction in fuel
gas. Finally, shutting down one of the
turbines cut turbine maintenance costs
in half.
The lean-burn, two-cycle MEP en-
gines have a reputation of being noto-
riously difficult to start, run and main-
tain, largely because they use
old-style pneumatic controls and in-
corporate various potentially trouble-
some components such as O-rings,
sending pistons and volume pots.
Tony Henny, branch manager for
Ignition Systems and Controls (ISC),
Katy, Texas, U.S.A., proposed a custom
electronic control solution using what
amounted to off-the-shelf compo-
nents manufactured by Altronic Inc. of
Girard, Ohio, U.S.A. His plan would al-
low the engine to be controlled with-
out the need for a dedicated PLC and
the costly programming inherent to it.
Included in the first-of-its-kind pack-
age from ISC are an Altronic CPU-95
Advanced Digital Ignition System, an
Altronic GOV10 Gas Engine Governor,
an Altronic EPC-200 Engine Perform-
ance Controller, an Altronic DE-3000
Configurable Safety Shutdown and
Control System, and the Altronic
EZRail Modular Ignition Rail System.
The engine was already equipped with
an Altronic ETS Digital Temperature
Scanner, which remained in place.
The MEP refit project was under-
taken as a collaborative effort between
ISC and DCP. DCP relied heavily on the
expertise of Henny to directly program
the DE-3000 and coordinate it with the
other controls and the mechanical ex-
perience of their own team, which in-
cluded Donnie Wesneski, equipment
analyst/mechanical support, DCP
Austin Gathering, and Bobby Jarrett,
maintenance supervisor, DCP Mid-
stream Central Texas Asset, to imple-
ment the rebuild. Eventually, 75% of all
pneumatic tubing will be replaced,
along with most of the high-mainte-
nance mechanical components, includ-
ing the original governor and linkage.
According to Wesneski, a local MEP
expert was openly skeptical of the
planned approach. In that experts
opinion, the Altronic control package
would not be able to start let alone
CUSTOM CONTROL INSTALLATION FOR GAS PLANT
ISC and Altronic Develop Entire System for DCP Midstream
Using Off-the-Shelf Components
n DCP Midstream has five Fairbanks
Morse MEP-6G engines at its Giddings
facility in Fayette County, Texas, U.S.A.
Two
CT221.qxp 3/24/09 11:46 AM Page 1
run the cantankerous engine. In the end, however, all
such doubts were erased when the old engine sprang to life
without hesitation at the touch of a button on the DE-3000.
That same expert now admits that the MEP runs as well as it
possibly can. Emissions control, provided by the Altronic
EPC-200, was well below permit level on the initial start-up.
When the engine was restarted in a cold weather test at
about freezing, it again responded immediately.
According to Altronic, the DE-3000 Configurable Safety
Shutdown and Control System utilizes advanced microcon-
trollers and surface-mount PCB assembly technology to
provide a sophisticated, yet reliable, means of protecting
and controlling both the MEP and the compressor. The DE-
3000 offers a number of digital and analog outputs, as well
as 60 inputs that can be individually configured for use
with switch contacts, thermocouples or analog transducers.
The company explained that a single DE-3000 can control
all of DCPs MEP units, thus simplifying maintenance and
part stocking requirements, as well as system training re-
quirements for operating personnel. USB-based connectivity
to the device and a Windows-based terminal program for
system configuration eliminated the need for any knowl-
edge of ladder logic or other functional programming lan-
guages. ModBus-RTU communications are fully supported
for remote monitoring and/or control applications.
The Altronic CPU-95 Digital Ignition System is 24 Vdc
powered and microprocessor based. It includes a full-
featured user display and interface, spark characteristic con-
trol, advanced timing adjustment options, serial communica-
tions and diagnostics. Operating data and control functional-
ity are available through a user-friendly display module or
via a PC. The CPU-95 displays rpm, timing angle, spark en-
ergy level and diagnostic messages, along with global and
individual cylinder timing adjustments, spark energy level
control, overspeed setpoint and double strike/extended
spark (VariSpark variant) selectability.
Altronic also indicated that the Enhanced Display Module
also features extensive spark reference number graphing and
trending. Patented CPU-95 diagnostics and prognostics (pre-
dictive diagnostics) supervise all ignition system-related func-
tions. The secondary analysis capabilities detect shorted spark
plugs and leads, as well as spark plugs that exhibit high volt-
age demand or are not firing at all. A display of the relative
voltage demand of each spark plug is provided, allowing
spark plug changes to be predicted and scheduled. Module
and pickup operation, timing input and primary output func-
tions are also monitored for operation within preset limits.
Using its standard Terminal Program and the Enhanced
CPU-95 Display Module, Altronic said that DCP has the added
Two
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n This idle MEP-6G engine was pneumatically controlled at the begin-
ning of the project described in this article.
CT221.qxp 3/24/09 11:47 AM Page 2
flexibility and convenience associated
with a USB-based connection to the
system for programming. Ignition oper-
ating parameters (firing code, number
of monitored gear teeth, 4 to 20 mA or
rpm control loop, for example) can be
downloaded from the connected
Ignition Module and retained in the
Enhanced Display Module. Should the
Ignition Module ever require replace-
ment, the Enhanced Display Module
can simply upload the correct ignition
operating parameters into the new unit
without need for a laptop, the Terminal
Program or the services of an instru-
mentation technician.
The Altronic GOV10 is both a fuel
valve and electronic governor inte-
grated into a single unit for engines
up to approximately 3500 hp (2.6
MW). The GOV completely eliminates
hydraulic governors, actuators and
linkages, and Altronic said it signifi-
cantly improves starting performance
and speed stability. The GOV can also
be ordered with a fuel flow measure-
ment option utilizing a built-in orifice
meter and built-in pressure, differen-
tial pressure and temperature sensors.
Utilizing fuel flow and fuel flow/revo-
lution values, maximum engine horse-
power and maximum engine torque
limits can be applied for improved
engine/compressor safety. Altronic
credited a sophisticated engine start-
up and governing algorithm that is
resident in the GOV10 for its ability to
operate as a stand-alone replacement
governor. All control parameter, timer
and setpoint configuration is accom-
plished through the GOV Display
Module. The complete governor sys-
tem consists of the GOV10, a speed-
sensing magnetic pickup and the
Display Module, a small computer-
based terminal that serves as a display
and configuration device.
The Altronic EPC-200C Engine
Performance Controller used in the re-
fit strategy is designed to maximize
engine performance and efficiency,
according to the company. Micro-
processor based, the EPC electroni-
cally controls ignition timing and
air/fuel ratio and replaces the pneu-
matic control system traditionally used
for these functions. Engine rpm, plus
up to four other analog inputs, can be
used as control variables. Typically,
these would include fuel manifold
pressure, air manifold pressure and air
manifold temperature.
In addition to the two analog con-
trol functions (ignition timing and
air/fuel ratio), the EPC-200C also has
six user-programmable solid-state re-
lay outputs related to common start-up
Two
n Taken during the retro-
fit, this photograph
shows the MEP-6G and
an array of Altronic elec-
tronic components in
place. When finished,
more than 75% of the
original pneumatic tubing
will have been removed.
CT221.qxp 3/24/09 11:47 AM Page 3
30+ years.
3,000+ compression units.
No wonder they call us the natural gas experts.
Sales Denver, CO 475 17th Street, Suite 1020 80202 United States | Tel: +1 303 292 2423
Fabrication Casper, WY 2289 Renauna Avenue 82601 United States | Tel: +1 307 265 4450 toromontsystems.com
sequencing functions such as purge,
overcrank, crank disconnect and
flooding. A seventh discrete output
provides a signal in the event of over-
speed, overload or loss of any input. If
this occurs, timing and air/fuel ratio
are set to preset values. In addition,
there is a manual override mode to al-
low changing and checking of pro-
gram data while the engine is running.
The EPC-200C has an RS422 interface
for communications capability with
other process or control computers.
The ETS Electronic Temperature
Scanner from Altronic is a micro-
processor-based product that displays
and processes monitored temperatures
to protect the engine. Up to 40 points
can be monitored and divided into as
many as 14 different groups and seven
outputs. For each group, there is a
choice of protection from any combi-
nation of absolute high limit, absolute
low limit and differential. All setpoint
temperatures, output logic and lockout
times are user-entered from the
sealed-membrane keyboard. The de-
vice can be used to monitor tempera-
tures from more than one engine, and
RS422 capability allows data and alarm
status to be communicated to other
computers. The displays capability in-
cludes the monitored temperature of
each point, automatic scan of all
points or of a selected output and av-
erage temperature for each group.
There is also a fault display feature
with a first-out fault display channel
and a channel showing the fault status
of all seven outputs simultaneously.
Regardless of the display mode, scan-
ning of all points continues.
Finally, Altronics EZRail Modular
Ignition Rail System is a CSA-certified,
complete wiring/mounting system
from the ignition unit to the ignition
coils that the company said eliminates
hours of wire and conduit cutting in
the field and eliminates skinned insula-
tion due to long conduit pulls. The
universal design of the EZRail takes
advantage of standard cables, wiring
rails and integral/flange or off-mounted
coils (shielded or unshielded). Bolt-on
coil mounting rails provide a robust
and reliable means of mounting igni-
tion coils without compromising the
integrity of the wiring rail or the abil-
ity of the rail to be serviced if neces-
sary. The EZRail System is flexible
and can be upgraded if coil types are
changed. Altronic pointed out that
EZRail features high-quality aluminum
extrusions, sealed junction boxes, and
military-style connectors and har-
nesses, and that all connector back
shells are potted and strain relieved.
The installation also uses standard
Altronic ignition components includ-
ing the primary and secondary cables
and leads. The EZRail system can be
easily disconnected, removed and re-
installed if necessary.
Given the success of this project,
DCP has indicated it is seriously con-
sidering similar retrofits to one or
more of the four remaining MEPs at
Giddings, as well as talking to ISC
about other units in East Texas. s
SEE DIRECTLINK AT
Two
s All components are accessible in the new
Altronic Controls panel. Here, a technician
inspects the lockout tag.
CT221.qxp 3/24/09 11:48 AM Page 4
Lubrication is the lifeblood of most
machinery, without which the machine
will most likely come to a grinding,
expensive and unscheduled halt.
Repair costs can be very high, and
costs of downtime and loss of produc-
tion can often far outweigh those just
to repair the equipment. Additional
consequences of over-lubrication, both
financial and environmental, com-
pound the importance of proper ma-
chinery lubrication.
Environmental consequences can
include fugitive emissions into the at-
mosphere as well as improper dis-
posal of excess oil. Additional finan-
cial costs include the cost of wasted
oil (which can amount to several thou-
sand dollars per year) as well as re-
moval of excessive oil from natural
gas and associated processing systems,
and the proper disposal of that oil.
Sloan Brothers Co. (SBCO) has
made lubrication systems the lifeblood
of its company by specializing exclu-
sively on critical machinery lubrication
systems, particularly for engines and
compressors, for its entire 86 years of
existence. Walter Sloan, president of
SBCO and a member of the third gen-
eration of Sloans to operate the busi-
ness, explained that numerous oppor-
tunities for diversification into other
fields have occurred over the years.
He said, however, that SBCOs deci-
sion to maintain a narrow focus on
machinery lubrication has been driven
by a desire to provide customers with
a level of lubrication system knowl-
edge and experience that is second to
none in the industry.
The original Sloan brothers (Ralph,
Paul and Walter) founded the company
in Pittsburgh, Pennsylvania, U.S.A., in
1922. Sloan Brothers at that time was
strictly a lubrication system sales com-
pany, selling systems that were manu-
factured by others. Walter explained
that over the years, and for a variety of
compelling reasons related to product
availability and quality, SBCO evolved
into a manufacturer of complete lubri-
cation systems and components. This
metamorphosis from only sales to
manufacturing as well as sales and
service, began in 1975 under the lead-
ership of the second generation of
Sloans (John and Margaret), with
Walter manufacturing their first lubrica-
tion systems in a basement workshop.
Since that initial basement work-
shop the company has found it neces-
sary to double its shop space about
every eight years, said Matt McCarthy,
sales manager for SBCO. After seven
different locations in 85 years, SBCO
moved to its current facility, which is
a modern 20,000 sq.ft. (1858 m
2
) in-
dustrial building in Freeport, Pen-
nsylvania, (about 25 mi. [ 40 km]
northeast of Pittsburgh). Walter ex-
plained that this move has provided
the floor space necessary to accom-
modate CNC machine tools (such as a
new four-axis horizontal machining
center) and other machinery and
equipment used in the high-precision
manufacture of its products.
These machines were selected
specifically for manufacturing the most
critical component of any pressurized
lubrication system the divider
block. Walter further explained that
making the high-precision, high-pres-
sure, low-volume divider block and its
components from the ground up has
laid the groundwork for the legacy of
the fourth generation of Sloan
Brothers. C.J., Eric and Brian (Walters
sons) have quite convincingly begun
to contribute to the family business.
C.J., already active in the business
for a number of years, is the inventor
of the patent-pending Sloan Brothers
visual cycle indicator and also has
been the driving force behind Sloan
Brothers venture into the manufactur-
ing of divider blocks. Eric and Brian
have more recently joined the com-
pany Eric in manufacturing and
Brian in sales and customer service.
Matt and Walter said that divider
I Walter Sloan, president of SBCO (left), is shown in the lobby of the companys new building (right photo) which is located in Freeport,
Pennsylvania, U.S.A., about 25 mi. (40 km) northeast of Pittsburgh, Pennsylvania pointing out his grandfather who co-founded the company in
1922. The family photograph was taken in 1912.
Two
SBCO CELEBRATES 86-YEAR ANNIVERSARY
WITH MOVE TO NEW FACILITY
Sloan Brothers Co. (SBCO) Continues to Focus on Machinery Lubrication
as it Expands Further into Lubrication System Manufacturing
By Richard P. Schook
CT218.qxp 3/23/09 10:26 AM Page 1
blocks are all about moving oil through a maze of internal
ports by pistons designed to cycle precisely. Between three
and nine blocks are assembled on what is called a base
plate. The sideways motion of the piston uncovers one in-
ternal port at a time, allowing oil to move through the
blocks. As each piston completes its cycle the next blocks
cycle begins, until each piston in each block on the plate
has completed one back-and-forth cycle. The end result is
that a very accurate amount of fluid is delivered to each
outlet port. They further explained that Sloan Brothers di-
vider blocks are available in a variety of displacements
ranging from the SB-6T for 0.006 cu.in./cycle per outlet (0.1
ml) to the SB-30S that displaces 0.06 cu.in. (0.98 ml) per cy-
cle. For comparison, 0.006 cu.in. is roughly equivalent to
three drops of oil.
Lubricating both the power and compressor cylinders on a
10-cylinder integral engine/compressor may require accurate
oil delivery to hundreds of points for 200 gal. (757 L) total
delivery per day, whereas a small plant air compressor may
have only two lubricating points that need less than 1 pint
(16 oz.) a day. Micro lube systems may use under 2 pints
(33.3 oz.) per month. Divider cycle times can range from one
per second to one in 15 minutes. These varied critical appli-
cations require a precision-manufactured divider. To further
understand what a workhorse of a component the divider
block needs to be, Eric Sloan, shop manager for SBCO, said
APRIL 2009 51
I An SBCO technician is shown assembling a lubrication panel in one
of the companys fabrication shops in its new building (top). The bot-
tom photo pictures SBCOs new four-axis horizontal machining center,
which adds the precision manufacturing capabilities required to man-
ufacture close tolerance divider block assemblies.
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CT218.qxp 3/23/09 10:27 AM Page 2
that when manufacturing blocks, very
close internal tolerances are critical for
achieving optimal operation. When
providing minimal lubrication to com-
pressor cylinders with high internal
pressures, the blocks as well as
other system components must be
capable of operating at up to 7500 psi
(51,700 kPa).
Meeting these possible extreme con-
ditions explains why precision-milled
surfaces, tight connection tolerances
and the reproducibility of fine piston
fits is so important in order to achieve
proper, uninterrupted, reliable opera-
tion over millions of cycles and
decades of service. Walter said, It
stands to reason that a dependable au-
tomatic lubrication system would need
to be automatically monitored, and the
options vary from simple indicators
and switches to dedicated stand-alone
PLC-based monitors. He further ex-
plained that there are visual indicators
to show divider cycles, fault indicators
to show over-pressure, proximity
switches to connect to a control or
alarm system and monitors that display
actual delivery rates. The Sloan
Brothers lubrication system monitor,
the Wizard, can display the actual oil
flow rate in up to four lubrication
zones (power cylinders, compressor
cylinders, multiple compressor stages,
etc.). It tracks and displays the total
volume of oil delivered in pints per
day. In case of a lubrication fault, the
Wizard will generate an alarm or signal
a safety shutdown to prevent damage
to the equipment to which oil is being
supplied. Other components of the
complete lubrication system, which
Sloan Brothers provides under the
Watchman System name, are the lubri-
cator boxes and pumps, check valves,
filters and associated accessories.
Sloan Brothers typically provides
complete lubrication systems custom
engineered for each application, but
many configurations are either skid
mounted or panel mounted. The
Watchman skid-mounted lubrication
system is completely self-contained
and ready to run, and includes a drive
motor, oil tank, pumps, divider
blocks, monitor, etc. It is designed to
be physically installed and easily con-
nected through tubing to the lubrica-
tion points in a short time once on-
site. Sloan Brothers strives to ship
skid-mounted Watchman Systems
within two days of ordering.
The other common configuration of
lubrication system is the Watchman
panel, which is more typically used
on larger on-compressor applications
with machine-driven pumps and ex-
ternal oil supplies. In this arrange-
ment the panel typically is mounted
Two
Great customer service is our trademark at WEG. We service all global markets so
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I A Watchman free-standing
skid-mounted lubrication sys-
tem is pictured here installed
on a Clark integral compressor,
which is in service for Cinergy.
CT218.qxp 3/23/09 10:27 AM Page 3
to the side or end of an engine. Once
mounted it can be connected through
tubing with the other system compo-
nents, from crankcase supply with fil-
ters, to secondary divider blocks and
terminal check valves for a totally in-
tegrated system that is neat, clean and
easy to inspect and service.
Matt McCarthy, who has been with
Sloan Brothers for 18 years, identified
the typical Watchman system market.
In natural gas and CNG, it is at every
compression stage from wellhead
through transmission to storage and
distribution. Also refinery and chemical
gas compression, manufacturing plant
air, cement bulk handling, vapor recov-
ery if there is gas moving, it is likely
moved by a compressor that we lubri-
cate. There are other applications not
related to gas from food mixers, at-
omizers and kilns, to pulverizers and
drilling equipment. Automatic Lubrica-
tion even includes a potato peeler.
He said that over the long history of
the company, an exhaustive database
has been developed that holds design
details for every application. Chances
are, when a customer calls with an ap-
plication, we already have the details.
We may have done one like it 5, 15 or
30 years ago. He further pointed out
that each one can be slightly different,
so attention to those details is critical.
Walter and Matt both said that the
company is constantly mindful of the
fact that the machines being lubri-
cated by their systems are perform-
ing extremely critical operations in
processes where machine downtime
cannot be tolerated. Because of this
criticality, we strive to ship system
spare parts and components the
same day they are ordered, and to
deliver (and install if logistically pos-
sible) complete lubrication systems
as soon after the order as possible.
They also said that they serve both
original equipment manufacturers and
end users not only in the United States
but also throughout the world. Walter
lamented lightheartedly that sometimes
he feels that our systems dont need
to be maintained or replaced nearly of-
ten enough. One customer called last
week, stating that hes never had a
problem with the system we installed
in 1972 and admitted that he should
probably get a quote on a complete
new system. He said, This is what
builds customer loyalty properly de-
signed lubrication systems from people
with experience systems that work
right and seldom need help. And, in a
few decades when they do, Sloan
Brothers plans to still be providing the
best service available. I
SEE DIRECTLINK AT
Two
I A Wat chman engi ne-
mounted lubrication panel is
pictured here mounted on the
side of a Clark BA-8 integral
engine/compressor in natural
gas pipeline compressor serv-
ice for Michigan Gas.
CT218.qxp 3/25/09 9:14 AM Page 4
A diesel hydrotreater (DHDT) was
commissioned in the Mathura Refinery
in 2005 to produce Euro 2, Euro 3
and Euro 4 diesel fuel (for blending
with diesel from other units to finally
supply Euro 2 and Euro 3 diesel to
the market) until April 2010. The re-
finery will supply Euro 3 and Euro 4
diesel (no Euro 2) after April 2010 on-
ward, according to recommendations
of the Indian Governments task force
on auto-fuel policy.
The hydrotreater is operated at high
pressure (reaction section pressure is
OPTIMIZING POWER LOAD
ON HYDROGEN MAKEUP COMPRESSOR
Analytical Formula Determines Hydrogen Consumption
By Devesh Kumar Agrawal and Ashis Kumar Dhar
I Figure 1. The hydrogen makeup compressor
was manufactured by Mitsui Engineering &
Shipbuilding Co. Ltd., Tokyo, Japan (MITSUI). The
compressor is a double-acting, four-cylinder,
two-stage horizontal, balanced, reciprocating
machine, Type C454 rated at 333 rpm with water-
cooled cylinder jackets. Stage 1, cylinder bore
and stroke are (450 x 350 mm), while stage two
bore and stroke are (310 x 310 mm). Each cylin-
der is equipped with two loader valves for a total
of eight valves. The first-stage suction and dis-
charge pressures are 285.7 psi (19.7 bar) and
690.4 psi (47.6 bar), while the second-stage dis-
charge pressure is 1535.9 psi (106 bar).
Two
Devesh Kumar Agrawal is a production
engineer in Mathura Refinery of Indian
Oil Corp. Ltd. He is actively involved in
process monitoring, troubleshooting and
field operations of a diesel hydrotreating
unit (DHDT). His job profile also includes
updating operation manuals, preparing
guidelines and day-to-day instructions
for operators. He holds a Bachelor of
Technology (B.Tech.) degree in chemical
engineering from Indian Institute of
Technology (IIT), Kanpur, India.
Ashis Kumar Dhar is a production man-
ager and has been associated with the
Indian Oil Corp. Ltd. for 27 years. He has
worked on different refinery units includ-
ing atmospheric and vacuum distillation
unit, FCC unit, hydrocracker unit, diesel
hydrotreating unit. He also has performed
various assignments in the commissioning
of hydrocracker unit (licensor: Chevron,
U.S.A.) and a diesel hydrotreating unit (li-
censor: Axens, France). He actively partic-
ipated with Shell Global Solutions for an
Integrated Refinery Business Improvement
Program. He obtained BS degree in
Chemistry with honors and, at present, he
is in charge of DHDS and DHDT units of
the Mathura Refinery.
Comparision of online & calculated values
of hydrogen consumption
1000
1500
2000
2500
3000
3500
1
/7
/2
0
0
8
3
/7
/2
0
0
8
5
/7
/2
0
0
8
7
/7
/2
0
0
8
9
/7
/2
0
0
8
1
1
/7
/2
0
0
8
1
3
/7
/2
0
0
8
1
5
/7
/2
0
0
8
1
7
/7
/2
0
0
8
1
9
/7
/2
0
0
8
2
1
/7
/2
0
0
8
2
3
/7
/2
0
0
8
2
5
/7
/2
0
0
8
2
7
/7
/2
0
0
8
2
9
/7
/2
0
0
8
3
1
/7
/2
0
0
8
Date
H
y
d
r
o
g
e
n
C
o
n
s
u
m
p
t
i
o
n
H2 Consp. (Online)
H2 Consp. (Calculated)
IPlot 1: Comparison of online and calculated values of hydrogen consumption (kg/h), CN=53.
CT212.qxp 3/25/09 9:18 AM Page 1
1477.81 psi [101,891 mbar]), which fa-
cilitates aromatics saturation resulting
in the enhancement of cetane number
(CN). The quality of diesel is repres-
ented by its cetane number and the
part per million (ppm) of sulphur pre-
sent. The objective is to improve the
quality of diesel products to reduce
SO
2
emission to the atmosphere from
running vehicles and to improve en-
gine performance.
The quality improvement is achieved
by hydro-treatment of the diesel fuel
(mainly hydro-desulphurization and
aromatics, olefins saturation), which in-
curs additional cost to the refineries.
This additional cost mainly includes
hydrogen, HP, MP, LP streams, amine,
water, fuel gas, chemicals and electric-
ity consumption.
In the present work: 1. Mathe-
matical formula for the calculation of
hydrogen consumption is presented,
which is used to optimize power load
on the hydrogen makeup compressor
(MUC) designed for 6035 hp (4.5
MW); 2. Strategies are also discussed
to reduce power load on the hydro-
gen makeup compressor.
Details of the DHDT Makeup
Compressor
The DHDT unit has makeup com-
pressor step control at zero, 25, 50, 75
and 100% load only to maintain the re-
action section pressure by supplying
hydrogen from the header. The com-
pressor is operated at 50 and 100%
loads only for the purpose of maintain-
ing reaction section pressure (not oper-
ated on 25 and 75% for load balanc-
ing). The electricity consumption at
100% loading of the compressor with
maximum feed rate (225 tons/h) is
5365 hp [4 MW (not 4.5 MW)] because
spill back remains open around ~16%.
The key point in running the MUC at
50 or 100% load is the amount of hy-
drogen consumption in the hydro-treat-
ing reactions. The consumption of hy-
drogen mainly depends upon the
percent of sulphur, olefins and aromat-
ics present in the feed mixture of
diesel and total cycle oil (TCO)
which is a cracked product from a fluid
catalytic cracking (FCC) unit to the
treating unit. The hydrogen consump-
tion is less per ton of diesel processed
compared to per ton of TCO processed
in the unit. Therefore, hydrogen con-
sumption will vary with the amount of
TCO mixed in the diesel even if the
feed rate of the unit is fixed.
Formula for Calculating the
Hydrogen Consumption
From the actual average hydrogen
consumption with different combina-
tions of feed rate, TCO processing rate
and cetane number, a formula was de-
veloped for optimizing hydrogen con-
sumption and MUC power load.
Hydrogen consumption (HC) =
aW
1 (feed rate)
+ bW
2 (TCO)
+
c(Cetane number - 53) (Formula 1)
W
1(feed rate)
: is the amount of feed
rate processed in the unit in tons/h.
W
2(TCO)
: is the amount of TCO
processed in the unit in tons/h and a,
b are constants and c is the function of
cetane number. For different values of
cetane numbers, a and b will be
constants and c will vary to compen-
sate for increase and decrease in hy-
drogen consumption because of cetane
number. The value of coefficient c
can be calculated from the actual aver-
age hydrogen consumption data.
a = C
1
, b = C
2
and c= f(Cetane
number)
HC is in kg/h
Cetane number mentioned in the
formula covers the severity of the
Two
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recession and wear of piston rings,
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and saved over $70,000 per year for one
gas eld operation.
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Maintenance Coordinator of Production Operations
CT212.qxp 3/23/09 10:17 AM Page 2
system. Cetane number can be ob-
tained from formula.
1
So, HC = C
1
W
1(feed rate)
+ C
2
W
2(TCO)
+ f(CN)(CN - 53).(Formula 2)
Where, constant C
1
, C
2
and the
variable f can be obtained by keep-
ing two variables constant and vary-
ing the other one. The coefficient C
1
can be found by keeping W

2
and CN
constant, and varying W1. Similarly C
2
and f can be found. We have calcu-
lated C
1
, C
2
, f for cetane number 53.
For CN = 53,
HC = C
1
*W
1(feed rate)
+ C2*W
2(TCO)
+
0 (Formula 3)
Where, C
1
=11.5 and C
2
=13.5 was
obtained by solving Formula 3 by
keeping W
2(TCO)
constant and varying
W1(feed rate) and vice versa.
HC=11.5W
1(feed rate)
+13.5W
2(TCO)
(Formula 4)
Formula 4 infers that hydrogen con-
sumption increases by 18.1 lb./h (13.5
kg/h) for each ton/h increase in TCO
processing rate at constant feed rate. The
Formula 4 is used in calculating hydro-
gen consumption for different combina-
tions of feed rate and TCO (for CN=53),
which helps in deciding the compressor
load, i.e., 50 or 100%. Similarly, hydro-
gen consumption equations can be de-
veloped for other cetane numbers.
The online and calculated values of
hydrogen consumption for different
combinations of feed rate and TCO
processed in the unit (for July 2008)
are plotted in plot 1.
Optimizing Power Load on
Makeup Compressor
The strategies with the help of above
formula are developed to optimize the
electricity consumption in the MUC
while processing the desired feed rate.
The different combinations of feed
rate and TCO can be obtained based
on hydrogen consumption (from
Formula 4), which can be processed
while running the unit on 50% MUC
load. At 50% MUC load, maximum
makeup hydrogen flow is ~5512 lb./h
(~2500 kg/h). Based on CN and feed
rate (W
1(feed rate)
), as decided by plan-
ning and coordination (P&C) and oil
movement and storage (OM&S) de-
partment, TCO processing rate
(W
2(TCO)
) was adjusted accordingly as
found by the Formula 4. The remain-
ing amount of TCO was stored in the
OM&S tanks and TCO tank level was
allowed to build up. For example: for
processing the unit on 180 tons/h of
feed rate, <25 tons/h of TCO can be
processed at 50% MUC load and re-
maining TCO (~30 tons/h) was stored
in the OM&S tank.
While on maximum feed rate, i.e.,
225 tons/h (as per demand from mar-
keting), TCO processing rate was
maximized (as permitted by design)
and TCO tank level (which earlier
was allowed to build up) was brought
down on 100% MUC load. In this
way, because of this strategy, we are
running our unit on 50% MUC load
around 15 days in a month, which re-
sults in huge saving in the operating
cost for the company.
We found that running MUC at
50% load consumes ~2 MW of elec-
tricity and at 100% load, ~3.5 to 4
MW, dependi ng upon spi l l back
opening. Therefore, on running the
unit on 50% MUC load results in 1.5
to 2 MW saving of electricity, which
on calculation comes out to be ~2
lacks rupees (~US$4000 at 4 rupees
per kWh) per day. So, even if the
MUC runs on 50% load for 15 days a
month, it will result in the saving of
~30 lacks rupees (US$60,000) per
month on a recurring basis. Annually,
i t wi l l be ~3. 6 chores rupees or
US$720,000. I
Reference:
1. Dhar, A. K. Improve calculating
cetane numbers. Hydrocarbon
Processing, vol. 87, no. 10, October
2008, p. 117.
Two
ACI Services, Inc. ......................................................................43
AXH air-coolers..........................................................................28
Air-X-Changers ............................................................................9
Altronic, Inc. .................................................................................1
ARIEL.........................................................................................15
BRM, Brush Research Manufacturing Co., Inc. ...........................8
*Burckhardt Compression AG................................................21, 27
CECO, Compressor Engineering Corp. .....................................53
*CPI, Compressor Products International....................................17
Camerons Compression Systems Group.............................32-33
*Cook Compression ......................................................Third Cover
*Dresser-Rand Company.......................................................37, 39
ECG, Ellwood Crankshaft Group ...............................................11
EMIT Technologies, Inc. ..........................................Second Cover
Energy Exposition......................................................................62
Exline, Inc. .................................................................................38
FLSmidth Inc..............................................................................19
GCIC..........................................................................................29
*GE Oil & Gas................................................................................5
Gaumer Process........................................................................41
Generon IGS..............................................................................26
*HOERBIGER Kompressortechnik Holding GmbH................30-31
In The News...............................................................................62
LCEC, Louisiana Chemical Equip. Co., LP ................................38
LMF, Leobersdorfer Maschinenfabrik AG.....................................7
*MAN TURBO AG........................................................................23
Masters Synthetic Oil Solutions .................................................45
MOTORTECH GmbH.................................................................59
Multi-Wing..................................................................................13
Murphy, FW ..............................................................Fourth Cover
*Neuman & Esser Group .............................................................25
Petro-Canada.............................................................................55
Platts Midstream Development & Management Conference........61
SGA, Southern Gas Association................................................63
Safety Seal Piston Ring Company.............................................35
Stewart & Stevenson..................................................................47
Synthetic Oil Solutions, LLC ......................................................45
*Tech Transfer, Inc..........................................................................2
Testo, Inc....................................................................................51
Toromont Energy Systems.........................................................49
WEG Electric Corp.....................................................................52
Wesco Valve & Manufacturing Company ...................................35
Company Name Page Number Company Name Page Number
* Further information on this companys products can be found
in the 2008 Edition of the Global Sourcing Guide and 2009 Compression Technology Sourcing Supplement.
Advertisers Index
www.compressortech2.com
APRIL
CT212.qxp 3/25/09 9:07 AM Page 3
(Coming in May 2009)
GSGnet.net.qxp 9/9/08 4:06 PM Page 1
ticipate voluntarily and represent Harris Countys (Texas)
best interest in terms of producing quality graduates to
supply the industry.
Adjunct faculty are part-time instructors responsible
for teaching courses related to their education or indus-
try. Adjunct faculty support full-time faculty to teach
courses hosted at non-conventional times (nights and
weekends), or for courses that are unique to industry.
Adjunct faculty require a minimum of an associates
degree and three years of industry experience. Some
exceptions can be made.
The Lone Star College System is the former North
Harris Montgomery Community College District. The
Lone Star College System consists of six main colleges
and seven satellite campuses throughout its 1400-square-
mile district. Lone Star College-CyFair was built in 2003
as a response to the needs of the growing residential and
industrial communities of northwest Harris County.
For more information contact Christopher Newton,
Professor - Industrial Maintenance Technology.
Phone: 281-290-3281
E-mail: Christopher.A.Newton@lonestar.edu
Website: CyFair.LoneStar.edu/advtech
The Industrial Maintenance Technology Program of
Lone Star College-CyFair (Cypress, Texas, U.S.A.) is seek-
ing equipment and educational materials to use as instruc-
tional aids. Any type of equipment, new or used, will be
greatly appreciated small pumps, hydraulic cylinders and
components, seals, bearings, gearboxes, compressors,
engines, rigging equipment, hand tools, etc. Educational
materials include photos, drawings, digital images, posters,
video, and literature anything students can utilize to gain
a well rounded view of todays technology.
The program is also seeking advisory committee mem-
bers and adjunct faculty. The advisory committee meets a
few times throughout the year to discuss and review the
curriculum and industry needs. Committee members par-
John Hopkins Unlimited Inc.
E-mail: envirofuge@aol.com
Global distributors wanted for
Duration Filter System.
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Display or non-display classified
advertising accepted.
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one inch minimum.
Photographs not accepted.
No charge for typesetting.
Payment must accompany order.
For an immediate price quote fax or
e-mail your ad copy to:
Kara Kane
E-mail: kkane@dieselpub.com
Fax: (262) 754-4175
Phone: (262) 754-4100
Marketplace COMPRESSORTech
Two
CT_Apr09Marktplc.qxp 3/23/09 2:05 PM Page 1
The U.S. Environmental Protection
Agency (EPA) said it is proposing na-
tional emission standards for haz-
ardous air pollutants for stationary
reciprocating internal combustion en-
gines that are not already covered by
earlier EPA regulations.
The newly announced regulation
would set emission limits for for-
maldehyde, benzene, acrolein and
other air toxics from certain stationary
diesel and gas-fired engines. EPA said
the plan is expected to be fully imple-
mented by 2013.
The schedule for completing this
regulation is part of a consent de-
cree with Environmental Defense,
which required the EPA administra-
tor to complete a proposed rule by
Feb. 25, 2009, and a final rule by
Feb. 10, 2010.
EPAs announcement said that in
2008, over 1 million of these engines
generated electricity, powered equip-
ment and operated during emergen-
cies at industrial, agricultural and
other facilities. The proposed limits
would apply to engines located at
smaller sources of air toxics.
Specifically, EPA said these engines
are used at facilities such as power
plants, chemical and manufacturing
plants to generate electricity and
power pumps and compressors, as
well as applications to produce elec-
tricity and pump water for flood and
fire control in emergencies.
EPA said this rule would apply to
engines that are smaller or equal to
500 hp (327 kW) that were manufac-
tured, or remanufactured, before June
12, 2006. It also covers engines larger
than or equal to 500 hp (327 kW) that
were manufactured or remanufactured
before Dec. 19, 2002, at major sources
of air toxics.
The EPA definition of major sources
of air toxics are operations that emit 10
tons per year of a single air toxic or 25
tons per year of a mixture of air toxics.
EPA said that owners or operators
of existing engines would be required
to install emissions control equipment
that would limit air toxics emissions
by up to 90%, perform emissions tests
to demonstrate engine performance
and compliance with rule require-
ments, and burn ultra-low sulfur
diesel fuel in non-emergency engines
with a site rating greater than 300 hp
(223 kW).
To meet the proposed emissions re-
quirements, owners and operators of
the engines covered in the regulation
would need to install aftertreatment
controls, such as filters or catalysts, to
engine exhaust systems, EPA said.
This proposed EPA rule focuses on
two options for aftertreatment control
of emissions from existing diesel en-
gines. One option is oxidation cata-
lysts, a technology that EPA said can
achieve up to 90% air toxics reduc-
tions from diesel engines but can only
reduce fine particle pollution by
about 25 to 30%. Oxidation catalysts
also provide negligible reductions of
black carbon soot, EPA said.
Also in EPAs plans are catalyzed
diesel particulate filters that can re-
duce air toxics and fine particle emis-
sions from diesel engines. This tech-
nology is very effective in reducing
diesel black carbon soot at over 90%,
EPA said.
The agency also said it expects that
owners or operators of existing rich-
burn engines, burning natural gas,
gasoline or other fuels, would install a
nonselective catalytic reduction device
to meet the proposed limits on air
toxics emissions. I
EPA PROPOSES NEW EMISSIONS
REGS FOR STATIONARY DIESEL,
GAS ENGINES
Plan is Expected to be Fully Implemented by 2013
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CT209.qxp 3/24/09 10:24 AM Page 1
Black powder generally consists of
various forms of iron sulfide or iron
oxide, and is included with the other
unwanted constituents such as water,
liquid hydrocarbons and sand in nat-
ural gas and fluid transmission deliv-
ery systems. The ferrous contaminate,
ranging from 10 microns to sub-mi-
cron sizes (finer than talcum powder),
is created by the internal erosion/cor-
rosion of the carbon steel used in
pipelines, storage reservoirs and oper-
ating equipment. It is found in both
dry and wet gas. Under dry condi-
tions, it is a very fine black or brown
powder, and under wet conditions it
appears as a tar-like substance.
Black powder causes many opera-
tional problems, said Roger Simon-
son, president of One Eye Industries
Inc. (OEI) in Calgary, Alberta, Canada.
It negatively affects operating equip-
ment and impairs pipeline perform-
ance. It also has a detrimental effect
on the quality of the product passing
through the line. Many individuals be-
lieve that since new product is deliv-
ered in a closed pipeline, it is contam-
inant free. This is not the case.
Products delivered by carbon steel
systems always contain ferrous mater-
ial caused by internal erosion.
Black powder occurs in all pipe-
lines around the world, with some
lines experiencing severe problems
and others not. From data collected, it
appears that shorter lines that are
closer to final distribution systems
(versus close to gas gathering net-
works) are less likely to experience
major problems. Simonson stated that
one other important factor is the qual-
ity of the carbon steel. Poor quality
steel tends to produce larger quanti-
ties of ferrous particulate.
High-speed flow in a pipeline picks
up metal contaminants, which then act
like sandpaper to create more ferrous
particulate, said Simonson. We have
seen situations where there is so much
black powder in a line that traditional
filters become clogged, pipeline flow is
severely reduced, meters and burner
orifices become plugged and inopera-
tive, and compressors and natural gas-
fueled engines shut down. The best
way to avoid these problems and ex-
tend the life of pipelines and equip-
ment is to remove the black powder
before it reaches metering stations,
processing plants and city gates. Our
magnetic separation systems are de-
signed to do that.
To remove the fine black powder
from a high-velocity flowing pipeline
required that OEI design a magnetic
separator with the strength to extract
and hold sub-micron ferrous contami-
nants from the product flow. Using
the patented OEI design, a new 2 in.
(49 mm) diameter separator rod was
created. It delivers holding power in
excess of 600 lb. (272 kg) of metal
per 12 in. (305 mm) of rod.
The design also allows for the sepa-
ration and collection of nonferrous
contamination because of static adhe-
sion. When product flows through a
pipeline, static electricity is created,
which is attached to the contaminated
ferrous and nonferrous materials in
the flow. This causes the contami-
nants to join together, which allows
the nonferrous materials to be ex-
tracted and held in place along with
the ferrous contaminants as they pass
by the magnetic separator.
The separator was placed in a
newly designed cone strainer and to-
gether they were sent to the Centro
De Tecnolga Em Dutos in Brazil. This
facility performs equipment and pro-
cessing tests for pipelines, and
planned to evaluate the filtration ca-
pability of the new separator rod in
capturing pipeline erosion. The sepa-
Two
I (Left) Black powder is a ferrous contaminate that is created by the internal ero-
sion/corrosion of carbon steel pipelines and operating equipment. Under dry condi-
tions, it is a very fine black or brown powder that ranges from 10 microns to sub-mi-
cron size. It must be handled carefully because it can be absorbed through pores into
the body by simply touching it. (Below) The Mechanical Cleaned Magnetic Separator
system has been designed to separate black powder from high-velocity process
flows in pipelines that are 6 in. (150 mm) in diameter and up. A mechanical cleaning
station is located between the two separation housings, with the piping designed for
continuous flow during separator cleaning.
BLACK POWDER REMOVAL
One Eye Industries Addresses a Growing Concern in Pipeline
and Processing Industries with Magnetic Separator Systems
By Neil Purslow
CT222.qxp 3/24/09 10:14 AM Page 1
Register by April 17, 2009 and SAVE $300!
Midstream Development & Management
Environment and Outlook for Gathering and Processing
Supply/Demand, Margins, Project Development, and Financing
May 2122, 2009 Hilton Americas Houston, Texas
Registration Code: PC928CTAD
For more information and speaking
opportunities, contact:
Cynthia Rugg, tel: 781-430-2105
cynthia
_
rugg@platts.com
For sponsorship opportunities,
contact:
Joshua Vernon, tel: 781-430-2113
joshua
_
vernon@platts.com
For media inquiries, contact:
Gina Herlihy, tel: 781-430-2109
gina
_
herlihy@platts.com
Industry Leaders from:
Provide In-depth Information for Effective Forward Strategies:
Upstream supply outlook, downstream demand, and pipeline development and constraints
Oil & gas prices, processing margins, and mitigating market risk
Investment issues, project development prospects, and financing strategies
Plus Case Study of Regencys Haynesville expansion
For a complete agenda or to register and SAVE $300, please visit us online at www.events.platts.com
or call us at 866-355-2930 (toll-free in the US) or 781-430-2100 (direct).
Blue Phoenix Midstream
Caiman Energy
Carrizo Oil & Gas
CDM MAX
CenterPoint Energy
Crestwood Midstream Partners
Dominion Transmission
EnCana USA
Koch Supply & Trading
Range Resources Corporation
Regency Energy Partners
Tristream Energy
Williams Midstream
BENTEK Energy
Mercator Energy
NGP Midstream and Resources
Petral Worldwide
Quantum Energy Partners
Royal Bank of Scotland
Tudor Pickering Holt & Co.
UBS Investment Bank
WindShift Capital Corp.
Wood Mackenzie
rator rod and cone strainer were in-
stalled in a 14 in. (356 mm) x 1000 ft.
(305 m) test loop that had been previ-
ously cleaned to remove all metal
contamination. Exactly 2.2 lb. (1 kg)
of black powder originating from an-
other pipeline was added to the test
medium, and the medium was
pumped through the loop at a rate of
31,700 gph (120 m
3
/h). After about
nine hours of circulation, the mag-
netic separator was removed. The
black powder captured by the separa-
tor exceeded the test amount placed
in the loop.
With the new magnetic separator
and cone strainer proven effective for
removing black powder in smaller ap-
plications, continued Robert Albee,
sales manager for OEI, a design for
larger pipelines was started. We devel-
oped the Mechanical Cleaned
Magnetic Separator system to answer
the need for high contamination lev-
els in pipelines that are 6 in. [150 mm]
and up. The system uses a duplex
design for continuous operation
while one separation unit is operat-
ing, the other can be cleaned. A me-
chanical cleaning station is positioned
between the two magnetic separation
housings, along with an overhead
crane and an operator walkway.
For a 12 in. (31 mm) pipeline, each
magnetic separator housing contains
nine 4 ft. (1.2 m) long by 2 in. (49
mm) diameter magnetic separators.
When it is time to clean a unit, the
overhead crane lifts the separators out
of their main housing and places
them in the cleaning station. Once
clean, the separators are returned to
the main housing ready to be used
again. During the cleaning process,
technicians experience minimal expo-
sure to the magnetic fields of the sep-
arators and trapped contamination.
The contaminants are safely contained
in a removable mineral bag for safe
transportation to a recycling facility.
Simonson said that the separation
system is designed for an operating life
of 10+ years, with minimal operating
costs and no filter elements to replace.
Other advantages include continuous
pipeline operation, no flow restriction
and, most importantly, a significant re-
duction in black powder. By placing
magnetic separation systems before re-
fineries, chemical plants, and residen-
tial and industrial distribution systems,
downstream processes operate more
efficiently and equipment life can be
extended, he explained.
The 2 in. (49 mm) rods have also
been used in other filtration products
manufactured by OEI. Those products
include basket strainers; and Y, single
Two
I The 2 in. (49 mm) diameter separator rod
was placed in a newly designed cone
strainer, and was sent to the Centro De
Tecnolga Em Dutos in Brazil for testing. This
facility performs equipment and processing
tests for pipelines. The unit was installed in a
14 in. (356 mm) x 1000 ft. (305 m) test loop to
evaluate its filtration capability in capturing
pipeline erosion.
CT222.qxp 3/24/09 10:14 AM Page 2
and dual scrubbers. (For more information on these and
other OEI products, see COMPRESSORTech
Two
, June 2007.)
OEI recently tripled the size of its production facility in
Calgary. The production area is divided into four distinct
sections one each for machining, assembly, product stor-
age and research and development. Expansion into
Australia in the first quarter of 2009 will include a produc-
tion facility, with plans to set up facilities in Brazil and Italy
later this year.
The problem with black powder and ferrous metal con-
tamination (corrosion slag) in pipelines and equipment is
becoming more serious and costly, said Simonson. We are
seeing increased metal particulate in pipeline systems be-
cause of poor quality pipe being installed, as well as from
the maturing of existing pipeline systems. Industry is be-
coming more aware of the issue and its detrimental effects
on their equipment and products. I
Two
I Exactly 2.2 lb. (1 kg) of black powder that originated from another
pipeline was added to the test medium, which was then pumped
through the loop at a rate of 31,700 gph (120 m
3
/hr). After nine hours of
circulation, the magnetic separator was removed. The black powder
captured by the separator exceeded the test amount placed in the loop.
I This magnetic sep-
arator rod removed
ferrous contamination
from diesel fuel as it
was pumped from an
on-site storage tank
to its final destination.
The metal comes from
the carbon steel com-
ponents used in the
manufacturing proc-
ess, the delivery sys-
tem and the storage
tank and pumps.
CT222.qxp 3/24/09 10:15 AM Page 3
OFFSHORE GAS OPERATIONS
CONFERENCE & EXHIBIT
June 17-19, 2009
Moody Gardens Hotel Galveston TX
www.southerngas.org
Motor And Load Protection
Eaton has announced the first product
from its Intelligent Power Control
Solutions Family. The Motor Insight is de-
signed to offer solid-state motor protec-
tion, control and advanced monitoring
capabilities in a single device for the
petrochemical, mining, water and waste-
water industries. With configurable line,
load and motor protection, with ground
fault detection, power voltage and cur-
rent monitoring and flexible communica-
tions, users are able to configure the type
and level of protection required for var-
ied applications.
Motor Insight was designed with an
IP20 rated terminal block, a user interface
with an LED display and easy-to-under-
stand settings. Options include a remote
display and multiple communications
adapters. Its available with 240, 480 to
600 V, a full load amperes range of 1 to
540 Amps, and two output relays.
SEE DIRECTLINK AT
Oil Reclamation Filtration
Quality Filtration, a designer and
manufacturer of custom-engineered fil-
tration products for industrial and hy-
draulic applications, has introduced
QMedia. QMedia was designed specifi-
cally for oil reclamation systems. It was
developed with high-flow capacity and
the ability to hold more dirt and clean
systems more quickly. Quality Filtration
said QMedia is able to hold 30% more
dirt and has proven effective at 1 mi-
cron media. Its engineered for use in
18, 36 and 39 in. (45.72, 91.44 and 99.06
cm) elements specific to the oil reclama-
tion in generation plants, pulp and pa-
per mills, mining operations and the oil
and gas industry.
SEE DIRECTLINK AT
Gas Compression Module
Performance Program
Emerson Process Management has re-
leased the version 2.02 of its Copeland
Scroll gas compression module perform-
ance program. The program is designed
to project the performance of all produc-
tion-released Copeland Scroll modules,
proving users a forecast of performance
characteristics and requirements before
they purchase and install. The program
is Excel based, making downloading,
updating and saving data easier. Users
can input specific gravity and compress-
ibility factors or enter individual con-
stituents using the gas-property calcula-
tion page.
SEE DIRECTLINK AT
Two
Products COMPRESSORTech
Two
CT213andProducts.qxp 3/24/09 11:40 AM Page 3
I Burckhardt Compression (US)
Inc. has signed an agreement to ac-
quire all shares of Selltech Com-
pressor Pumps & Engine Products Inc.
in Valencia, California, U.S.A. The pur-
chase does not include Selltechs used
equipment business, which will be
continued in a new company by the
former owner of Selltech.
Selltech was founded in 1996 and has
been servicing the oil and gas industry
ever since its inception, providing cus-
tomer service including reconditioning
of cylinders, valves, pistons, rods, pack-
ing cases and complete compressors.
Selltechs capabilities and tradition
[of service to] customers is a perfect fit
for Burckhardt Compression. It also
gives us the opportunity to build up
our compressor component and serv-
ice business and reach new customers
on the West Coast, said Rudy
Buschauer, president of Burckhardt
Compression (US) Inc.
I Hoerbiger has signed a definitive
agreement to acquire 100% ownership
of Tritech Compression Inc., Spruce
Grove, Alberta, Canada. Since March
2, 2009, the oil field equipment supply
and maintenance service company has
operated as a business division of
Hoerbiger (Canada) Ltd., Mississauga,
Ontario, Canada, within Hoerbigers
Service Division.
Tritech Compression Inc. serves cus-
tomers primarily in the Northern Alberta
region, and employs roughly 100.
Tritechs Alberta operations are located
in Spruce Grove, Edson and Grand
Prairie, from which they provide service
for natural gas and oil field equipment
operators with field and shop services
and parts supply for compressors and
gas engines. According to Hoerbiger,
Tritech is known for its extensive inven-
tory of swing engines, which help its
customers profit from short overhaul
turnaround times. The possibility of
testing overhauled engines up to 2000
hp (1490 kW) on its in-house engine
test rig is an additional strength,
Hoerbiger indicated.
It remains a key strategic objective
for Hoerbiger Compression Tech-
nology to continuously proceed with
the growth course of the Hoerbiger
Service Division. Acquiring Tritech
Compression in conjunction with
the recent acquisition of Altronic Inc.
is a significant step in completing
Hoerbigers service offering for end
users of compressors and gas en-
gines, said Franz Ottitsch, president
of the Hoerbiger Service Division.
Hoerbigers stated intention is to
transform itself from a valve service
company to a leading maintenance
services provider for rotating equip-
ment, including compressors, engines
and turbines in North America. The
acquisition of Tritech brings new peo-
ple, skills and access to new markets
to Hoerbiger, said Franz Ottitsch.
This gives us the opportunity to dra-
matically strengthen Hoerbigers engi-
neering, maintenance and service ac-
tivities in Western Canada.
I JAG flocomponents LP has es-
tablished a valve distribution facility
in the major Mediterranean trans-
shipment logistic center in Malta. The
facility will serve valve customers in
the oil and gas sectors in Europe,
Central Asia and Africa. Salvo Grima
(Freeport Operations) Ltd. is the
Maltese logistics partner for the new
operation. The Salvo Grima Group
was founded in the mid-19
th
century
as a ship supplies company and is
said to be one of the longest-estab-
lished organizations in the Maltese
Islands, with maritime, commercial
and international ties.
Denis Taschuk, president of JAG flo-
components said, JAG is excited
about setting up this operation in Malta
because it is strategically located in the
center of the Mediterranean Sea, near
major shipping lanes. Malta is approxi-
mately 90 km [56 mi.] from Italy and
300 km [186 mi.] from North Africa.
With excellent port facilities, solid in-
frastructure, an educated work force, a
favorable tax regime and EU member-
ship, Malta represents a location that is
ideal for servicing our customers in
Europe and North Africa.
JAG flocomponents headquarters
and fi rst di stri buti on center i n
Edmonton, Alberta, Canada, was es-
tablished in 2001. Its U.S. distribution
center, located in Houston, Texas,
was opened in 2006 to support the
oil and gas midstream, upstream and
producti on markets. Inventori ed
product includes 0.25 to 36 in. (6.35
to 914.4 mm) ASME Class 150-2500#
trunnion and floating ball valves, 2 to
24 i n. (50. 8 to 609. 6 mm) check
valves in all pressure classes and end
configurations, thru-conduit gates,
pigging and mud valves. While the
initial focus was on API 6D quarter-
turn valves, JAGs international ex-
pansion includes API 6A, 600 and 603
multi-turn valves.
I Cook Compression has been
named an authorized distributor of
OEM replacement parts for Ariel gas
compressors. The arrangement en-
ables Cook Compression to purchase
and resell genuine Ariel parts and to
utilize them for all maintenance and
repair services in its own shops.
This development enhances our
ability to deliver a full range of quality
repair services for Ariel compressors,
said Don York, president of Cook
Compression. As an authorized Ariel
distributor, we offer customers with
Ariel machines not only the highest
quality service and technical support,
but also replacement parts that are fully
compliant with Ariel warranties. I
For up-to-the-minute news on developments in the gas compression world,
turn to the COMPRESSORTech
Two
Home Page at WWW.COMPRESSORTECH2.COM
About the Business
Two
BURCKHARDT COMPRESSION SELLTECH
COOK COMPRESSION ARIEL HOERBIGER
TRITECH JAG FLOWCOMPONENTS
Edited By Phil Burnside
CT224.qxp 3/24/09 1:20 PM Page 1
Engineered emissions solutions
www.cookcompression.com
Authorized Ariel
replacement parts
distributor
With compressor emissions, a partial
solution is really no solution at all.
Thats why Cook Compression offers a
complete range of technical support
and engineered products to satisfy
your emissions goals.
Your answer may include:
Buffered and purged unloaders
and packing cases
HSR leak-preventing valve restraints
RTV gas-sealing wiper rings
Seal-enhancing rod coatings
Cook Clean purged packing cases
Patented Seal Assist System secondary
containment
Static-Pac shutdown seals
Emissions control panel systems
plus much more
Whether youre aiming at a specific
VOC target or looking to reduce fugitive
emissions within an acceptable range
we have everything you need.
Clear Answers
Compressor Emissions Solutions
Cook.qxp 3/11/09 1:29 PM Page 1

At Quicksilver, if theres an opportunity to save money, well do it. Were always looking for ways to save
on fuel usage and cost. Murphy Power Ignition controls increased our engines efficiency and paid for
themselves within a few months.
When some of our compressor controls needed an update, we decided to put new MPI controllers instead
of rebuilding the old magneto systems. We installed MPI-16 controllers on our 12 and 16 cylinder engines.
We track fuel usage closely, and within days the fuel savings was clear. We save an average 7 MCF [thousand
cubic feet] of fuel per day. At an average price of $6 per MCF, we are saving $42 per unit per day. Thats an
annual total of $15,330 on each unit.
It wasnt a hard decision. MPI has more accurate timing, longer spark plug life and true secondary diagnostics.
Were saving a lot of money with MPI.
BEEN THERE.
SOLVED THAT
TM
.
FW Murphy
Corporate Offices, Tulsa, Oklahoma - +1 918 317 4100
Control Systems & Services Division, Rosenberg, TX - +1 281 633 4500
e-mail sales@fwmurphy.com
www.fwmurphy.com
Randy Reiman II
Emissions Tech, Quicksilver Resources
WE INSTALLED MPI AND SAVED
$15,330 ON EACH UNIT PER YEAR.
0710162
Murphy_C4.qxp 10/18/07 1:59 PM Page 1

2009 April

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New Stationary Engine

Brush.qxp 3/23/09 3:21 PM Page 1

In service June 1977

Parts available 24/7

SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM

We tripled our drain duration with

can be found by keeping W

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