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Volume - XV: Issue - IV
Can We Justify Our Angst?
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Joe Kane
We’ve moved past the worst — so we hope. The stock market, while still waffling, seems to be moving up as a trend. It’s now flirting with the magic pivot point of 11,000 on the Dow Industrial Index. This is good news for those depending on their 401Ks for their retirement nest eggs. We last reported a move past the 11,000 mark in January of 2006. At that time, we were just coming off a very favorable 2005. However, economists already were raising flags regarding sustainability. To them, it seemed a bit overheated. No one had an inkling of a housing bubble or a subprime disaster as an underlying cause. Though durable goods have reacted to a somewhat modest demand, the U.S. public is concerned about growth sustainability. If we are going to make the stuff, someone first has to purchase it on a regular basis. Taking the pulse of the buying public has to be a marketing nightmare. Consumers are spending more, factories are producing more, but, layoffs have not tapered off as fast as expected. Until we see some stability in the buying public, growth will remain less than what we had hoped. The job market looked to be rebounding, with some 162,000 jobs added during the month of March, only to run into a 24,000 jump in applications for unemployment benefits during the week ending April 10. Estimates are that about 17% of working-age Americans remain unemployed or underemployed. The question is asked, “Can the economy show much vigor if the unemployment rate remains at 4
9.7%?” The risk of a “double-dip” recession hovers over us like a dense cloud. One ray of light is that the odds of that happening are much less than at the start of the recovery. Why do we not see more hiring when factory output surged by 0.9% a month ago? One answer is that workers’ productivity grew 3.8% during 2009 — the fastest pace in seven years. A “Heard on the Street” column in The Wall Street Journal reported on a recent deal in the oil and gas i ndustry. It goes like this: “When they aren’t fending off killjoy regulators or rabid bank executives, short sellers contend with pesky stock buyouts. Right now, they have problems in the oil and gas exploration and production sector. “The reason is a surge in mergers and acquisitions. A week or so ago, Mariner Energy was to brief analysts on its strategy but instead surprised investors by announcing it would sell itself to Apache Corp. for $2.7 billion. Mariner’s stock shot up 42%. “Roughly $65.5 billion of E&P deals have been announced since October, according to Dealogic, more than in the previous 13 quarters combined. “Conditions are favorable for further consolidation. Stock markets are accommodatingly buoyant. The combination of low gas prices and high oil prices has exposed both the strains on some smaller companies’ balance sheets and made a move toward oil reserves desirable. The latest deal will enable Apache’s bigger balance sheet to finance development of Mariner’s deepwater Gulf of Mexico oil prospects. Short sellers in the sector should be losing sleep.” Though a lot of gloom exists in the world today, we always need to hold out hope for better times. History tells us that. The economy is moving for ward, even though slowly. We inevitably will reach another pivot point; a break in the employment barrier will burst. Hopefully, in spite of economists’ doubts, this will occur yet this year. In the meantime, may the Lord continue to hold you in the hollow of His hand. COMPRESSOR TechTwo
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MAY 2010
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Volume XV: Issue IV ............................................................................... .4
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Global Perspective — Is GTL a Viable Alternative to LNG? ..........................8
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Market Talk — EIA to Change Production Estimation Protocol ..................10
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LNG Regasification on Offshore Floating Terminals ................................12
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ASI Medium-Voltage Variable Frequency Drives ..................................... .14
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Atlas Energy, Reliance Industries Join Forces......................................... .18
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Konecranes Inspects Critical Components ............................................. .22
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Sentinel II Target — Peace of Mind ....................................................... .26
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Marine Applications for LNG Regasification Systems ..............................34
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Keeping Cool and Safe ......................................................................... .38
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TECHCorner — Torsional Behavior of Complex Compressor Trains ............42
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Gas Reinjection Modules Onboard an FPSO Surpass 60,000 Service Hours ........................................................................... .52
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Companies Recognized for Midstream Safety Statistics ..........................54
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Valerus Announces New Executive Team Members................................. .56
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Handling of Boil-Off Gas in Large LNG Plants ..........................................58
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New, Advanced Products from Altronic ................................................. .62
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A Different Grain of RICE....................................................................... .64
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Is Venezuela Becoming a Natural Gas Player in Latin America? ..............74
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About the Business — Power Ignition and Controls … Stoddard … SPX Hydraulic Technologies … Tension Systems Ltd. … Pump Users Symposium … Turbomachinery Symposium …Offshore Middle East Conf. & Expo … Laurence Reid Gas Conditioning Conf. … Apache Corp. … Mariner Energy ..................................................................................... .80
p. 58
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Dateline ............................................................................................... .11
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Industry News....................................................................................... .23
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Recent Orders ..................................................................................... .36
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Featured Products ............................................................................... .67
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Scheduled Downtime............................................................................. .70
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Literature Library ................................................................................. .71
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Advertisers’ Index ................................................................................. .72
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Marketplace ......................................................................................... .73 Two
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COMPRESSORTech (ISSN 1085-2468) Volume 15, No. 4 — Published 10 issues/year (January-February, March, April, May, June, July, August-September, October, November, December) by Diesel & Gas Turbine Publications, 20855 Watertown Road, Waukesha, WI 531861873, U.S.A. Subscription rates are $75.00 per year/$10.00 per copy worldwide. Periodicals postage paid at Waukesha, WI 53186 and at additional mailing offices. Copyright 2010 DIESEL & GAS TURBINE PUBLICATIONS. Canadian Publication Mail Agreement # 40035419. Return Undeliverable Canadian Addresses to: P.O. Box 456, Niagra Falls, ON L2E 6V2, Canada. E-mail :
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TAILOR–MADE
I GTL A VAB AAV LNG? Solving Problems Seems to be a Constant in the Development of New Industrial Processes By Roberto Chellini, Associate Publisher
Shell recently announced that the company’s Pearl gas-to-liquids (GTL) project in Ras Laffan, Qatar, could generate US$6 billion a year in profit. The Pearl GTL project, which is due on-stream in 2011, has seen its construction costs balloon from an initial $5 billion to $19 billion. The latest announcement helps to clarify how Shell expects to recoup this outlay. According to Shell officials, the annual profit of $6 billion is based on an oil price of $70 per barrel (bbl) and operating costs of around $6/bbl. The Pearl plant is now expected to start gas processing in late 2010 and begin fuel deliveries in early 2011. Following the start-up of deliveries from Pearl and a planned increase in output at the QatarGas liquefied natural gas (LNG) project, Shell’s operations in Qatar could account for as much as 10% of the company’s total hydrocarbons production. When complete, the plant is expected to be the largest in the world, with production levels of 120,000 bbl/d of natural gas liquids (NGLs) and ethane and 140,000 bbl/d of ultraclean diesel, naphtha and other GTL products. The project has been delayed several times from its original completion date in late 2009. With the start of deliveries now having been delayed until 2011, when the facility is likely to operate at full capacity remains unclear. If the company is able to make $6 billion a year in profits from the facility, the huge construction costs could be paid off relatively quickly, perhaps within a five-year period. As the profit estimates are based on an oil price of $70/bbl, any increase in oil prices could lift the project’s returns further. MAY 2010
The conversion of natural gas from the giant Qatar North Field to GTL is achieved through the Shell proprietary GTL process first developed for the Malaysian plant of Bintulu. This plant was started up in 1993 and was the world’s first commercial GTL plant. It has the capacity to convert approximately 106 Bcfd (3 x 10 6 m3/d) of natural gas into some 14,700 bbl/d of cleaner GTL products. Back in 2008, Shell set up an R&D center in Bintulu to develop the process further by extending catalyst life and reducing release of carbon dioxide. The other plants producing GTL are based on the Sasol process. The GTL is now jointly marketed in partnership with Chevron. Three plants are presently in operation with the Sasol process — two in South Africa and one again in Qatar. The Orky plant in Ras Laffan was first started in 2006, and only in March
Roberto Chellini
8
2009 — reached an output of 29,000 bbl/d very close to the design figure of 30,000 bbl/d. Also, in this case, the plant went through some unexpected teething problems and exhibited higher project costs than anticipated. Sasol is hard at work to reduce capital and operating costs. Developments include a new catalyst for the Fischer Tropsch process, with higher conversion efficiency, doubling plant capacity (economy of scale) and consideration of the Air Products one-stage ion membrane oxygen production and methane partial oxidation process. Both GTL processes presently on the marketplace appear to still be in the development stage. Shell and Sasol are working to reduce investment costs, increase productivity and minimize emissions. LNG, however, can be considered a mature process. Many changes have taken place since its first introduction in the late 1960s. Now, only small adjustments need to be introduced to gain a competitive advantage. At the present, GTL seems to be serving mostly local markets where liquid hydrocarbons are in short supply, and natural gas and coal can be transformed into clean fuel for transportation. Floating LNG versus floating GTL is still to be explored and could be an interesting alternative. The recent Shell announcement that the Pearl GTL plant is expecting to be profitable in spite of the higher than planned investment is certainly very promising for the future of GTL. Rising oil prices (over $70/bbl) will make the GTL solution even more attractive. However, LNG and GTL, in the long run, will finally cover two different market segments. COMPRESSOR TechTwo
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EIA T CHNG PDUTN ETTN PTL Withdrawal Season Demands Help Reduce Storage Surplus By Harold Lampe
The withdrawal season has come to a close for the winter of 2009-2010 and considering the way the season started, with an overage of 409 Bcf (11.6 x 10 9 m3), or 10%, over the five-year average, the industry exited the season with only 1638 Bcf (46.4 x 10 9 m3) in storage. While this remained 160 Bcf (4.5 x 109 m3) over the five-year average, it was actually less than what was in storage last year at this time by 16 Bcf (453 x 10 6 m 3). While this was excellent news for the industry, the market remains cautious as it attempts to comprehend the implications of new supply sources and the strength and impact of a recovering U.S. economy. Recent news from EIA could also have a profound impact on the market, too. The U.S. Energy Information Agency (EIA) indicated in a recen t Wall Street Journal article that it would be making a revision to their natural gas production data after finding that it has been overstating output. Production data is collected by EIA using Form 914, which surveys larger producers. This data is then extrapolated across the industry to establish an estimated monthly production total. One of the underlying issues is that it doesn’t capture the variation in production from smaller producers. The changes the EIA is planning could lead to a downward revision of the nation’s natural gas production figures. According to EIA, these changes will involve new sampling and estimation processes designed to simplify calculations and make use of the most recent reliable information available from the states. According to EIA, the new protocol will introduce three main changes: Monthly Sample — Moving for ward, the sample will be updated MAY 2010
every month using information that is more recent. Estimation — Estimation of production of nonsampled companies will use data that is six to 18 months old (rather than the previous practice that used data that was two to seven years old). Timing — Calibration will be updated monthly rather than annually. How the market will respond when revised data is provided is yet to be seen, but if findings lead to lower production numbers it could relieve some of the pressure on the market and could potentially lead to an upward movement on prices going forward. It is likely, though, that even if production output estimates are re vised downward, the market will remain cautious. In part, that will re-
Harold Lampe Harold Lampe is principal of Energy Research Services of Tulsa, Oklahoma, U.S.A., which provides a range of marketing services for the energy industry. He can be reached at
[email protected]. 10
sult from a perception that the increased drilling we are currently seeing in the U.S. will lead to new production and result in an oversupplied market as demand for natural gas remains muted. Currently, consumption numbers are rebounding, but a clear pace and evidence of sustainability will be needed to ensure that the financial market has turned the corner. As previously indicated (April 2010 COMPRESSORTech ), drilling activities continue to rise. As of April 1, Baker Hughes reported that there were 949 rigs drilling for natural gas in the United States. This is an increase of almost 200 rigs from the first of this year. At the same time, future prices remain under pressure with the 12month strip at US$4.75 (at the time of this writing), down from the previous month of $5.18. Future prices also briefly dipped below $4 as contracts closed out for the month. Spot prices at Henry Hub have been running below $4 as the industry exited the withdrawal season and weather that is more seasonal has settled in over the United States. While generally the economic news has been positive, lingering concern about unemployment numbers continues to weigh on the market . Generally, experts predict that unemployment will probably remain high for the foreseeable future. An extended period of high unemployment numbers could undermine a longterm recovery. I am hopeful that next month will provide some clarity regarding EIA’s production estimating modifications and a better sense of how the market will interpret those revisions. At that time, we may be able to better understand their likely impact on future prices. I look forward to visiting with you then. Two
COMPRESSOR TechTwo
Dateline For a complete listing of upco ming events, please visit our website at www.compressortech2.com
*May 3-6, Offshore Technology Conference - Reliant Center at Reliant Park, Houston, Texas, U.S.A.; Tel: (972) 952-9494; Fax: (972) 952-9435 *May 11-13, Eastern Gas Compression Roundtable - Ro ber t Morris University, Moon Township, Pennsylvania, U.S.A.; Tel: (304) 2933745/(304) 293-3745; Fax: (304) 293-6751 *May 12-13, Four Corners Oil & G a s C o n f e r e n c e - M cG ee P ar k, Farmington, New Mexico, U.S.A.; Tel: (505) 325-0279; Fax: (505) 327-7556
June 21-25, Neftegaz 2010 Expocentre, Moscow, Russia; Tel: 0812 320 6363; Fax: 0812 320 8090 Aug. 24-27, ONS 2010 Exhibition and Conference - Stavanger Forum, Stavanger, Norway; Tel: +47 51 59 81 21; Fax: +47 51 55 10 15
Sept. 13-16, Rio Oil & Gas Expo and Conference - Riocentro Convention Center, Rio de Janeiro, Brazil, IBP; Tel: 55 21 2112 9000; Fax: 55 21 2220 1596 *Sept 15-17, Wyoming Natural Gas Fair
- Snow King Center, Jackson Hole, Wyoming, U.S.A.; Tel: (307) 234-7147: Fax: (307) 234-5306
*Indicates shows and conferences in which COMPRESSOR Tech
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*May 18-20, Sensor+Test 2010 - Int’l Trade Fair for Sensorics, Measuring and Testing Technology Nuernberg Messe, Nuremberg, Germany; Tel: +49 5033 9639-0; Fax: +49 5033 1056 *June 1-4, AchemAsia - 8th International Exhibition-Congress on Chemical Engineering and Biotechnology, Beijing, People’s Republic of China; Tel: +49 69 7564-423; Fax: +49 69 7564 450
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June 1-4, Caspian Oil & Gas 2010 17th Int’l Caspian Oil & Gas Exhibition & Conference Incorporating Refining and Petrochemicals, Hyatt Meeting and Conference Centre, Baku, Azerbaijan; Tel: +44 207 596 5000; Fax: +44 207 596 5106 1. Place on firm, flat surface. 2. Follow directions in circle. 3. Repeat Step 2 as needed.
June 7-9, Sensors Expo & Conference - D o n al d E . S t ep h e ns C o nv e n ti o n Center, Chicago, Illinois, U.S.A.; Tel: (888) 219-8300; Fax: (617) 219-8310
MAY WE SUGGEST A BETTER ALTERNATIVE? *June 8-10, Global Petroleum Show Calgary Stampede Park, Calgary, Alberta, Canada; Tel: (403) 209-3562; Fax: (403) 245-8649 *June 9-10, Energy Exposition Cam-Plex Convention, Gillette, Wyoming, U.S.A.; Tel: (307) 234-1868; Fax: (307) 234-1868 *June 14-18, ASME Turbo Expo Scottish Exhibition & Conference Centre, Glasgow, Scotland; Tel: (404) 847-0072; Fax: (404) 847-0151
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MAY 2010
11
COMPRESSOR TechTwo
Computer rendering of Cryostar’s EcoVap system. The system uses propane as intermediate fluid. Sea water transfers the heat to a propane loop, which is kept within reasonable tempera- ture ranges.
LNG AIFIATI FFH FATI TIA Cryostar’s EcoVap Modular System Designed for Regasification on LNG Vessels By Roberto Chellini Exploiting gas fields in remote spots accounts for increased volumes of LNG from these fields, which are not other wise connected to consumer areas. It poses a problem of construction of import regasification terminals in populated sites. For both safety and environmental reasons, authorization to build a regasification terminal onshore is getting more and more difficult. The latest trend is to bypass the obstacle by building regasification terminals offshore on artificial islands, barges or Floating Storage and Regasification Units (FSRU-vessel). This trend can apply to LNG carriers, which become very flexible because they are able to deliver cargo to any submerged buoy connected to a mainland pipeline. The French company Cryostar, which specializes in handling industrial gases at cryogenic temperatures, has developed and patented its EcoVap modular system specifically MAY 2010
designed for the regasification process on LNG vessels. A 1 MW capacity pilot EcoVap-SW plant was recently presented to potential customers and classification societies at Cryostar’s Hésingue, France, headquarters.
According to Bernard Mann, director, Process and Shipboard Line of Cryostar, the 1 MW size demonstration plant was needed to allow modeling for a dynamic simulation of a standard 40 MW plant. The 1 MW was selected to avoid distortion in the scaling-up process. The EcoVap-SW system is designed to use seawater as a final heating medium. However, in the first generation of regasification vessels, seawater was in direct contact with the very cold pipes of the heat exchanger that circulates the LNG. This could give rise to many concerns related to safety, especially the risk of water freezing and leakage, which would then contaminate and influence sea water system availability. Cryostar’s EcoVap system uses propane as intermediate fluid. Sea water transfers the heat to a propane loop, which is kept within reasonable temperature ranges. The propane loop, in turn, transfers the heat to the LNG. In this process, propane is vaporized by the seawater and condensed again by the LNG while the LNG is vaporized at low temperature. At this point, the cold natural gas is directed through a second propane loop, which raises it to the desired temperature before being delivered to the pipeline. The heat exchangers are of semi-welded plate technology made of titanium to ensure smooth operation with seawater. The propane is contained in a tank that fills the two closed loops where it is recirculated without consumption. LNG from the cryogenic tanks is fed to the EcoVap system at high pressure 725 to 2029 psi (50 to 140 bar) by special booster pumps (RVP) also designed by Cryostar. This pump is based on a proven design, but specially adapted for offshore application. The RVP is a Class-Approved, vertical, multistage, centrifugal pump designed for deckmounted operation. It is driven by a
The complete EcoVap testing installation at the Cryostar site of Hésingue, France. From the left: cryogenic nitrogen storage tank, high-pressure pump and 1 MW EcoVap module. 12
COMPRESSOR TechTwo
EcoVap demonstration module. The 1 MW capac- ity plant is a scaled-down representative of the ac- tual plant.
standard electric motor. The number of stages (up to 14) enclosed in the barrel depends on the pressure selected to match the pipeline pressure downstream of the vaporization process. A deck-mounted pump is easier to maintain when compared to an LNG submerged pump. Motor bearings of a submerged pump are lubricated by LNG and have to be serviced every 8000 hours, while the bearings of a standard motor need service after 40,000 hours. Maintenance operations are also easier. While a submerged pump rotor has to be removed completely from the barrel and then dismantled, only the motor of an RVP pump has to be pulled down while the impeller shaft, which has no wearing points, remains in the barrel. These pumps are fed, at low pressure around 73 psi (5 bar), by the submerged pump inside the cryogenic tank. While this pump features the suction nozzle at the lower end and the discharge at the motor end in the RVP, the flow direction has been re versed in order to keep the dry gas seals (API approved) working on the low-pressure side. A typical booster pump module is equipped with two 50% pumps having a total operating range of 725 to 2029 psi (50 to 140 bar) discharge pressure, with a flow range of 4238 to 17,657 cfh (120 to 500 m 3/h). Pressures and flows can be adjusted to customer specifications. An arrangement with two booster pumps per skid usually enables an operation range from 10 to 100% of deMAY 2010
sign rating. More than one skid may be required to match the plant output. The simulation test of the 1 MW pilot plant was accomplished with liquid nitrogen simulating LNG in the gas loop, while the two propane loops were actually filled with propane gas out of a 883 cu.ft. (25 m 3 ) tank. Among the guests invited to witness the pilot plant test were representatives of GDF-Suez, presumably the first customer of the EcoVap-SW for the Triton project and Bureau Veritas. The pilot plant test was mandatory to be qualified for the Triton project. Cryostar’s EcoVap-SW main features are: high reliability and maintainability; excellent range ability because of the pump configuration; modular construction for easy scaling; skid design for versatile installation; manufactured from
proven components; reliable and versatile pumps; and in-house cryogenic process and equipment knowledge. The Triton LNG Project
In May 2008, Gaz de France (GDFSuez following merger in July) and Höegh LNG AS signed a joint de velopment agreement related to the design, construction supervision and operation of a FSRU through a 50/50 joint venture. The FSRU will serve the Triton offshore LNG terminal, developed by GDF-Suez in the Adriatic Sea about 20 mi. (34 km) off the Italian shore in the Marche Region. The FSRU with LNG storage capacity of about 6.0 MMcf (170,000 m 3), will be moored to a submerged buoy and pipeline system receiving LNG from conventional LNG carriers and supplying natural gas to the Italian energy market through a subsea pipeline. The base load regasification capacity will be 177 Bcf (5 x 10 9 m 3 ) per year, which can be increased to 354 Bcf (10 x 109 m3) per year with a second FSRU vessel. The FSRU vessel will be leased from GDF-Suez to the Joint Venture and operated by Höegh LNG on behalf of the joint venture. The technologies applied in the FSRU vessel and in the ship-to-ship LNG transfer will be selected in order to represent the safest and most costefficient solution with a minimal effect on the environment. Such a concept is particularly well adapted to meeting the growing gas needs and the stringent environmental requirements of Italy. It will put Italy in the forefront of new technological developments in LNG regasification. The studies related to the permitting and development of the Triton offshore LNG terminal are already well ad vanced. The final investment decision is expected by end of 2010. SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
Detail of the upper section of the EcoVap demonstration module. 13
COMPRESSOR TechTwo
Silcovert TH is a Neutral Point Clamped Voltage Source Drive with IGBT power devices, air cooling and a more efficient and precise control for induction and synchronous motors. H series drives (TH/NH) are compatible with existing motor systems, regardless of brand or age.
ASI MU-VLTG VBL FQUNY D Compressors can be Driven by Variable Speed Motors up to 100 MW Thanks to Power Electronics By Roberto Chellini Ansaldo Sistemi Industriali (ASI) has been developing power controls for over 110 years. In the early 1990s, the Italian company pioneered high-speed technology for gas compression applications, developments which led to the present power electronic solutions for high-power, high-speed applications. ASI said that its medium-voltage (MV) drives are designed to improve the overall flexibility and efficiency of the plant — achieving significant, longterm cost savings and emission containment by reducing energy consumption. They feature a user-friendly interface, high reliability, optimum power quality, near to unit power factor and more than 98% drive efficiency. The company maintains complete capabilities manufacturing both the drives and the electric motors in-house. The power conversion system can be configured up to 100 MW based on standard drive technology. The company’s product range comprises two different power systems: the TN and GN series, which the company engineered for regenerative operation MAY 2010
and demanding performance applications, and the TH and NH series, which are designed for retrofitting to improve efficiency and reduce environmental impact. ASI said that MV drives use a stateof-the-art control system that allows full control of the entire process and enhances overall plant efficiency. That common control platform is based on
a high-performance 32-bit CPU for distributed control and processing. The control system supports a wide variety of built-in standard communication protocols for seamless integration into the customer’s plant automation platform. Standard power modules are used to provide the correct power solution for a given application. Users can select a 12-pulse, 24-pulse or 36-pulse incoming diode rectifier (DFE). The N series drives can also be configured for active front-end (AFE) operation. By placing standard modules in parallel, it is easy to configure the drive to match specific power needs. All drives can cooled by air or water. The forced air cooling system is applied in low-power applications in which the amount of heat to be dissipated is low. For highpower applications (or dusty, polluted environments), the watercooled system is preferred because it significantly reduces ventilation and air conditioning costs. The closed-loop water cooling system also keeps the inside of the drive free from harmful agents. ASI equips its drives with a number of auxiliaries such as switchgears, transformers and harmonic filters. Normally ASI drives do not require harmonic filters, however, filters can be provided for particularly weak net works posing the risk of disturbance. The TH drives feature an intrinsically integrated transformer. ASI’s other drives can be equipped with integrated or separate transformers to meet plant requirements. The company said its intuitive human machine interface (HMI) is highly versatile and permits the user to personalize the drive settings and controls at the touch of a finger through the front panel-mounted touchscreen. This control system provides customized reports that can be easily continued on page 16
Silcovert NH is a Neutral Point Clamped Voltage Source Drive with IGBT power devices and a more efficient and pre- cise control for induction and synchronous mo- tors. Its water cooling method enables high out- put power ranges.
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COMPRESSOR TechTwo
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integrated into existing production reports. The software package includes full-diagnostics capability, and con verter data can be consulted on the drive or sent to a master control or supervision system. This control system can be configured to support a single I/O point to hundreds of digital, analog, sequence of events, and/or pulse accumulator I/O points, data trending, historic tracking, alarm processing, etc. Frequency converters are known for their tendency to generate voltage and current harmonics, but ASI said its MV drives ensure excellent power factor line-side in every situation due to the full wave rectification using multiphase diode operation. Their very low harmonic content meets the most stringent require-
Silcovert TN is a Neutral Point Clamped Voltage Source Drive with IGBT power devices and digital control for high-per- formance variable speed dri- ves for induction motors. The PWM technique with high switching frequency allows an almost sinusoidal motor cur- rent with low total losses and ripple-free torque. Diode Front End and Active Front End configurations are available.
ments for current and voltage harmonic distortion as defined by IEC and NEMA standards. The harmonic content motor-side is also extremely low thanks to the special pulse width modulation (PWM) control that eliminates the Silcovert GN is a Neutral Point Clamped Voltage Source Drive with IGCT power devices and fields-oriented control technol- ogy for synchronous and in- duction motors. Its three-level topology with Active Front End configuration achieves near-unity efficiency, near- unity power factor, minimum torque ripple and low har- monic content, both on the line and on the motor side.
current harmonics without increasing the drive’s complexity. The reliability of ASI MV drives is enhanced by the low number of components (most of them available off-theshelf) and their modular construction. Those characteristics increase equipment life by leading to reduced repair and maintenance costs. The sophisticated algorithms of the torque and speed control eliminate current peaks and produce very low torque ripple on the motor shaft, thus reducing stress on mechanical and electric components. According to ASI, experience has shown that mean time between failures (MTBF) for their variable frequency drives can be set at 60,000 working hours. SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
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lobal expansion t Compressor Products International we have been planning and impleme nting a proactive program of global expansion, to bring CPI’s expertise and de pendable quality of products and services closer to operators, wherever they may be around the world.
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) . y g r e n E s a l t A f o y s e t r u o c e g a m I (
Atlas Energy Inc. is a large independent natural gas producer with U.S. holdings in the Appalachia and Michigan Basins and in the Marcellus Shale in Pennsylvania.
ATL ENGY, RLN INDUT JN F US$1.7 Billion Venture in Marcellus Shale Atlas Energy Inc. (Atlas) has entered into a joint venture transaction with a wholly owned affiliate of Reliance Industries Ltd. (Reliance), a global energy firm that is the largest private sector company in India. The deal has Atlas transferring an interest in its Marcellus Shale position equal to 120,000 net acres (48,600 ha) in a transaction valued at US$1.7 billion. Reliance will pay approximately $340 million in cash upon closing and an additional $1.36 billion in the form of a drilling carry. Atlas will serve as the de velopment operator for the joint venture. Reliance will have the option to operate in certain project areas in the coming years outside of Atlas’ core operating areas of Fayette, Greene, Washington and Westmoreland Counties in southwestern Pennsylvania, U.S.A. Reliance will acquire a 40% undi vided interest in approximately 300,000 net acres (121,000 ha) of undeveloped leasehold held by Atlas, and Atlas will retain a 60% undivided interest in the acreage. In addition to funding its own 40% of drilling obligations, Reliance has agreed to fund 75% of Atlas’ respective portion of drilling and completion costs until the $1.36 billion drilling carry is fully utilized. Atlas has five and one-half years to utilize the drilling carry, subject to a two-year exMAY 2010
tension under certain conditions. The companies have agreed upon a five year development plan that calls for the drilling of 45 horizontal Marcellus Shale wells for the joint venture during the remainder of 2010, increasing to 108 wells in 2011, 178 wells in 2012, and 300 wells in 2013 and 2014. Atlas will act as the sole leasing agent for the joint venture in the area of mutual interest (“AMI”). In the near future, Atlas and Reliance expect to considerably grow the joint venture’s Marcellus Shale leasehold position within the AMI. Reliance will have the option to acquire a 40% share of such new acreage under terms comparable to those agreed to by Atlas, with each party paying its proportionate share of acquisition costs. In addition, if Atlas decides to sell all or part of the 280,000 additional Appalachian acres (113,000 ha) currently controlled by it, but excluded from the joint venture and not included in the AMI, Atlas has granted Reliance a right to purchase such acreage at a price of $8,000 per acre ($3240/ha). Reliance also receives a right of first offer with respect to potential future sales of this acreage by Atlas at lower prices. The acreage is located predominantly in Mercer, Crawford and other Pennsylvania 18
counties not currently included in Atlas’ core Marcellus area of south western Pennsylvania. “We are excited by this opportunity to partner with Reliance, one of the world’s largest vertically integrated energy companies, and one that has demonstrated exceptional capability in all aspects of the energy business. We believe that this joint venture will greatly increase the value of Atlas’ business,” said Edward E. Cohen, chairman and chief executive officer of Atlas Energy. “This transaction will enable us to accelerate sharply our development of the Marcellus while further reducing our already low finding and development costs, and our capital structure will immediately benefit from reduced leverage and enhanced liquidity,” he said. “As a result of this joint venture, we anticipate creating a significant number of new, well-paying Pennsylvania jobs. Pennsylvania will also benefit from our strong commitment to the highest environmental and safety standards.” The purchase and sale is subject to certain closing conditions, including the consent of participating lenders under Atlas’ senior secured credit facility. Reliance Industries Ltd. is an Indiabased industrial enterprise that ranks among the largest refiners and petrochemical producers in the world. Its recent market capitalization was over $78 billion, with current production of almost 3 Bcfed (85 x 10 6 m3/day) of oil and gas production from its E&P operations. Atlas Energy Inc. is a large independent natural gas producer in the Appalachia and Michigan Basins and in the Marcellus Shale in Pennsylvania. Atlas reports that it is also the country’s largest sponsor and manager of tax-advantaged energy investment partnerships. Atlas also owns 1.1 million common units in Atlas Pipeline Partners L.P. and a 64% interest in Atlas Pipeline Holdings L.P., a limited partnership that owns the general partner interest of APL. Atlas Pipeline Partners L.P. is active in the gathering and processing segments of the midstream natural gas industry. In the Midcontinent region in Oklahoma and Texas, U.S.A., APL owns and operates eight active gas processing plants and a treating facility, as well as approximately 10,300 mi. (16,600 km) of active intrastate gas gathering pipeline. In Appalachia, APL is a 49% joint venture partner with The Williams Companies in Laurel Mountain Midstream LLC. SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
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Undetected defects and deficiencies in critical components can lead to catastrophic failure. The CCA is an in-depth as- sessment that goes be- yond visual observations and measurements.
KNAN INT CTAL CNNT In-Depth NDT Inspection and Assessment of Load-Bearing and Safety-Related Overhead Lifting Components Konecranes, a familiar name in the world of overhead cranes and other lifting equipment, offers its Critical Component Assessment (CCA), an ad vanced inspection process utilizing nondestructive technology (NDT). CCA enables inspectors to identify and evaluate defects and deficiencies in critical load-bearing and safety-related overhead lifting components not normally discovered during routine inspection. According to Konecranes, its CCA produces a meaningful and consistent condition assessment, which allows customers to determine the reliability of their equipment. Undetected defects and deficiencies in critical components can lead to catastrophic failure. Most compliance and preventive maintenance inspections rely on visual observations and measurements, despite the fact that many defects and deficiencies cannot be identified with the naked eye. Konecranes said that the in-depth assessment possible with the CCA reaches beyond what is possible with visual observations and measurements. Experienced, certified inspectors efficiently perform CCA inspections usMAY 2010
ing proven proprietary methods such as thermal imaging and electromagnetic-inductive technology to assess the condition of critical components. Those components can include items such as internal wires, strands and wire rope core; the mechanical coupling between hoist motor and gearbox; motor winding insulation; gearbox and mechanical load brakes; and mechanical components. A complete bottom block hook inspection using NDT can also be conducted to check for cumulative fatigue that could lead to hook failure. To provide maximum flexibility, the company said that various elements of the CCA can be applied individually or grouped in the most appropriate combination to suit a customer’s particular application. These elements focus on critical areas of crane operation and include an overall crane inspection and analysis, an evaluation of the operating environment, a key components analysis and a maintenance and reliability study. The CCA results summarize the current condition of the equipment including its current operating capacity 22
and the extent of its usability. This comprehensive report allows customers to make informed decisions on how to maximize the service life and use of equipment, prioritize maintenance schedules and forecast maintenance expenses. No matter what the findings, Konecranes can provide customers with the required repairs, replacement parts and training to ensure safe equipment operation. Konecranes technicians can also provide customers with engineered solutions to maximize productivity while minimizing downtime and total life-cycle costs. Konecranes is a group of lifting businesses that serve serving a broad range of customers, including manufacturing and process industries, shipyards, ports and terminals. Konecranes provides productivity-enhancing lifting solutions as well as services for lifting equipment and machine tools of all makes. The group has 9800 employees, at more than 545 locations in 43 c ountries, including 100 service branches in North America. SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
COMPRESSOR TechTwo
Industry News Champion Laboratories Inc. Filtration manufacturer Champion Laboratories Inc. has been listed at Number 11 in Quality Magazine ’s 2010 “Leadership 100” list, which honors companies that have encouraged their employees to take an active role in ensuring quality, and for using and integrating employee ideas and opinions in the production process. This is the first year that Champion Laboratories has been included on Quality ’s Leadership 100, and it was the only company from the filter industry listed. “We’ve made some significant improvements in our quality-control system over the last few years and every one of those improvements has been the result of a committed joint effort from all of us here at Champ Labs,” said John Gaither, vice president of Engineering and Quality. Quality Magazine chose the honorees after surveying more than 800 manufacturers on criteria such as scrap and re work as a percentage of sales, warranty costs as a percentage of sales, rejected parts per million shipped, and contribution of quality to profitability and shareholder value. Companies were also evaluated based on the number of quality programs in place; registration to various standards; percentage of employees dedicated to quality responsibilities; average number of hours monthly that employees receive quality training; and the role that quality professionals play in the acquisition of test, measurement and inspection tools, software and services.
fs-Elliott, Curtis Toledo, fs-Curtis fs-Elliott co. LLC and Curtis Toledo Inc., operating under the name fs-Curtis, have established a customer support center in Houston, Texas, U.S.A. The company will focus on industrial equipment sales, customer service, repairs, field service and timely access to genuine service parts for fs-Elliott centrifugal air compressors and auxiliary equipment. fs-Compression is certified to service all fs-Elliott products. The company will also fully support fs-Curtis distributors in the Houston area with local stocking of complete units and service parts. fs-Elliott is dedicated to centrifugal air compressor technology, providing flexible air compressor solutions to various industries from automotive manufacturing, food and beverage processing, to refining and the oil and gas industries. With
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complete market focus, fs-Elliott is able to provide its customers with a complete air compressor package. fs-Elliott’s headquarters, engineering center and manufacturing operations are based in Export, Pennsylvania, U.S.A. fsElliott also has service and packaging facilities in Shanghai, China; Bangalore, India; and Jubail, Saudi Arabia. fs-Curtis, a 154-year-old compressor manufacturing firm, offers a complete line of compressors from 0.33 to 300 hp
(0.25 to 224 kW), in reciprocating, rotary screw, portable and oil-less configurations. fs-Curtis also offers vacuum pumps, refrigerated compressed air dryers, desiccant air dryers, compressed air filters, climate control compressors, and genuine fs-Curtis parts and compressor lubricants. fs-Curtis maintains a modern 150,000 sq.ft. (1390 m 2) production facility in St. Louis, Missouri, U.S.A., as well as facilities in San Diego and Los Angeles, California, U.S.A. continued on page 32
THE 5 TH EDITION HAS RAISED THE BAR. Non-linear Time Domain pulsation analysis software is necessary to meet 5 th edition requirements (including dynamic pressure drop)
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The 5 edition of API 618 has new, more stringent requirements for pulsation and mechanical vibration analysis including dynamic pressure drop, shaking forces, forced response studies, and complete range of operating conditions. Beta has been meeting these high standards for years through some unique qualifications (see above captions) earning the complete trust of global OEMs, packagers & owners. th
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23
COMPRESSOR TechTwo
SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
The Sentinel II system uses a unique and patented process that incorporates crankshaft refer- enced pressure and vibration data. Specific crank angle “windows” are identified for specific machinery faults.This data is then statistically analyzed to describe a “normal” operating signa- ture for each unit and operating condition.
SNNL II TAG — PA F MND Dynalco’s Engine and Compressor Control and Monitoring System — Modularly Designed with Operating Experience Built In By Bob Webber
The Problem
Complicated, expensive, dangerous and often remote production machinery that is subject to frequent breakdowns, is being serviced by too few trained and experienced personnel. Data exists everywhere, mountains of it, and rivers of it — being generated by more and more devices attached to the equipment. Managers and operators are drowning in data. And, on top of this, they are faced with the ever-present and changing environmental regulations. The current popular engine shutdown panels are designed to shut the skid down based on static setpoints. Although this can be sufficient, often
Bob Webber is principal engineer, Dynalco Inc., Fort Lauderdale, Florida, U.S.A. MAY 2010
they either trigger a nuisance trip, or they intervene too late and shutdown panels are there to salvage skids before additional damage is done. The practice of preventive or time-based
maintenance, while more effective than run to failure, still leaves room for improvement. We know this because machinery still breaks down at the worst possible moment. The gas industry is currently challenged with the exodus of experienced operations and maintenance personnel, and the lack of qualified replacements. Basically, the industry is being forced to grow its own again. The result of this is that inexperienced personnel are doing the best they can, but often will perform the wrong repair or not do the work correctly, leading to another failure and shutdown. Existing and new environmental regulations require higher levels of maintenance and control of compression equipment. NOx, CO, VOCs and fugitive emissions are all under increasing scrutiny by state, local and federal regulators. Control and monitoring systems are, in large part, not designed to mitigate the risks or identify the faults and recommend corrective action. In order to address these current issues, the need now is for devices, products and services that are more predictive and diagnostic in nature and take action or produce actionable information based on a thorough analysis of current operating conditions and the wear patterns of critical components. Sentinel II
The Sentinel II is an engine and compressor control and monitoring system modularly designed with intellectual capital (experience) built in. The system uses a unique and patented process that incorporates crankshaft referenced pressure and vibration data. Specific crank angle “windows” are identified for specific machinery faults. This data is then statistically analyzed to describe a “normal” operating signature for each unit and operating condition. This is called continued on page 28
Table 1. 26
COMPRESSOR TechTwo
Figure 1 and Figure 2.
Figure 3.
a “learn,” so along with temperature, fuel flow and other pieces of operating data, a complete picture of the machinery condition is developed. MAY 2010
This “learn” is then used as a “baseline” to determine how mechanical condition and performance are changing over time. The system looks at 28
every window then compares the result to the statistical norm or baseline and uses either an “SPC”-calculated alert of warning or alarm, or an operatorentered setpoint. The system has the capability for complete shutdown and start sequencing along with the ability to establish shutdown setpoints for any operating parameter, calculated parameter or windowed alert. Although not a PLC, the system sequence engine is a simple “drag and drop” operation. Because it is not a PLC, it does not require programming or ladder logic skills. When a threshold is met, the condition must persist for a period of time determined by the variance in the data or user set to ensure the condition is real. The system then provides specific information on the alert condition such as “Cylinder 1L intake valve hitting hard” and a specific recommendation such as “Schedule repair next 30 days” in the case of a warning or “Shut down and repair now” in the case of an alarm. Once the operator acknowledges the alert, a yellow or red light on the alert beacon goes from blinking to steady, to indicate the condition has been noticed. The system records the alert, the recommendation, the date and time it occurred, along with the date and time, and who acknowledged it. To clear the alert and return the system to “green,” the condition must return to within the normal statistical limits and persist at the normal state for the calculated or preset persist period. The system also provides real-time comparison to empirically measured compressor efficiency or hp/MMscfd, and measures and reports the compressor load and flow by the use of empirically developed compressor performance equations. Every piece of data, information or Sentinel-derived recommendation is made available to SCADA, via Modbus Ethernet or via the Internet if the client’s infrastructure is so equipped. Modularity provides a highly customizable solution for engine-only applications, compressor-only applications or both. A large number of I/O, both analog and digital, is supplied by adding boards, thus allowing a tight custom applicationspecific installation. I/O is configured using a windows-based configuration tool. The system provides operators with performance measures of compressor flow and horsepower, efficiency (hp/MMscfd) and deviation from baseline. The system also provides operators with driver energy usage COMPRESSOR TechTwo
and efficiency such as engine heatrate deviation from manufacturer’s guarantee, energy conversion rate and more. Application and Real-World Use
Figure 4.
The system is designed for highspeed and slow-speed machinery although its initial market penetration is high-speed engine and compressor packages running in gasgathering operations. The system is applicable to electric motor-driven compressors, engine-driven generators or pumps running at speeds from 100 to 1800 rpm. Sentinel II provides information and recommendations for impending mechanical faults that, when used on a fleet of machines, allow efficient resource allocation and equipment use. Because the system continuously monitors the key mechanical faults that impact emissions levels, the unit can be programmed to shut down when the likelihood of emission violations are high, thus saving the client the cost and headache of fines. A Scenario
Routine valve-lash adjustments are not effective. After adjustment, the Sentinel system begins warning that intake valve 2R and 6R were exceeding Figure 5.
continued on page 30
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the “learned” norm by the calculated number of standard deviations. The entire right bank was louder and had larger standard deviations after the adjustment than before. An investigation found that two different technicians set each bank and that both were “soft.” Lifter and rocker arm wear problems were encountered on those valves that continued to have high amplitudes and react to speed changes. The Sentinel data (Table 1 and Figures 1 through 6) shows that the right-side amplitudes increased by 32% from before and after the adjustments were made. The deviations only increase slightly, indicating that the mechanical looseness causing cycle-to-cycle variations was not caused by the valve lash. The graph in Figure 7 shows how a properly adjusted valve lash along with mechanically sound components respond to speed changes as compared to a valve with known problems and poor adjustment. The black line is a running average of the data.
Conclusion
This presentation concentrates on just one of many issues and characteristics of this particular Waukesha 7042 sparkignited, natural gas-fueled engine. Sentinel alarmed on and documented several other mechanical condition faults on both the engine and compressor. The graphs come primarily from another Dynalco tool called M-Health. In this small case, how quality control of maintenance activity can be tracked and documented is easy to understand. It also allows a manager to quantify the performance impact that a poorly adjusted or maintained valvetrain has on the cost of operation. Of course, this has emissions implications as well. Sentinel II is a control system that provides direct diagnosis of a problem and suggests actions to frontline personnel while providing economic justification. Start-up, shutdown, sequencing, diagnostics and fleet wide comparisons are in one modular system. SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
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30
COMPRESSOR TechTwo
Insight onsite.™ Anywhere. Any Time. When your gas compression cooling system breaks down, you’re out of business. That’s why we created our rapid-response Field Service Department – ready to put our expertise and experience to work for you on-site: anywhere, any time, 24-7-365. Who better to keep your coolers running at peak performance than the people who’ve built the best coolers in the industry for more than 55 years? For on-site maintenance, repairs, hydrostatic testing, component replacements or technical advice – for any cooler model, our brand or any other – call our Field Service Department, direct: 1-800-404-3904. Visit our new website: harscoaxc.com Mission-critical:
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Industry News Alliance Engineering
M. McKinstry
T. Yates
Wood Group’s Alliance Engineering has hired Matthew A. McKinstry an d Tommy L. Yates as facility engineers whose responsibility will be to develop and execute major offshore projects. McKinstry has a process engineering background, with 14 years of experience in domestic and overseas oil and gas projects. He has been the lead process engineer on Gulf of Mexico production platforms and on several large FEEDs for international projects. He holds MS and BS degrees in Chemical Engineering from the University of Michigan. Yates has a mechanical engineering background and, for the past 18 years, has led the engineering, design and conMAY 2010
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struction efforts for numerous onshore and offshore production and transmission facilities around the world. He earned a BS degree in Mechanical Engineering from Ohio State University and is a registered Professional Engineer in the U.S. state of Texas. Alliance Engineering has also hired Greg Vetter as manager of offshore business development within its offshore business unit. In his new role, Vetter will be responsible for identifying opportunities and enhancing the growth of Alliance in existing and new offshore markets. He G. Vetter has over 10 years of sales, marketing and business development experience, with eight of those servicing the offshore oil and gas majors and independents. He has a record of successful accomplishment, and comes to Alliance from EDG, where he served as business development consultant responsible for offshore business development. He holds a BBA degree in 32
Management from Baylor University, and is a member of SPE, PMI, API, GPA and AMA. Based in Houston, Texas, U.S.A., Alliance Engineering provides “highly optimized concept-to-completion custom engineering solutions” for the oil and gas industry. Some of the most visible projects in the world compose Alliance’s onshore and offshore project portfolio, according to the company. Alliance said it emphasizes quality initiatives and cost-effective engineering as it serves customers in three energy market segments: deepwater, shelf/ FPSO and onshore. In addition to its Houston headquarters, Alliance operates out of an office in Denver, Colorado, U.S.A. Wood Group is an international energy services company with approximately US$5 billion in revenue, employing 28,000 people worldwide and operating in 50 countries. The group consists of three businesses — Engineering & Production Facilities, Well Support and Gas Turbine Services — that provide a range of engineering, production support, maintenance management and industrial gas turbine overhaul and repair services COMPRESSOR TechTwo
sible.
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Industry News to the oil and gas, and power generation industries.
Dresser Waukesha Natural gas engine manufacturer Dresser Waukesha has been awarded ISO 14001 certification for its headquarters and manufacturing operations in Waukesha, Wisconsin, U.S.A. ISO 14001 is an internationally recognized standard for environmental management systems that helps organizations indentify the impact and risks associated with carbon emissions, energy and water use, and waste stream management, as well as to develop programs to control and improve performance in those areas. “The decision to seek ISO 14001 certification demonstrates Dresser Waukesha’s commitment to minimizing the impact of our operations and products on the environment,” said Somnath Dasgupta, director of Environmental Health & Safety for Dresser Waukesha. “Receiving this certification is the culmination of a rigorous process that began over a year ago and required the company to conduct a thorough review of every aspect of our operations. It in volves a detailed process by which we MAY 2010
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identified potential environmental impacts. Going forward, we will use a process of continuous improvement to de velop plans to eliminate or minimize those impacts and promote sustainable processes,” he said. “The ISO process also provides a platform for moving beyond compliance to establishing future sustainability goals and further reducing our impact on the environment,” he said. Dasgupta also underscored Dresser Waukesha’s ongoing commitment to helping other companies reduce their energy footprint by developing “greener,” more efficient engines. He said that Waukesha’s product lineup includes engines that operate with very low emissions, engine-generator sets designed for combined heat and power applications to squeeze maximum energy out of the fuel they burn and engines that operate on waste gases such as methane from digesters and landfills. The company has an ongoing partnership with the U.S. Department of Energy for the development of efficient, low-emission engines. The first result of this collaboration is Waukesha’s highly efficient 1 MW APG1000, which was in33
troduced in 2006. Recently, the company received another grant that is being used to increase the efficiency of its APG2000/3000 models.
Shenhua Group China’s state-owned Shenhua Group has completed a feasibility study for its second coal-to-liquids (CTL) plant. The plant is being developed with South African coal processing specialist Sasol. While the commercialization of the technology is still at an early stage in China, its success in South Africa suggests that over time it could come to play an important role in China’s fuels balance. The facility would have a capacity of 93,000 bbl/d, above earlier estimates of 80,000 bbl/d.
The PROS Co. The PROS Co. has announced the addition of a sales engineer. Tom Logsdon , who resides in Farmington, New Mexico, U.S.A., will be responsible for sales and company promotions in the Rocky Mountain States and Eastern Plains. Logsdon has a professional background in the Air Drilling sector of the industry. continued on page 50 COMPRESSOR TechTwo
The first ship to complete its official regasification test was Golar Winter , Golar LNG’s LNG’s 4.9 MMcf 3 (138,000 m ) LNG floating storage and regasification unit. unit. Hamworthy outfitted outfitted the vessel vessel with regasification technology technology that uses seawater as the heating medium for vaporizing LNG.
MI AITI F LNG RIFITI SYT Hamworthy’s Hamworthy’ s Regasification Systems Systems on FPSO Fleet By Ian Cameron Hamworthy Gas Systems has delivered its first vessels to feature feature regasification technology that uses seawater as the heating medium for vaporizing liquefied natural gas (LNG). “This is a milestone in the introduction of another new technology to the offshore market,” said Reidar Strande, director of LNG Marine. Hamworthy supplied the onboard vaporizer system, comprising three LNG regasification skids. The technology is based on an intermediate closed propane loop that that transfers heat energy from seawater for vaporizing LNG. “The intermediate propane circuit between seawater and LNG is applied to avoid freezing. As it is based on sea water heating the equipment, it has a high level of efficiency and therefore requires less fuel and operating cost to regasify the LNG than steam-based systems,” said Strande. The first ship to complete its official regasification test was Golar LNG’s 4.9 MMcf (138,000 m3) LNG floatin floating g storage storage and regasification unit (FSRU) Golar Winter,, which is chartered Winter chartered by Petrobra Petrobrass and is part of an LNG import project in Guanabara Bay, Brazil. LNG carriers will tranship cargoes to the FSRU, which will then send gas to an onshore gas grid through a subsea pipeline. Built as an LNG carrier in 2004, Golar Winter was converted to an FSRU by Keppel Shipyard in MAY MA Y 2010
Singapore. After leaving the Keppel yard, yard, LNG LNG cargo cargo was collecte collected d in Trinidad en route to Petrobras’ Pecem Terminal, Brazil. Initial commissioning and testing began in Pecem before the vessel departed for Petrobras’ Rio terminal for further testing. Golar Winter was tested with two skids operating in parallel for full regasification capacity of 495 MMcfd (14 x 106 m3/d) at 1739 psi (120 bar), equivalent to 507 tons/h (460 tonnes/h), said Hamworthy. Hamworthy signed a contract with Golar LNG in July 2007 to deliver the propane regasification skids. Capacity per skid is 247 MMcfd (7 x 10 6 m3/d), outlet pressure pressure is 1492 psi (103 bar), and outlet outlet tempe temperature rature can reach reach 42°F (6°C). Two skids will be used during nominal send-out, with a third skid on standby. Each 77 ton (70 tonne) skid is 34 x 20 x 26 ft. (10.5 x 6.1 x 8 m), and contains the required pumps, motors, heat exchangers, instrumentation and control systems to provide the required capacity. The equipment is designed for marine installations and cryogenic working conditions, and can handle large variations in sendout capacity, Hamworthy said. The vaporizer system also was commissioned on the Suez Neptune , a 4 MMc MMcff (145 (145,00 ,000 0 m3) LNG shu shuttl ttle e reregasification vessel (SRV) built by 34
Samsung Heavy Industries and delivered in December 2009. The vessel has picked up an LNG cargo in Trinidad, and regasification tests being held off Boston, Massachusetts, U.S.A., were due to be finalized in February 2010. SRVs transport and store LNG, which is then vaporized into natural gas and sent ashore by subsea pipeline. A seco second nd Neptune Neptune SRV SRV,, Suez Cape scheduled for delivery delivery during Ann , is scheduled the second quarter 2010. For both ships, Hamworthy is supplying three regasification skids per ship with each vessel having a regasification capacity of 231 tons (210 tonnes/h) tonnes/h) of LNG with send-out pressure of 1666 psi (115 bar). Hamworthy’s third regasification project was for the 4.5 MMcf (126,000 m 3 ) F S R U Golar Freeze for Dubai Supply Authority (DUSUP) and Shell in Dubai, United Arab Emirates. Hamworthy delivered the regasification skids for this vessel in September 2009. The system was installed on the 1977-built LNG carrier, which is being converted into an FSRU before being chartered by DUSUP for 10 years, with options to extend for up to another five years. After its delivery to DUSUP in the second quarter of 2010, Golar Freeze will be permanently moored alongside a purpose purpose-built -built jetty jetty within the existing existing Jebel Ali port. The FSRU will be capable of storing 4.4 MMcf (125,000 m 3) of LNG and delivering up to 494 MMcfd (14 x 106 m3/d) of regasified LNG to DUSUP for further delivery into the Dubai gas network. In a separate move, Hamworthy Moss AS has signed contracts to deliver 10 shipboard inert gas systems to be installed on a series of 316,000 dwt crude oil and product tankers being built by Waigaoqiao Shipyard, China. The company has won orders specifying Hamworthy Moss flue gas systems for four 316,000 dwt crude oil tankers due for delivery between June 2010 and August 2011 to Nanjing Changjiang Oil Transportation Corp. Hamworthy has also secured contracts to supply Moss Multi-Inert systems for six 316,000 dwt crude oil and product tankers to be delivered by Waigaoqiao Shipyard to Singaporean ship owner Ocean Tankers between June 2010 and October 2011. Geir Hellum, managing director of Hamworthy Moss, said, “These sophisticated systems have been designed to enable Ocean Tankers the choice to handle or store surplus product, in line with the demanding trading patterns of the ships.” SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
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Recent Orders Burckhardt Compressors to Polysilicon Production Burckhardt Compression delivered three process gas compressors to “Semiconductor Plant” JSC for its polysilicon production plant in Zaporozhye, Ukraine. The contractor for the proje project ct is centroth centrotherm erm photo photo- voltaics, from Blaubeuren, Germany, which provides technology, equipment and services for the photo voltaics industry. The contract consists of three process gas compressors including auxiliaries, lube oil system, piping, compressor control system and electric drive motors. The compressor trains will be installed in the gas recovery unit within the chlorine-silane regeneration operation. This specific compression process requires knowledge in dry-running technology, an accurate material selection for this severe operating en vrionment as well as reliability and high availability. MAY 2010
Burckhardt Compression has over 20 years of experience in in-house tribology research and therefore offers a wide range of application-specific materials available with extensive expertise for process gases with extremely abrasive pollution. Polysilicon is used in the production of monocrystalline and multicrystalline solar wafers. The principal raw material is used to produce the solar cells that converts sunlight into electricity. Start-up of the polysilicon production is scheduled to be in the second quarter of 2010. Burckhardt Compression is supporting the customer by supervision of the assembly and the commissioning of the compressors on-site. Burckhardt Compression’s process gas compressors are used in the refinery and petrochemical industry as well as for industrial gases and gas transport and storage. The company said its products offer high availability and a long mean time between 36
overhauls thanks to design, in-house engineered high-quality components and valves, which together with great serviceability result in lowest life-cycle cost. Burckhardt Compression is the only manufacturer offering a complete range of laby (labyrinth piston), process gas and hyper compressors.
Dresser-Rand Turbomachinery for Four FPSOs Dresser-Rand Group Inc. will supply advanced turbomachinery to three different clients for four floating, production, storage and offloading (FPSO) vessels. Three of the four are destined for Petrobras’ pre-salt oil fields in the Santos Basin offshore Brazil and one will work in the U.K. sector of the North Sea. The order is for 14 centrifugal compressor trains comprising 18 casings, two DR-61G (LM2500) mechanical drive gas turbines and four DR-61GP COMPRESSOR TechTwo
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Recent Orders
(LM2500+) gas turbine generator sets for these projects. The total price for the scope being supplied exceeds US$120 million. The compressor trains will be manufactured in Le Havre, France, and Olean, New York, U.S.A; the gas turbine generator sets will be engineered by Dresser-Rand’s gas turbine packaging center of excellence in Kongsberg, Norway. Dresser-Rand booked these orders in March 2010. “We “W e are very pleased that that we have have been selected to supply the critical rotating equipment for these important projects. Leveraging our global presence and world-class singular processes, our teams in Houston [Texas, U.S.A], Le Havre, Kongsberg and Kuala Lumpur [Malaysia] worked closely with our clients’ teams on selecting the best technology to meet application requirements and offer singlesource solutions for compression and power generation,” said Jesus Pacheco, MAY 2010
Dresser-Rand’s executive vice president, New Equipment Worldwide. Among the equipment being supplied will be some of the highest-density reinjection compressors ever built, such as the 550 bar [7975 psi] units to compress a 35+ mole weight natural gas/CO2-blended stream, as well as CO2 compressors to re-inject carbon dioxide to over 300 bar [4350 psi] pressure,” he said. “Two of the four FPSO projects in volve relocation of existing vessels and required very short cycle times, which we were able to meet. This award is representative of the value our technology, cycle times and ad vanced business processes bring to our clients,” added Pacheco. These vessels will be capable of handling oil production and treatment of approximately 100,000 to 120,000 bbls/d and have gas compression capabilities of up to 150 MMscfd (4.25 x 106 m3/day). 37
“We believe activity in the floating production market will continue to be significant and, as our success in every FPSO project that has closed since the fourth quarter of 2009 shows, that our value proposition remains compelling,” said Pacheco. Dresser-Rand supplies rotating equipment to the worldwide oil, gas, petrochemical and process industries. The company operates manufacturing facilities in the United States, France, United Kingdom, Germany, Norway, India and China, and maintains a network of 37 service and supportt centers suppor centers coverin covering g more than 140 countries. Follow us on
www.compressortech2.com COMPRESSOR TechTwo
Caterpillar has introduced the C7 ACERT, C9 ACERT and C32 ACERT hazardous location water-cooled mani- fold diesel engines, designed to meet the requirements of offshore and other haz- ardous applications where an ignition source from the engine, such as hot skin temperatures or electrical arching, could spark an explosion.
KING CL AND SF Caterpillar Introduces Hazardous Location Water-Cooled Manifold Diesel Engines Caterpillar Global Petroleum has introduced the C7 ACERT, C9 ACERT and C32 ACERT hazardous location water-cooled manifold diesel engines, designed to meet the requirements of offshore and other hazardous applications where an ignition source from the engine, such as hot skin temperatures or electrical arching, could spark an explosion due to hazardous chemicals or gases in the environment or cause danger due to engines housed in close quarters. The C7 is available with ratings of 205, 231 and 275 hp (153, 172 and 205 kW) at 2200 rpm; the C9 is rated 341 hp (254 kW) at 2200 rpm; and the C32 is available at 801, 860, 920 or 1100 hp (597, 641, 686 or 820 kW at 2100 rpm. The engines were developed to meet the most current land and offshore emission requirements including EPA Tier 3, EU Stage 3a and I MO an d E PA M a ri n e T i er 2. Additionally, said Caterpillar, with the use of the EPA Tier 4 flexibility provisions, the EPA Tier 3 ratings will be applicable for land-based applications until 2018. Caterpillar’s manifold engines feature water-cooled exhausts and turMAY 2010
bochargers to maintain lower engine skin temperatures. The reduced engine skin temperature allows the engine to operate in enclosed areas and around hazardous materials. ATEX safety directives require that engine skin temperatures remain below 392°F (200°C) (T3). Certifications obtained by the engines include: •ATEX 94/9 Group II, 3G (Zone 2) Ex nA T3; • Electrical system certified to gas group IIC; • Mechanical system certified to gas group IIA; •NEC 500 — Class I Division 2 Non-incendive Field Wiring Group T3 certification; and •NEC 500 — Class I Zone 2 AEx nA nR Group IIC T3 certification. To prevent errant sparks, the electrical harness and components are designed with a protective molding to keep contained any sparks that may occur . Depending on the application, different cooling options are available to provide packaging flexibility. Both the separate circuit (water-to-air) aftercooled and the remote aftercooled cooling system are available on the 38
C9 ACERT engines. The C7 ACERT and C32 ACERT engines feature the separate circuit (water-to-air) aftercooled cooling system. ATEX safety directives require that engine skin temperatures remain below 392°F (200°C) (T3). In order to comply, some ATEX configurations come with software to automatically derate engine power to maintain ATEX T3 skin temperatures in all ambient conditions up to 113°F (45°C), said the company. Caterpillar said these engines represent the first from the company that come from the factory with the hazardous location certifications. While previous engine models were able to operate in those environments, the user had to apply for certifications. Typical application can be found in offshore well servicing duties such as workover, pumping, fracturing, cementing and coiled tubing. The C7 and C9 engines are manufactured in Greenville, South Carolina, U.S.A., and the C32s are manufactured in Griffin, Georgia, U.S.A. They are all currently available for order. SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
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AJAX C-202 Separable Compressor
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TINAL BHAVI F CLX C TAIN The Design of Complex Machine Trains Includes Optimization for Dynamic Loads Acting on Foundations, Irregularity Degree and Torsional Stresses By Amin Almasi
ity degree and torsional stresses [1, 2]. It needs detailed torsional analysis to ensure reliability, availability and proper design. Avoiding torsional resonance (particularly at or near the lower operating speed harmonics), and to ensure that shafts and other components are suitably sized to avoid failure during possible severe transient disturbances is of paramount importance. If shaft or rotating component failures occur, the consequences can be catastrophic. An entire machine can be wrecked as a result of large unbalancing forces that can arise following shaft separation. These have actually occurred [3]. Vast damage and loss of human life can occur.
This is the fourth in a series of technical articles by the author. The first article, “Recommendations for Pulsation Control of Reciprocating Compressors,” was published in the January-February issue of COMPRESSORTech . The second, “Piston-Rod Load Capability of Reciprocating Compressors,” appeared in the March issue, and the third, “Crosshead Slap in Reciprocating Compressors,” was published in the April issue. Editor’s Note:
Two
A multimachine train consists of several complex shafts and rotors and relatively flexible shaft extensions and couplings. It may also include gears and flywheels. Because connected machines function as spring systems in series, the potential exists for torsional resonance and torsional fatigue damage. Couplings are often modified to tune the overall system. Multimachine complex trains have complex torsional behavior. Complex rotating machine trains are becoming common trains in industries. For example: 1. Train including compressor, electric motor and turbo expander gas recovery turbine. 2. Multi-throw and multicylinder reciprocating machines. Figure 1 shows an example of complex rotating machine trains.
Torsional Model
The model must be accurate enough to simulate the real system behavior (usually below the 10 th multiple of the maximum rotating speed). Very high frequency additional modes have no effect on reliability (no resonance is foreseen and also they are high-frequency and low-amplitude exciting harmonics)[4]. Basically, the model is represented by a number of rotating masses connected to each other by means of mass-less shaft intervals with appropriate torsional stiffness. Rotating masses can represent both the shaft or rotor intervals and the connected components (such as impellers, blades, connecting rods, piston rods, crossheads, etc). Proper dedicated lumped masses for all accessories (such as flywheel, gear wheel, exciter, connecting flange, etc.) also must be added to the model. Figure 2 shows a torsional model for a complex rotating machine train.
Figure 1.Three machine casings, compressor, motor and recovery tur- bine, joined through couplings and SSS clutch.
The design of complex machine trains includes optimization for dynamic loads acting on foundation, irregular Amin Almasi is
lead rotating equipment engineer in Technicas Reunidas S.A., Madrid, Spain. He holds a chartered engineer certificate from IMechE (CEng MIMechE), a chartered professional engineer license from Engineers Australia (MIEAust CPEng – Mechanical) and he also holds MS and BS degrees in Mechanical Engineering. He specializes in rotating machines including reciprocating, centrifugal and screw compressors, gas and steam turbines, process pumps, condition monitoring and reliability. Almasi is an active member of IMechE, Engineers Australia, ASME, CMVI, Vibration Institute, SPE, IEEE, SMRP and IDGTE. He has authored more than 30 papers and articles dealing with rotating machines, condition monitoring and reliability. For additional information or answers to questions, contact the author via his e-mail address:
[email protected] MAY 2010
Figure 2. Torsional model for a complex rotating machine train.
Nomenclature used in presented model: Torsional displacement of mass i (rad). i Polar moment of inertia of mass i (kg s 3/m). J i Torsional stiffness of the shaft internal i (Nm). K i Damping coefficient for interval i (kg s 2/m). C i Damping coefficient for the mass i (kg s 2/m). C Mi continued on page 44 42
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n m M a,i
M i
Model lumped mass total number. Maximum torque harmonic order. Resonance amplifier for shaft interval i. Torsional natural frequency (rad/s). Applied torque to mass i (Nm).
(mostly diameter) can be studied jointly with electric machine sub-vendor. Rotating machine rotor, shaft or crankshaft geometry is never modified to accommodate torsional application requirements. Steady-State and Transient Torsional Responses
The governing equations of system to calculate the damped forced torsional vibration are as equation (2).
Torsional Natural Frequencies
The goal is to locate natural frequencies away (usually by 10%) from potential excitation frequencies that might come from machines[4, 5, 6]. In addition, as a recommendation, natural frequencies should be placed 10% outside of electrical net frequency and 5% outside of its second multiple [4]. In practice, the first three modes of vibration usually need to be investigated carefully.
&& + K (θ − θ ) = 0 J 1θ 1 1 1 2 & & J iθ i + K i −1 (θ i − θ i −1 )+ K i (θ i−θ i +1 ) = 0 , && + K (θ − θ ) = 0 J θ n
n
n −1
n
= 2,..., n − 1
n −1
Torsional natural frequencies come from equation (1). The calculation of the undamped natural frequencies is a problem of Eigen values and Eigen vectors that represent natural frequencies and mode shapes respectively. Because of low damping level [3, 4], undamped natural frequencies can represent natural frequencies of the real train. In case the torsional natural frequencies do not meet mentioned margins (10% away from potential excitation frequencies), individual train components should be modified. A parametric study of the natural frequency calculation method presented here can provide information on how to denute a rotating machine’s train. Modification of the coupling torsional stiffness by an appropriate tuning of the coupling type or space diameter is primary and is the easiest solution. Generally, the coupling is the most flexible shaft interval in a train and has a strong influence on torsional natural frequencies, especially the first torsional natural frequency. Range of available coupling options is vast, from flexible couplings to rigid forged flanged connection (without coupling). However, if a coupling modification is not sufficient and further modification is required (for example more torsional stiffness is required to raise torsional natural frequencies), modification of the electric machine shaft geometry
L E A DI N G
+ K 1 (θ 1 − θ 2 )+ C 1 θ &1 − θ &2 + C M 1θ &1 = M 1
&& J iθ i
+ K i −1 (θ i − θ i −1 )+ K i (θ i−θ i +1 )+ C i −1 θ &i − θ &i −1
(
(
)
+ C i θ &i − θ &i +1 + C Miθ &i = M i ,
&& J nθ n
Equation (1) i
&& J 1θ 1
(
i
Equation (2)
)
= 2,..., n − 1
)
+ K n−1 (θ n − θ n−1 )+ C n−1 θ &n − θ &n −1 + C Mnθ &n = M n
The general expression of the steady-state applied torques (Mi), includes a vibrating component superimposed on an average torque level as shown in equation (3). Train load torques can be decomposed, through a “Fourier Analysis” into a series of sinusoidal curves, which frequencies are multiples of the machine running speed. The modulus generally decreases as the harmonic order increases. Optimum solution suggested as calculation of 25 harmonics (m=1 to 25 in this formula). Equation (3) m
M i = ∑ M i , p sin ( pω t + α p ) p =0
The torsional dampening is assumed to be the hysteretic. Solution of equation (2) can be obtained based on “Principle of Linear Superposition.” The system is composed of (n) linear differential equations with (n) parameters, tri-diagonal and symmetrical. Its solution can be transferred to the solution of (m) differential equation systems (each equation related to a different harmonic of the exciting forces). The transient torsional analysis requires a different and more time-consuming calculation method. It requires a direct integration of the motion equations, and the solution is time dependent. The differential equations of motion are similar to those of the steady-state equation (2) but they have different exciting torques [4]. continued on page 46
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MAY 2010
44
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Leave it to the experts when it comes to critical parts for your engine, and enjoy peace of mind. Avoid potential early failure and unscheduled downtime caused by using “will fit” parts. For parts and service information, contact your local Cummins distributor or OEM dealer, call our 1-800-DIESELS™ Customer Assistance Center or visit quickserve.cummins.com.
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Case Study
Analytical results are presented for a multi-throw, heavyduty, complex reciprocating compressor for refinery service. Driver is a direct-coupled, 18-pole, 330 rpm, induction electric motor. Extensive simulations are shown for this train regarding frequency separation, required maximum current pulsation and all possible transient cases. A flexible coupling is the best and optimum option. The first torsional natural frequency is well below the train operating speed. (It is around 3.7 Hz and approximately 33% below train speed.) The second natural frequency is well above the 10 th harmonic of train operating speed. (It is around 70 Hz.) This implies an adequate separation. Coupling stiffness variance of about 30% would be required for the train to reach resonance. Figure 3 shows the reciprocating compressor brake torque vs. crank angle for one revolution of the crankshaft under steady-state conditions. The solid and dashed-dotted curves represent compressor torque for normal full load and (50%) unloaded conditions, respectively. The transient event of a phase short circuit is assumed to last about 0.8 seconds. The electric motor is subjected to a high-frequency and high-amplitude oscillating torque. Peak torque is around 3.5 times the normal value. Torsional tran e 1.8 u q r o T 1.6 d e t a R 1.4 r o t o M1.2 c i r t c e 1 l E / e u 0.8 q r
sient response is substantially reduced by train damping with a flexible coupling. The compressor is started while unloaded, and the nominal running speed is achieved within five seconds. Table I shows equivalent moment of inertia for compressor train components. It shows the importance of electric motor moment of inertia.
Half Load (50%)
50
100
150 200 250 Crank Angle (Degree)
300
Each Cylinder Throw (Four Throw)
~ 1%
Flywheel and Half Coupling
31.5%
Half Coupling
1.5%
Electric Motor
63%
Table II shows equivalent interval stiffness for compressor train components (other train components are considerably stiffer than flexible coupling). For a train with flexible coupling (specifically for when a flexible coupling with rubber elements which have low stiffness is used), it is possible to approximate the first natural torsional frequency with a simple 2° of freedom model (considering that the coupling as the only flexible interval). Usually it provides the first natural torsional frequency with around 10 to 20% error. According to the API, proper margins (with natural frequencies) for all harmonics up to 10 th multiple of machine speed shall be investigated. In addition, other coincidences up to 20 th multiple of machine speed shall be respected if there are lower frequencies or frequencies around the third natural torsional frequency. In this example, very close margins are evident for 13th, 15th and 16th multiples of machine speed with second and third torsional natural frequencies. No significant source of excitation in all parts of the package should occur to excite these frequencies (such as bearings, meshes, grids, teeth, mechanisms, VSD, etc.). The case of the 16th multiple of machine speed is of more concern.
Normal Full Load
0
Equivalent Moment of Inertia of Components as % of Train (Total) Moment of Inertia
Table I: Equivalent moment of inertia for compressor train components.
T e 0.6 k a r B r 0.4 o s s e r p 0.2 m o C
0
Component
350
Figure 3. Reciprocating compressor torque vs. crank angle.
continued on page 48
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MAY 2010
46
COMPRESSOR TechTwo
Bringing energy and the environment into harmony.
24/7/365 SERVICE — BECAUSE EVERY PART COUNTS. Dresser-Rand Services cover everything from upgrades, revamps, rerates, product training, and field services, right down to the nuts and bolts. And with the largest installed base of rotating equipment in the industry, Dresser-Rand is ready to deliver comprehensive service solutions for your centrifugal and reciprocating compressors, steam and gas turbines, and control systems—quickly, efficiently and safely. With approximately 40 service centers around the world, our personnel stand ready to help maximize the reliability, production revenue, and profitability of your rotating equipment. So keep downtime down—with service that’s up to any challenge.
Visit us at OTC .10, Booth 6105 and EGCR, Booths 317 & 319
The Americas: (Int’l +1) 713-354-6100 / EMEA: (Int’l +33) 2-35-25-5225 Asia-Pacific: (Int’l +60) 3-2093-6633 /
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First Throw – Second Throw
172
Second Throw – Third Throw
27
Third Throw – Fourth Throw
172
Compressor (Fourth Throw) – Flywheel
94
Coupling
1
Electric Motor
31
Table II: Equivalent interval stiffness for compressor train components. Practical Recommendation
Numerous torsional vibration problems continue to occur in complex rotating machine trains. Main reasons are lack of comprehensive torsional vibration study, improper application and maintenance of couplings (mainly flexible couplings), using electric machines traditionally used in noncomplex applications (such as variable speed motors) and lack of monitoring. As a rule of thumb, the electric machine shaft diameter should be equal to or greater than the reciprocating machine crankshaft diameter. Shaft materials should be highstrength steel. If welds are required on the shaft, a weldable shaft material should be used. Proper weld procedures and material compatibility must be considered. Fabrication details such as the electric machine pole bolt torque, etc., should consider loads caused by torsional vibration. Continuous operation at torsional resonance should be avoided. Coupling and electric machine torsional characteristics have strong influence on train torsional vibration and can be modified to tune the system. Avoid full-load shutdowns especially of trains with torque-sensitive equipment. Trains with short flanged connections (no coupling) and singlebearing electric machines have much lower damping; however, they have higher natural frequencies and may be acceptable after careful review of torsional analysis. Measuring and verifying torsional vibration is important during performance tests. Transient events are critical and should be respected in details. They include synchronous electric machine start-up, short circuit and loaded shutdown. A train that passes through a torsional natural frequency during start-up may produce significant transient shaft stresses. A start-up analysis should be performed to determine if low-cycle fatigue is a potential problem. Coupling torque is usually chosen on the basis of mean requirements for full load. It must have a sufficient service factor to handle likely overload (such as electrical faults). Only accurate modeling of an electrical machine can result in an accurate torsional analysis of a train (accurate modeling such as detailed Finite Element Model [F.E.M.] or detailed analytical model to obtain flexibility and inertia of rotating parts of an electric machine). Otherwise, it can result in missed torsional natural frequencies, inaccurate torsional analysis and torsional problems. Recommendations for coupling include high torsional stiffness coupling (best and optimum option, if torsional simulation confirmed, frequency separation and transient torques) or flexible coupling (more elasticity and damping and more maintenance) or integral, rigid, forged-flange connection (more rigidity, high natural frequencies and much less damping). Conclusions
The torsional analysis method for complex rotating equipment should include data used in mass elastic systems, display
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Equivalent Interval Stiffness as Ratio of Flexible Coupling Stiffness (K/Kcoupling)
continued on page 50 48
COMPRESSOR TechTwo
SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
of torque vs. speed, torsional critical speeds, mode shape diagrams, all possible steady-state and transient cases, worst-case design, upset condition results and sensitivity analysis. References [1]
Heinz P. Bloch, “Compressor and Modern Process Application,” John Wiley and Sons, 2006. [2] Heinz P. Bloch, “A Practical Guide To Compressor Technology,” Second Edition, John Wiley and Sons, 2006. [3 ] Duncan N. Walker, “Torsional Vibration of Turbomachinery,” McGraw-Hill, 2004. [4] Enzo Giacomelli, Carlo Mazzali, Nocola Campo, Paolo Battagli, Fabio Falciani, “Torsional Analysis of A-20 Cylinder Hypercompressor Train, Proceeding of ESDA2006, Engineering System and Analysis,” Torino, Italy, July 4-7, 2006. [5] Shelley Greenfeld and Kelly Eberle, “New API Standard 618 (5 th Edition) and its Impact on Reciprocating Compressor Package Design – Part I, II and III,” Two COMPRESSOR Tech , June, July, August/September 2008. [6] Vibration in Reciprocating Machinery and Piping Systems, Engineering Dynamics Inc., Engineering Dynamic Inc. (EDI), San Antonio, Texas, U.S.A., June 2007.
Industry News
CTechTwo
Hardy Instruments Inc.
SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
Rebuild all brands, makes, models of screw Compressors and Gear Boxes Sample of The PROS Company work.
Hardy Instruments Inc. recently appointed Stan Modzel as North American service sales manager. Modzel will play a key role in expanding Hardy’s service business, including pre-sales application engineering, system installation and start-up, scale verification, calibration and certification, emergency troubleshooting and service and pre ventive maintenance and inspection throughout North America. Modzel brings over 30 years of applicaS. Modzel tion and field service experience to his position. Prior to joining Hardy Instruments, Modzel served as service manager for Mettler-Toledo Scales in Florida, U.S.A., and most recently formed and managed SMS Services, a weighing/construction services business.
Burckhardt Compression
Before
&
Burckhardt Compression has modernized its existing Training Center at its headquarters in Winterthur, Switzerland. In order to meet the requirements of customers that operate laby, process gas or hyper compressors, Burckhardt expanded the range of compressors available for hands-on practice in the center. Theoretical compressor training continues to be offered at the center. Space available for training is now about 3230 sq.ft. (300 m2) in a dedicated building located at the company’s headquarters. The Training Center stands adjacent to the building where the compressors are engineered and manufactured. Burckhardt Compression’s compressor training has always taken place nearby the company’s workshops. That proximity allows participants to observe compressor components and view the assembly process for a variety of compressor models. As an OEM, Burckhardt Compression’s reciprocating compressor experts can provide tailor-made theoretical education as well as practical courses. The chief training instructors gained extensive knowledge in compressor operation, optimization and efficient compressor troubleshooting on international jobs, and have broad technical backgrounds. continued on page 57
After
The PROS Company 601 Texas Avenue Lubbock, Texas 79401 806-749-7761 (PRO1) www.thePROSco.com
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50
COMPRESSOR TechTwo
RUNNING TIMES
36 UPDATE
13,000 HOURS STILL RUNNING STITT S-AGR18LLBEX17-2 one-piece, extendedlength, Annular Gap electrode spark plugs with STITT USL2LE-VHP4 secondary leads being operated at a field booster, engine-compressor station in the coal seam methane zone in the Powder River Basin of Wyoming.
Engine is a 1200rpm, 4-stroke cycle V-12 cylinder, Waukesha© L7044GSI driving separable compressors. This engine has a cylinder head design in which the engine manufacturer fits a short, conventional spark plug, a plastic extension, and an ignition coil that bolts to the valve cover. This arrangement has some durability and maintenance deficiencies. And it requires the usage of expensive components. Contrast the engine manufacturer’s ignition arrangement to the STITT solution. 1. LOWEST COST STITT-RECOMMENDED IGNITION COMPONENTS Remote-Mounted Ignition coil
Secondary Lead Extended-Barrel Spark Plug
MANUFACTURER and PART NUMBER
LIST PRICE
Altronic 501-061 (or Equivalent)
$58.00
Stitt USL2LE-VHP4
$40.54
Stitt S-R807LLBEX17-2 $28.99 or Stitt S-AGR18LLBEX17-2 $39.47
HIGH VOLTAGE COMPONENTS TOTAL COST
$127.53 $138.01
STITT Selected Components ORIGINAL EQUIPMENT IGNITION ENGINE MANUFACTURER LIST COMPONENTS PART NUMBER PRICE Valve Cover-Mounted Ignition coil Plastic (PTFE) Extension Short Spark Plug
69694G
$263.89
A211797G
$169.94
60999Z
$47.34
HIGH VOLTAGE COMPONENTS TOTAL COST
$481.17
Factory Selected Components 2. COMPLETELY ISOLATES SECONDARY CIRCUIT FROM ELECTRICAL CONTAMINANTS. 3. ELIMINATES THE NEED TO REMOVE THE IGNITION COIL TO CHANGE THE SPARK PLUG. 4. OFFERS A “HANDS-ON” SPARK PLUG INSTALLATION PROCEDURE.
STITT
®
STITT SPARK PLUG COMPANY Conroe, Texas 281-443-2279 • 936-756-7796 Fax: 936-539-9762 • Email:
[email protected] Web: www.stitt-sparkplug.com SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
The Petrojarl I FPSO in which the LMF reinjection module has been in operation for more than 60,000 service hours.
GA INJTIN DUL NBAD AN FPSO UA 60,000 VI HU Upgrades Include a Water Reinjection, Two Gas Reinjection Modules and Diesel-Driven Generator Sets
DNV issued certificates for another 15 years of operation. Upgrading of this FPSO included the installation, in a more friendly way, of a water reinjection module, two gas reinjection modules and new diesel-driven generating sets to produce the power required onboard. The production stream arriving on the Petrojarl I is first treated in the separation plant where the oil is stored in the 180,000 bbl FPSO storage tanks to be then exported to the UK. Produced water is purified and reinjected in the reservoir and the low-pressure 24.6 psi (1.7 bar) associated gas, still in wet condition, is recompressed up to 297 psi (20.5 bar) to be further processed onboard before being reinjected in the same well used to reinject production water. LMF has engineered and manufactured the compressor module according to API 618 code. The 178,000 lb. (81,000 kg) module features an LMF B 154 balanced opposed reciprocating compressor driven, at 720 rpm, by an 805 hp (600 kW) electric motor, with interstage heat exchangers, moister separators, interconnecting piping, instruments and controls. The four-cylinder compressor features a cast-iron crankcase with integral crosshead extensions. The four-throw, forged-steel crankshaft has a 5.9 in. (150 mm) stroke with a 11.6 fps (3.6 m/s) mean piston speed, which allows a long service life for the PTFE piston and rider rings. The first compression stage consists of two double-acting cylin-
By Roberto Chellini
Flaring of associated gas at oil wellheads has been a long-standing practice in spite of international recommendations. The Norwegian government has been one of the more strict guardians of the environment. Norway discourages oil companies from such practice on the continental shelf under its jurisdiction by introducing a heavy “carbon tax” that penalizes gas flaring. The first application of associated gas reinjection modules onboard an FPSO is said to date back to 2001. Then, LMF of Austria was asked to supply one gas reinjection module for the Petrojarl I FPSO. At the beginning of the new century Statoil Hydro (at that time Statoil) started producing oil from the Glitne Field located in the North Sea, 143 mi. MAY 2010
(230 km) west of Stavanger, Norway, in water depth just over 328 ft. (100 m). Glitne is the smallest oil field in Norwegian waters and is estimated to contain 25 MMbbl of recoverable oil reserves to be produced within a twoto three-year timeframe. Subsequent drilling more than doubled the estimated reserves (Glitne II) and extended the time of recovery well be yond the original timeframe. The Petrojarl I is a purpose built, turret-mooring, production vessel, built in Japan in 1986 that had performed 10 different jobs in the North Sea in 15 years. In 2001, the decision was made to upgrade it to make it comply with the latest Norwegian Shelf conditions. The refurbishing operations took place at the Kvaerner’s Rosenberg yards in Stavanger and 52
The LMF associated gas reinjection module being lifted for installment on the Petrojarl I FPSO deck during the upgrading operations performed in 2001 at Kvaerner’s Rosenberg shipyard in Stavanger, Norway.
COMPRESSORTechTwo
Detail of the LMF bal- anced opposed com- pressor inside a gas reinjection module.
ders featuring a 21.7 in. (550 mm) bore while the second-stage cylinders have a 11.4 in. (290 mm) bore. To handle a wide variety of gas compositions and flows (and to also meet different condensation rates of the compressed gas), each compressor stage is designed to be controlled individually between 10 and
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100% by the HydroCOM hydraulic suction valve control system and a bypass valve to meet zero to 10%, also, if necessary. The complete control system, designed by LMF, includes a PLC controlling the compressor logic system. The water-cooled cylinders are oil lubricated, the lube oil system for
crankcase and cylinder lubrication is included in the package. Pulsation suppression is achieved with a vessel system at the inlet and discharge sides of each compression stage. The vessel system is built according to a pulsation study responding to API 618, Approach III. All the equipment is assembled on one steel skid and some top frames that are bolted together to form the module. The complete assembly was submitted to a test run, according to API 618, at LMF premises prior to shipment. The various skids and frames were shipped separately and the modules reassembled in Bremerhaven, Germany, before being lifted and placed on board the FPSO. Oil production at the Glitne Field started on Aug. 28, 2001, and all the water and natural gas associated with oil production have been reinjected in the reservoir in order not to pollute the environment. According to LMF, the gas compression module has been operating in continuous service with full satisfaction of the operator. The total number of service hours reported by the operator in September 2009 is 56,618, presumably surpassing the 60,000 service-hour milestone at the time of publication. SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
CANI RGNIZD F MIDTA SAFTY STATITI Annual Safety Honors Given by Gas Processors Association At its 89th annual convention in Austin, Texas, U.S.A., the Gas Processors Association (GPA) recognized both GPA and Gas Processors Suppliers Association (GPSA) member companies for outstanding midstream industry safety achievements in 2009. GPA President Bob Dunn made the presentations before an audience of more than 1600 industry professionals from around the world. “Despite gas processing involving volatile substances at high pressures, the natural gas industry has a superb safety record,” said Dunn, senior vice president of Prism Gas Systems. “Recognizing the outstanding safety performances of our member companies each year and routinely bringing together safety managers throughout the year to share learned knowledge for the benefit of everyone, are important parts of this association’s continuous focus on safety.” GPA member companies that received Safety Award recognitions for being the top performers according to last year’s safety statistics include those listed here. In Division I (companies reporting more than 500,000 workhours), Hess Corp. (Houston, Texas) received firstplace honors for its 0.290 “total cases” incident rate and zero “fatalities plus lost workdays” incident rate over 688,508 workhours among top U.S. firms. Second place was awarded to BP America Production Co. (Houston) for a 0.338 “total cases” incident rate and zero “fatalities plus lost workdays” incident rate for 592,418 workhours. Among GPA’s international-based entrants, the Division I first-place winner was United Gas Derivatives Co. (Cairo, Egypt) with a 0.170 “total cases” incident rate and zero “fatalities plus lost workdays” incident rate for 1,173,249 workhours. Pharanoic Petroleum Co. (Cairo, Egypt) received second place with a 0.199 “total cases” incident rate and zero “fatalities plus lost workdays” incident rate for 1,005,577 workhours. In Division II (companies reporting 100,000 to 500,000 workhours), first place went to U.S.-based CenterPoint Energy Field Services (Shreveport, Louisiana, U.S.A.) with a zero “total MAY 2010
Workhours/Years 7,000,000 Workhours 5,000,000 Workhours 2,500,000 Workhours 2,000,000 Workhours 1,500,000 Workhours 1,000,000 Workhours
500,000 Workhours
45 Years 30 Years 15 Years
10 Years 5 Years
Company United Gas Derivatives Co. Plants Anadarko Petroleum Corp. San Juan River Gas Plant Pharaonic Petroleum Co. Operations Saudi Aramco Yanbu NGL Fractionation Saudi Aramco Haradh Gas Plant Saudi Aramco Juaymah NGL Fractionation Aux Sable Liquid Products Chevron Hatter Pond Gas Plant Saudi Aramco Hawiyah Gas Plant Saudi Aramco Juaymah NGL Fractionation Saudi Aramco Shedgum Gas Plant Aux Sable Liquid Products CenterPoint Energy Field Services Operations Southern Union Gas Services Ltd. Jal #3 Plant Saudi Aramco Shedgum Gas Plant Targa Resources Mont Belvieu Terminal Saudi Aramco Juaymah NGL Fractionation Saudi Aramco Uthmaniyah Gas Plant Devon Gas Service LP Worland Gas Plant Targa Resources Calvert City Targa Resources Lake Charles Plant Elkhorn Gas Processing Roystone Gas Processing Hiland Partners Eagle Chief Plant ONEOK Field Services Co. LLC Panther Creek Plant Targa Resources Lowry Plant Southern Union Gas Services Ltd. Jal #3 Plant Targa Resources Yscloskey Plant AKA Energy Group LLC San Bois Treating Facility Enerfin Resources Co. North Texas Operations Enerfin Resources Co. Cenpat Operations PVR Midstream Crescent Gas Plant Targa Resources Abilene Plant
Companies receiving facility safety honors for 2009.
cases” incident rate and zero “fatalities plus lost workdays” incident rate during 294,665 workhours. Second place was awarded to AKA Energy Group LLC (Durango, Colorado, U.S.A.), which reported “total cases” and “fatalities plus lost workdays” incident rates of zero for 164,069 workhours. On the international side, firstplace winner in Division II was Phoenix Park Gas Processors Ltd. (Trinidad, West Indies) with a zero “total cases” incident rate and zero “fatalities plus lost workdays” incident rate for 291,256 workhours. Division III (including companies reporting less than 100,000 workhours), SemGas LP (Tulsa, Oklahoma, U.S.A.) received the first-place award for companies based in the U.S. with 54
a zero “total cases” incident rate and zero “fatalities plus lost workdays” incident rate for 85,707 workhours. Second place went to Hawk Field Services LLC (Tyler, Texas) with zero “total cases” incident rate and zero “fatalities plus lost workdays” incident rate for 83,184 workhours. Aitken Creek Gas Storage ULC (Calgary, Alberta, Canada) received the top international honor for the di vision with zero “total cases” incident rate and zero “fatalities plus lost workdays” incident rate for 33,765 workhours. Also presented were the GPA President’s Awards for Safety Improvement, recognizing member companies that notably improved their own safety records. By the award’s criCOMPRESSOR TechTwo
Company ExxonMobil United Gas Derivatives Co. Pharaonic Petroleum Co. Bahrain National Gas Co. Hess Corp. Enogex LLC BP America Production Co. CenterPoint Energy Field Services Phoenix Park Gas Processors Ltd. Pioneer Natural Resources Chesapeake Energy Hiland Partners PVR Midstream LLC Red Cedar Gathering Co. AKA Energy Group LLC Mustang Fuel Corp. Questar Gas Management Aux Sable Liquid Products Inc. Enerfin Resources Co. Copano Energy SemGas LP Hawk Field Services LLC Superior Pipeline Co. Carrera Gas Companies LLC Prism Gas Systems LP M2 Midstream LLC El Paso Production Oil & Gas Gathering Co. LLC Aitken Creek Gas Storage ULC (Unocal - Chevron) Marlin Midstream Elkhorn Energy LLC
Workhours 1,185,583 1,173,249 1,005,577 833,097 688,508 660,160 592,418 294,665 291,256 233,203 227,713 180,957 176,645 167,607 164,069 142,650 138,895 117,860 103,657 85,802 85,707 83,184 75,803 67,546 62,685 50,226 45,117 33,765 29,787 27,040
Companies receiving Perfect Record certificates for 2009.
teria, the improvement must have been at least a 25% reduction in the company’s total recordable incident rate for the year in comparison to their average of comparable records for the three previous years, and they must not have had an Occupational Safety and Health Administration reportable incident during the year. GPA Safety Improvement winners were CenterPoint Energy Field Services (Shreveport, Louisiana), Hiland Partners (Enid, Oklahoma) and Saudi Aramco (Saudi Arabia). GPSA also honored safety winners from its membership of supplier companies. Barry D. Payne and Associates Inc. (Houston), CB&I (Houston), ENGlobal Engineering (Tulsa), Master Corp. and Ref-Chem (both of Odessa, Texas) received top distinctions from GPSA President Harvey Hensley from ENGlobal. A GPSA Award for Safety Improvement was also presented, going to member company URS Corp. (Tulsa). Facility safety honors, recognizing a facility for operating without a losttime accident or fatality, are recognized by the association each year, too. The following facilities were noted for such accomplishments based on having achieved at least half-million workhours or having satMAY 2010
isfied five-year-interval plateaus within statistical year 2009. Additionally, GPA member companies with no lost-time accidents from Jan. 1, 2009, through Dec. 31, 2009, received Perfect Record certificates. The Gas Processors Association (GPA) is an incorporated, nonprofit trade association made up of about 115 corporate members, all of whom are engaged in processing natural gas into merchantable pipeline gas, volume movement or further processing of liquid products from natural gas. The active membership, as a group, accounts for more than 90% of all natural gas liquids produced in the United States and also includes a number of Canadian companies and international companies that produce natural gas liquids on a global scale. GPA has served the light hydrocarbons industry since 1921 and has been instrumental in shaping the midstream business. SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
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VLU AU NW EXUI T MB Company Expands Procurement and Production Equipment Leadership
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Houston, Texas, U.S.A.-based Valerus Compression Services, a full-service provider of natural gas compression, processing and treating services, has announced two new members to its leadership team: Scott McKinnon, vice president of procurement; and Frank Smith, vice president of production equipment. In his role as vice president of procurement, McKinnon will be responsible for “enhancing vendor relationships and maximizing purchasing strength” in the manufacturing, packaging and general operations areas. A certified purchasing manager, McKinnon brings to Valerus more than 25 years of experience in global sourcing, supply chain and procurement manufacturing operations. He previously worked at Ingersoll Rand Co., where he most recently served as a sector vice president and oversaw spending in manufacturing and assembly facilities around the world. Prior to that, McKinnon spent 19 years with Pratt & Whitney as a procurement manager among various company divisions. McKinnon has an MBA from Embry-Riddle University and a BS degree from Florida State University. As vice president of production equipment, Frank Smith will be responsible for expanding overall business services and increasing market share in the production equipment business, with emphasis on shale play. Previously, Smith served as the executive vice president of NATCO, where throughout his 17-year tenure he helped grow the standard and traditional business segment to over US$350 million in revenue. He holds a BA degree in Marketing from Texas Tech University and currently serves on the board of directors for the Petroleum Equipment Suppliers Association and the Gas Processors Suppliers Association. Smith also is a member of the Society of Petroleum Engineers and the American Petroleum Institute. Valerus Compression Services owns and operates compression equipment in excess of 450,000 hp (336 MW) and currently operates more than 30 facilities worldwide. SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
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MAY 2010
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Industry News GE Oil & Gas, Petrovietnam GE Oil & Gas has signed a Memorandum of Understanding (MOU) with the Vietnam National Oil and Gas Group (Petrovietnam), the Government of Vietnam wholly owned company responsible for all oil and gas resources in the country and the third largest oil producer in Southeast Asia. Signatories to the MOU were Nguyen Quoc Thap, vice president of Petro vietnam, and Marco Caccavale, North America region, general manager of GE Oil & Gas, in the presence of His Excellency Nguyen Tan Dung, prime minister of the Socialist Republic of Vietnam, during his visit to Washington, D.C., U.S.A. Regarding the MOU, Nguyen Quoc Thap said, “This agreement will accelerate our already successful cooperation with GE Oil & Gas, reinforcing our longterm partnership to benefit the efficient development of oil and gas resources in Vietnam. We are confident that GE Oil & Gas will continue to play an important role in helping Petrovietnam contribute to the national and regional economy.” Claudi Santiago, president and CEO, GE Oil & Gas, said, “We are honored to sign this MOU with Petrovietnam — already a highly valued partner to GE Oil & Gas. Our agreement sets out a clear basis for continued successful cooperation in the coming years. We are dedicated to supporting the continued development of oil and gas resources in Vietnam and are capable of delivering technologically ad vanced projects of significant scale to meet the growing energy needs of Vietnam and the region.” The MOU outlines the principles and basis of long-term collaboration between GE Oil & Gas and Petrovietnam regarding the supply of advanced oil and gas equipment, services and spare parts to optimize the total life-cycle value of key oil and gas projects. It creates a frame work of standardized contractual terms, conditions and manufacturing slot reser vations, and provides for potential future cooperation on new oil and gas technologies, and access to GE’s Lean and Six Sigma management practices as well as other training and technical support. G E O i l & Ga s h a s a s tr o n g lo c a l presence in Vietnam in Hanoi and in Ho Chi Minh City for turbomachinery, drilling and production equipment, and services support, respectively. The company provides technology, equipment and services to projects such as the BP Pipeline, Dung Quat Refinery, Phu My Refinery, Caumau Fertilizer and Vietsovpetro. The MOU will enable GE Oil & Gas to more effectively collaborate on other projects with
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Petrovietnam, including Petrovietnam’s Nghi Son Refinery, Long Son Refinery, Chevron Block B Off-Shore development and the Long Son Petrochem Complex.
Monico Inc. Monico Inc. has relocated its headquarters to 5527 Louetta Rd., Suite D., Spring, Texas, 77379. Phone: 281-350-8751. Monico Inc. provides pre-configured monitoring solutions for industrial engine communications. The company specializes
in communications with industrial engines, generator sets, marine propulsion and auxiliary engines, and heavy construction equipment using many different standard and nonstandard protocols. Monico’s experience in communicating with Caterpillar engines and generator sets has earned it the opportunity to service dealers in Taiwan, China, Europe, Russia, the Middle East, Australia, South America and almost every dealer in the United States. continued on page 78
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MAY 2010
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COMPRESSOR TechTwo
Model of an electric motor drive boil-off gas (BOG) compressor train.
HADI F BI-OFF GA I LA LNG AT BOG and End Flash Compressors Complete GE’s Offer to Large LNG Producing and Receiving Terminals By Roberto Chellini reciprocating compressors, which are ber of ethylene compressors hanGE Oil & Gas has gained leaderdling gas at temperatures as low as ship status in the supply of large recurrently used in the majority of LNG frigerating compressors for LNG proplants, and by centrifugal compres148°F (-100°C) — a good starting ducing plants. However, these plants sors, which are gaining ground in the point to reach -256°F (-160°C). plants now under construction. Also in the IGV field, GE’s experialso need gas compression for what are called “auxiliary services” such as To better handle large flow variaence extends from the single-stage handling of boil-off gas (BOG) and tions, the service is typically subdi(SRL) to high-pressure (BCL) ammo vided into two or three machines nia synthesis compressors with recyflash gas. The size of the compressors cle impeller where the gas flow to used in these services is not as spec working in parallel (this configuratacular as those for the refrigeration tion is applicable both with recips be recycled depends on the reactor and centrifugals). The main features cat conditions. process, but the cryogenic temperaThe typical configuration of the GE ture of the gas and the variation in characterizing these centrifugal comcapacity call for dedicated machines. pressors are: the use of variable inlet Oil & Gas BOG compressor, to feed the In order to supply customers the guide vanes (IGV) to control the gas turbine fuel system, consists of a flow and the head; the use of cryotwo-casing centrifugal compressor train entire line of compressors installed driven by a fixed-speed electric motor in an LNG plant, GE Oil & Gas has genic materials for all components in introduced spethrough a step-up gear. BOG is fed at cialized “auxiliary” To better handle large flow variations, the service is typically approximately 14.5 compressors. Especially de- subdivided into two or three machines working in parallel psi (1 bar) around manding, due to -256°F (-160°C) at the inlet of the lowthe low and largely variable gas temperature (-256° to contact with very cold gas that can pressure casing (MCL) and delivered -112°F [-160° to -80°C]), and for the reach -256°F (-160°C). at the outlet of the high-pressure cas All other system components being at a pressure of 435 to 580 psi (30 wide variation of the flow to be hanto 40 bar) depending on the type of dled, is the BOG compressor. long to the horizontally split (MCL — (Minimum flow occurs when the plant low pressure) and vertically split gas turbine used to drive the main is on hold and the BOG comes from (BCL — high pressure) centrifugal LNG refrigerating compressors (the discharge pressure is set to match the the plant storage tanks. Maximum compressors. flow occurs when loading one or even GE started the development of needs of the turbine fuel system). two LNG carriers — an operating BOG centrifugal compressors by imDue to the largely variable flow plementing a technology that, to a and temperature conditions of this mode that can be found again in LNG service, the system is frequently receiving terminals.) certain degree, was already well BOG compression can be done by known. In fact, GE has built a numequipped with a large quenching MAY 2010
58
COMPRESSOR TechTwo
KIENE INDICATOR VALVES
drum receiving the BOG, the recycle gas (hot) and an LNG connection used to spray LNG to make up minimum flow and/or decrease the temperature. The LNG spray system is al ways present for safety reasons but its use is restricted to when it is really needed due to costs. It has to be noted that while the BOG temperature from the land storage tanks is practically constant and around -256°F (-160°C), the temperature of the BOG from LNG carriers can vary substantially (-184° to -112°F [-120° to -80°C]) based on the distance of the compressor system from the mooring point of the ship. LNG spray can be necessary to avoid thermal shocks in the piping and compressor materials. This is also when capacity control by IGV is not sufficient and
FOR COMPRESSOR ANALYSIS
FOR MAXIMUM ACCURACY, KIENE’S NEW FULL-OPENING CV-70 SERIES INDICATOR VALVES PROVIDE THESE FEATURES:
“While the BOG temperature from the land storage tanks is practically constant and around -256°F (-160°C), the temperature of the BOG from LNG carriers can vary substantially (-184° to -112°F [-120° to -80°C]) based on the distance of the compressor system from the mooring point of the ship.”
• Large, Straight-Through flow path minimizes channel resonance and maximizes accuracy.
• Compact design is safe — no need for separate nipples or adapters. • Vent Valve safely relieves pressure prior to removing transducer. • 2000 PSI, 250° (F) capacity. • Quarter-turn for fast operation
Safety Locking Handle option is also available THE CV-SERIES INDICATOR VALVES ARE DESIGNED SPECIFICALLY FOR COMPRESSOR ANALYSIS. CALL NOW FOR INFORMATION.
part of the compressed gas is recycled from discharge to the quenching drum. The cooler placed on the line can only mitigate the temperature rise due to compression. GE Oil & Gas has focused on the design of four components from the Centrifugal Compressor product line: variable inlet guide vanes (IGVs), dedicated inlet flange, cryogenic materials and dedicated mechanical design.
KIENE
DIESEL ACCESSORIES, INC. Telephone: 1-800-264-5950 Fax: 630-543-5953 E-mail:
[email protected] Website: www.kienediesel.com SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
Variable Inlet Guide Vanes GE’s experience in the use of IGVs is extensive (for axial and centrifugal compressors, gas turbines and expanders), but until recently did not cover cryogenic applications on compression stages. It was therefore decided to carry out an in-depth investigation of the aerodynamic and mechanic design of the system. On the aerodynamic side, CFD analysis allowed GE to optimize the profile, the length and the number of blades necessary to achieve a wide control of flow and head. In addition, the inlet scroll was redesigned and its distance from the first impeller eye calculated to minimize flow distortion at the impeller inlet. The system was then designed to withstand thermal
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Inside of the testing device showing the gears of the IGV during the test carried out at the Florence, Italy, R&D facility with liquid nitrogen. MAY 2010
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IDEAL ANALYZER TO MEASURE ENGINE EMISSIONS E INSTRUMENTS provides the latest technology in hand-held instrumentation with the NEW E2200 analyzer that is ideal for emissions monitoring including quarterly tests as well as tuning and maintenance of rich and lean burning gas & diesel engines.
Testing device and variable inlet guide vanes (IGVs) tested at cryogenic temperature, reached by means of liquefied nitrogen, in a specially de- signed pit located at the GE Oil & Gas R&D facility in Florence.
shocks and operate at cryogenic temperatures with the highest reliability. Aerodynamic and mechanical testing of the system took place on a prototype at the GE Oil & Gas research and development manufacturing center in Florence, Italy.
E2200 features include:
Dedicated Inlet Flange The IGVs are assembled on the inlet flange and submitted to the lowest temperatures and to thermal shocks during transients, which are common in this type of service. The inlet flange houses the dry gas seals, one main bearing and the shaft for the actuation of the IGV, which operates at cryogenic temperature at its inner section and at ambient temperature on the outer one, which in turn becomes a potential point of ice formation (blocking IGV turning). A heating serpentine has been incorporated in the flange to protect the dry gas seals and the bearing from excessive low temperatures. The serpentine is heated with oil drawn from the lube oil console and warmed up by a dedicated heater. Drainage of the oil from the serpentine is provided as a safety device to avoid oil freezing in case of power failure. A separate electric heating device has been placed around the shaft controlling the IGV. In case of heating
• O2, CO, and NO/NOx Gas Sensors • Pre-Calibrated & Field Replaceable Gas Sensors • CO2% and Excess Air Calculations • Built-In Impact Printer • Unbreakable Metal Hose Connections • PC Software Package & Internal Memory • Temperature & Draft/Diff. Pressure Measurements
E Instruments International Phone: 215-750-1212 www.E-Inst.com SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
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COMPRESSOR TechTwo
failure, a nitrogen buffering system will automatically replace the heater to avoid ice formation and thus blockage of the shaft controlling the IGV position. This dedicated flange has been designed to function as an end cover for barrel-type (BCL) centrifugal compressors and also to equip horizontally split (MCL) compressors after modifying the cold end of the casing. The IGV system is usually mounted only on the low-pressure casing, but depending on the degree of flow and head control requested, can be assembled on the high-pressure casing as well. Cryogenic Materials and Dedicated Mechanical Design To maintain a good resilience at low temperatures, alloy steel with 9% nickel content has been used for all components in contact with cryogenic gas. The 3-D and 2-D impellers are standard in their general configuration, however, the hub area has been extended to better distribute the stresses in their interface with the shaft and the key removed to avoid stress concentration. In fact, during start-up, the cryogenic gas will cool the impellers before the shaft cools down and the stresses on the hub tend to increase until a steady state is achieved. When the compressor is shut down, temperature stratification tends to build up inside the machine to avoid rotor bowing, which would induce high vibration during the dedicated start-up procedure that has been de veloped to create a homogenous temperature distribution across all of the internal components. During transients, which are very frequent in this type of service, expansion of the various components, due to their varying size and mass, occurs with different timing. Consequently, the clearance of the interstage labyrinth seals placed on the diaphragms, had to be substantially modified when compared with compressors handling gas at conventional temperatures. In fact, during shutdown, the rotor warms up more quickly than compared to the diaphragms and contact of the labyrinths with the impeller eye must be avoided. In addition, compressor performance has to be calculated taking into account internal recirculation in steadystate conditions. Testing Program A performance test on the IGV system plus first stage of compression has been performed and demonstrated very good flow control and
improved efficiency in respect to the original standard design. An IGV testing vehicle was set up to test the IGV operability at various temperatures including steady state, with the IGV immersed in liquid nitrogen down to -310°F (-190°C). The GE Oil & Gas offering for BOG compressors also includes a cryogenic performance and mechanical test, which is carried out in an external test bed. The cryogenic temperature is obtained in the inlet of the compressor through a heat exchanger capable of decreasing the inlet temperature
down to -184°F (-120°C). The testing facility provides the capability to completely simulate the operability of both low- and high-pressure casing compressors at full load. SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
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TAKE A CLOSER LOOK !
PATENT PENDING
TM
Can the CECO rMAX high-speed poppet valve outperform plate valves? HIGH-SPEED POPPET VALVES Yes! The rMAXTM high-speed
poppet valve provides greater reliability for high speed reducing compressor downtime. We installed CECO’s rMAX poppet valves “ in our high-speed compressors 2 years ago and they’re still going strong. Now that’s reliability! TM
— Brad L. Goodwin ” CenterPoint Energy
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COMPRESSOR TechTwo
Altronic Detonation Sensing Monitors are designed for use on natural gas-fueled engines to detect detonation and misfire and avoid consequential engine damage.
NW, U F ALI Detonation Sensing Monitors Help Guard Against Catastrophic Engine Damage Altronic Inc. has released the Detonation Sensing Monitors (DET1600 and DET-1620), 24 Vdc-powered, 32-bit microprocessor-based electronic instruments designed for use on natural gas-fueled engines to detect detonation and misfire and avoid consequential engine damage. Industry-standard, low-cost, piezoelectric vibration sensors are mounted directly on the engine and are used to transform the vibrations caused by combustion into electrical signals, which are then evaluated by the DET device. These values — generated for every cylinder on a cycle-by-cycle basis — are then measured against misfire and detonation setpoints configured by the user for the monitored engine. The monitor accepts up to 16 detonation sensors that are wired to pluggable Phoenix-type connectors; the recommended configuration is one sensor per cylinder. The DET-1600 is used in conjunction with standard negativeground ignition systems; the DET-1620 is used exclusively with the Altronic CPU-2000 digital ignition system. The DET system can be configured MAY 2010
to take a number of control actions to protect the monitored engine upon indication of detonation (or misfire). In many applications, the DET will use one of two solid-state output switches to activate an external unloader to reduce engine load. Should that remedial action be unsuccessful addressing the detonation issue, the DET can be configured (when used in conjunction with a digital ignition system) to automatically retard the ignition timing. In the event that an ignition timing adjustment also proves to be ineffective in eliminating engine detonation, the second output switch — typically tied to a digital annunciator or other moni-
toring device — acts as a final safety measure to shut down the engine. The DET system is housed in a rugged, powder-coated, aluminum enclosure and features an integral 2x16 backlit LCD to display the detonation and misfire reference level numbers, engine cylinder labels, control and output switch status, the cause of shutdown log and all diagnostic messages. System configuration is accomplished using an onboard RS485 serial port and a powerful, yet easy-to-use, system configuration and monitoring program. SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
ALI DIIL/B-GH SI GU MI PU, TU, VII OH VIL The Altronic DSG-1611DUPS, DSG-1692DUS, and DSG-1682DUPS are ad vanced digital/bar-graph setpoint gauges for monitoring, displaying and protecting either one or two process variables such as temperatures, pressures, etc. The DSG-1611 is a universal one-point model that replaces the former DSG-1301/1601 series. The DSG-1682DUPS and DSG-1692DUS are two-point versions. 62
COMPRESSORTechTwo
These universal models can be connected to either type J or K thermocouples, zero to 5 volts or zero to 25 mA (scalable) input signals. In the DSG1692, this choice is made independently for each of the two monitored points. In addition, all versions have an RS-485 serial port with Modbus communications protocol with five selectable baud rates: 9600, 19,200, 38,400, 57,600 and 115,200. This versatility makes the DSG gauges universal panel products, thus reducing spare parts requirements to a minimum. Power requirement is 12 to 36 Vdc, 0.25 Amps maximum. A unique feature of the DSG gauges is the high-resolution 16-character, eight-line digital readout/bar-graph display that gives the operator an immediate indication of the reading as a percent of (user-selectable) transducer span or span between high/low setpoints, as well as a reference to direction and amplitude of a rapid change in reading. The display also indicates the units and annunciates an alarm by number (first or second setpoint) and type (high or low). The front panel of the microprocessor-based gauge has a sealed membrane keypad for easy selection and adjustment of the units, transducer range and setpoints. There are two (one on the DSG-1682DUPS) solid-state, form C (N.O. and N.C.) output switches. Each output can be assigned both high and low setpoint values that are retained indefinitely. The precision nature of the output switch allows these gauges to be used as control devices. DSG-1611DUPS: The single-point model has both 4 to 20 mA proportional output and RS-485 serial communications. It replaces all prior models of the DSG-1301 and 1601 and can be programmed for both a low and high output for each of the two output switches. DSG-1682DUPS: The dual-channel DSG-1682DUPS is a single-loop PID controller that accepts up to two type J or K thermocouples or zero to 5 volt, zero to 25 mA transducer input signals. This sophisticated instrument/ controller is designed to offer the following modes of operation: • 4 to 20 mA output loop vs. the channel 1 input or channel 2 — channel 1 (differential); and • direct or inverse PID output based on the input of channel 1 or in a “mapping” mode that allows the channel 1 PID setpoint to be modified by the monitored input of channel 2. DSG-1692DUS: In the standard dual-point model, each channel is independently assigned for type J or K
thermocouple, zero to 5 volts or zero to 25 mA input signals. This allows the device to be used for one temperature and one pressure or two of either type. In addition, the device can be set up with a differential setpoint between the two monitored points.
Altronic digital/bar-graph setpoint gauge monitors are available in three configurations.
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• Field proven with over 55,000 units sold • Compressor O.E.M.’s Preference • 3 Year “Unconditional” Warranty • Ratings: CSA C-US 186200 Class 1, Division 1, Groups A,B,C,D T4 CE 0344 Class I, Zone 1, Ex md IIC T4 Ex II 2G EEx md IIB T5 KEMA 00ATEX 1090X, AMB. -40°C – +85°C
• Fail Safe in Open Loop or Closed Loop Modes • Manufactured in the USA by Whitlock Instrument Since 1996, ISO 9001:2000 Certified • Distributed by Progressive Equipment Celebrating 38 Years of Customer Service • Field Replaceable 3.6v Lithium Tadiran Battery PROGRESSIVE EQUIPMENT INCORPORATED
14028 Aston Avenue Houston, Texas 77040 USA 713.462.1061 • Fax 713.462.4027
[email protected] www.peilube.com
“Your Single Source For Any Lubrication Application” SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
MAY 2010
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COMPRESSOR TechTwo
Table 1. The “3 Ruling” history of RICE NESHAP — note the current NESHAP Subpart ZZZZ emission standards for both major and area sources are pending a final rule in August for SI RICE.
A DFFNT GN F RICE Revised National Emissions Standards for Reciprocating Internal Combustion Engines in Stationary Applications By Brian Kromer
Brian Kromer Brian Kromer is managing director of Infleksion, a firm dedicated to pro- viding custom market analytics, strate- gic dashboards and software to the en- ergy industry, with a special emphasis on point source emissions. He can be reached at
[email protected]. MAY 2010
In February of 2010 the U.S. Environmental Protection Agency (EPA) released a new amendment to the final rule on the “Subpart ZZZZ — National Emissions Standards for Hazardous Air Pollutants for Stationary Reciprocating Internal Combustion Engines,” with new requirements targeting compression ignition (CI) or diesel engines and revisions yet to be finalized for spark-ignited (SI) or natural gas and gaseous-fueled engines — herewith termed “CI RICE” and “SI RICE,” respectively. The SI RICE portion of the rule is anticipated to be finalized by September 2010, but both CI RICE and SI RICE emission standards stem from the March 2009 EPA proposed rule, which is just now happening. This one-year timeframe since last March to this February might seem like warp speed when we consider that 14 years passed from the time EPA was mandated by Congress to address the mitigation of hazardous air pollutant (HAP) emissions (through the Clean Air Act Amendments of 1990) to initial promulgation of the RICE NESHAP rule. 64
The only significant action other than this February 2010 final rule amendment was one promulgated in January 2008, tightening this very RICE NESHAP Subpart. Table 1 summarizes the timeline of each successive Subpart ZZZZ final ruling since 1990. The original 2004 Subpart ZZZZ targeted only those RICE with site rating over 500 hp (373 kW) located at facilities considered “major” for hazardous air pollutants HAPs. The terms “major source” and “area source” have been defined by the EPA based on the quantity of hazardous pollutant being emitted. A facility is considered a “major source” if it has the “potential to emit” at least 10 tpy (9.07 T/yr) of any single HAP or 25 tpy (22.7 T/yr) or more of any combined HAPs. The designation of major or area source is important because, generally speaking, mandates that are evermore stringent apply to major sources versus area sources. The history of air quality regulatory programs from the Clean Air Act COMPRESSOR TechTwo
Emission Limits for New and Reconstructed Stationary RICE 500 hp at Major Sources and New and Reconstructed Stationary RICE at Area Sources •
Engine Power
Engine Type and Fuel
Manufacture Date
Non-emergency July 1, 2008 25 < hp < 100 SI Natural Gas and Non-emergency SI July 1, 2008 Lean Burn LPG (severe duty) Non-emergency July 1, 2008 100 ≤ hp ≤ SI Natural Gas and Non-emergency SI Jan. 1, 2011 Lean Burn LPG Non-emergency July 1, 2008 hp < 500 SI Landfill or Digester Gas Jan. 1, 2011 25 < hp <130 ≥ 130 hp
Emergency Emergency
Jan. 1, 2009 Jan. 1, 2009
Emission Requirement g/KW-hr or (g/hp-hr) or [ppmvd at 15 % O2 ] HC+NO x NO x CO VOC 3.8 6.5 (2.8) (4.8) 3.8 200.0 (2.8) (149.2) (2.0) (4.0) (1.0) [160] [540] [86] (1.0) (2.0) (0.7) [82] [270] [60] (3.0) (5.0) (1.0) [220] [610] [80] (2.0) (5.0) (1.0) [150] [610] [80] (10.0) (387) (2.0) (4.) (1.0) [160] [540] [86]
RECIPROCATING AND CENTRIFUGAL COMPRESSORS
Table 2. New Source Performance Standards (NSPS) to consider with the pending RICE NESHAP’s yet to come in August for SI RICE.
follows a logical pattern of starting with the major sources first and then working toward the smaller area sources. In fact, the amendments specifically targeting RICE under NESHAP Subpart ZZZZ are a perfect example of why there have been two significant revisions since the original 2004 final rule — to include a broader spectrum at major sources and to bring in area source RICE as well. This is because the EPA has statutory obligations under the Clean Air Act of 1990 to address hazardous air pollutants from various source types. In particular, sections 112 (d), 112 (c) (3) and 112 (k) of the Clean Air Act Amendments (CAAA) of 1990 cover the impact to source types such as RICE in stationary service applications. Subparts C through ZZZZ define the “source categories” like turbines, boilers or internal combustion engines and set forth specific standards to be met through the application of emission controls for that given source category. Subpart ZZZZ is a different grain of RICE, because it focuses exclusively on reciprocating internal combustion engines in stationary service, thus the term RICE. Often, Subpart ZZZZ is called “Quad-Zee” or “the RICE NESHAP,” and the rule covers both CI RICE (diesel engines) and SI RICE (natural gas engines) in the present February 2010 final ruling. The passage of the CAAA legislation is important to understand in the context of SI RICE, because gas compression activities dominate this class of prime mover in service. Therefore, changes to Subpart ZZZZ that directly affect SI RICE also influence the natural gas industry as a whole. The original NESHAP Subpart ZZZZ RICE rule was not promulgated until 2004, or approximately 14 years after the passage of the Clean Air Act Amendments of 1990. This was in part because of the tremendous number of “source categories” EPA has addressed under Subparts C through ZZZZ of its NESHAP regulations. Logically, since Subpart ZZZZ seemingly is the last in the alphabet, there were many other “source categories” in line ahead of internal combustion engines in nonmobile applications. Or, could it be because the ZZZZ really looked like “Zzzz” and puts one to sleep? But the sleepy appearance of four Zs put together should not disguise
2 01 0 Z A G E T t h D11 N E F 21, Boo Ha l l
BORSIG ZM Compression GmbH, a member of the BORSIG Group, offers Reciprocating Compressors for Process Gases, Centrifugal Compressors for Process Gases, Reciprocating Compressors for CNG Filling Stations , Compressor Valves, Roots Blowers and Blower Systems. Our products stand for high quality, compentence and reliability.
RECIPROCATING COMPRESSORS for Process Gases acc. API 618, in vertical design (PV) as well as boxer type units with horizontal cylinder arrangement (PH) with up to a maximum of 6 axes. Discharge pressure: Capacity/flow: Power:
CENTRIFUGAL COMPRESSORS for Process Gases acc. API 617, API 672, API 614, up to four-stages Pressure ratio: Capacity/flow: Power:
1.4 ... 15, max. 4 stages 1,100 ... 40,000 m³/h 100 ... 12,000 kW
BORSIG ZM Compression GmbH Seiferitzer Allee 26 D-08393 Meerane Germany Phone: +49 (0) 3764 / 5390-0 Fax: +49 (0) 3764 / 5390-5092 e-mail:
[email protected] www.borsig.de/zm
continued on page 66 MAY 2010
3 ... 1,000 bara 100 ... 115,000 m³/h 50 ... 16,000 kW
A member of KNM Group Berhad
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Continuing to Lead The Industry with 286,000 SF of Manufacturing Facilities on 38 Acres
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the expanding scope of Subpart ZZZZ and the broader requirements it will bring to CI RICE and SI RICE. The original Subpart ZZZZ rule targeted only “major sources” and engines greater than 500 hp (373 kW). In January of 2008, a second final rule amendment was promulgated that covered not just “major sources,” but also certain types of RICE at “area sources.” In March 2009, additional Subpart ZZZZ amendments were proposed to specifically deal with other CI RICE and SI RICE (including certain types of existing engines at area sources). The amendment remained in the proposal state until recently, when in February 2010, the final ruling for CI RICE went into effect and the timeline for the SI RICE was set for August 2010. Now both “major source” and “area source” definitions, according to the EPA, will be targeting engines above and below 500 hp (373 kW) and result in a broader range of total impact CI RICE and SI RICE. While it is unclear as to the full implications of the upcoming final rule for Subpart ZZZZ with respect to SI RICE, the March 2009 proposed rule serves as the foundation for the changes to come because it is the March 2009 proposed rule that has served as the foundation for the February 2010 final ruling on CI RICE or diesel engines. The March 2009 proposed rule will serve as the foundation for the additional requirements targeting SI RICE or natural gas engines anticipated to be finalized in August 2010. The EPA has statutory obligations under the Clean Air Act Amendments of 1990 to address HAPs from various source categories such as RICE in stationary service applications. Certainly, this is a high-level overview of the air quality regulatory matrix that originates at the federal level targeting internal combustion engines. There are many points of consideration not necessarily covered in this article for the sake of timeliness and simplicity. There are other sections and subparts of air quality regulations that have less of a unilateral impact on stationary RICE (both CI and SI type engines) that must also be considered in the compliance equation. Subpart IIII and Subpart JJJJ of the New Source Performance Standards (NSPS) directly affect internal combustion engines, but, generally speaking, apply to installation date or modification date triggers as is the case with Subpart ZZZZ. Table 2 shows the current NSPS emission standards for SI RICE. Since the NSPS is known, these standards must be considered alongside the yet to be determined SI RICE requirements under Subpart ZZZZ coming in August 2010. NESHAP Subpart ZZZZ has been singled out and highlighted here because it is one of currency and significance to the natural gas industry. Remarkably, the legacy of legislation passed over 20 years ago is its ability to continue spawning new regulatory mandates even today. Ultimately, the assessment of regulatory impacts on air emission sources represents a complex analytical exercise that requires the consideration of many factors not fully explored by this simple overview. The roles and relationships among those many other nuances born out of the Clean Air Act gives growth to a different kind of grain of “RICE.” SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
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Featured Products COMPRESSORTechTwo Machine Condition Monitoring and Analysis Azima DLI, a provider of predictive machine condition monitoring and analysis services, offers a series of prepackaged programs designed to ensure comprehensive equipment reliability and uptime results, said the company. Azima offers three Watchman Reliability Service Plans that feature an evaluation of the plant environment and risk profile along with a set of solutions and deliverable to meet specific uptime, compliance and cost-avoidance objectives. Each package includes primary technologies, such as vibration analysis, lube oil analysis and infrared thermography as well as transparency of portal delivery, analysis support and a range of optional services to complete condition monitoring. The three models are: Watchman Professional, Watchman Insight and Watchman Select.
in. (45.7 cm x 40.6 cm x 25.4 cm), the N4XP line of polycarbonate enclosures provide high impact resistance and superior UV protection in a lightweight, noncorrosive design. Enclosures are available in opaque or clear covers for viewing, are UL/cUL listed and meet type 2, 3, 3R, 4, 4X, 5, 6/6P, 12, 13 and marine use.
for submersible 6P ratings or stainlesssteel latch cover designs for quick access. Accessories such as back panels, swing panels and panel adjustment kits are available. All enclosures can be ordered with modifications such as holes, slots or cutouts. While extremely lightweight, polycarbonate enclosures provide an impact resistance of over 900 lb.in. (102 Nm). Designed for use in rugged and harsh applications, the Adalet N4XP enclosures offer high strength and durability and UV protection when exposed to sunlight. The enclosures are noncorrosive when used in extreme environments and nonconductive, thereby eliminating a shock hazard. Adalet, a Scott Fetzer Co., manufactures explosionproof enclosure systems and cable accessories, enclosure thermal management products and industrial NEMA-rated sheet metal enclosures and related accessories.
Each enclosure ships with a cover gasket providing a watertight seal for NEMA 4 applications and add-on mounting feet for wall-mount applications. Threaded brass inserts are standard and provide secure back panel installation. The enclosures are light grey in color with a gloss finish and can be ordered as screw cover
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Polycarbonate Enclosures Adalet now offers thermoplastic, polycarbonate enclosures as part of its industrial enclosure product line. Ranging in sizes from 6 in. x 6 in. x 4 in. (15.2 cm x 15.2 cm x 10.2 cm) to 18 in. x 16 in. x 10
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Image Sensors with Extra Reach Banner Engineering’s iVu Remote Touch Screen Display is the latest addition continued on page 68
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Featured Products CTechTwo to its iVu Image Sensor series. The company said it delivers easy-to-apply yet comprehensive vision inspection to hard-toaccess areas. Both the iVu TG Image Sensor and iVu Bar Code Readers, first introduced with integrated touchscreens for on-site inspection setup and modifications, are available as iVu Remote Series Sensors, replacing the sensors’ touchscreens with a separate display. This arrangement allows users to program iVu sensors through a single display and to change inspection parameters remotely. Banner said that the iVu Remote Display offers an all-in-one vision inspection solution for difficult-to-reach areas without the need for a PC or other external devices. The iVu Remote Display boasts the same intuitive programming interface as the iVu’s integrated touchscreen, which speeds operator training and reduces installation time. One display can be used to program multiple iVu sensors. Remote Series Sensors operate independently of the Remote Display, so the display can also be hot-swapped, a feature that helps minimize downtime when reprogramming sensors to satisfy new application requirements. Connected via a cable between 3 ft. (1 m) and 50 ft. (16 m) in length, the Remote Display facilitates access to the user interface and allows personnel to view inspection images from a distance. The company said that capability proves particularly beneficial in certified application environments, where personnel access could compromise the integrity of the area. Banner said a number of features make the iVu Remote Touch Screen Display ideal for complex inspections in challenging-to-access areas. They include a display that incorporates two LEDs providing feedback on the remote sensor’s operation (one for Power/Error and the other indicating Pass/Fail inspection results), a 3.5 in. (8.89 cm) diagonal color LCD flatpanel touchscreen display, lightweight design with an ergonomic shape that fits comfortably in the hand and the ability to be hot-swapped among multiple live sensors. The screen offers a wide viewing angle of 60° left and right, 50° up and 55° down. A mounting bracket/docking station and stylus with cable are included. Banner offers a selection of five cordsets up to 50 ft. (16 m) in length. SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
Respiratory Facepiece Seal Technology Scott Health & Safety has launched its SureSeal System, which the company described as the “most dynamic facepiece seal available today for users of respiratory protection products.” Developed with numerous innovations such as an enhanced sealing surface and practical personal protective equipment (PPE) interfaces, the Scott SureSeal system combines greater user comfort with superior fit. Scott said that because it is integrated with the Scott AV-3000 facepiece, users experience an expansive field of vision and exceptional voice intelligibility. The SureSeal System utilizes a U-shaped seal that maintains a continuous circumferential seal around the user’s face. Scott developed its patent-pending design, called reverse reflex, to allow the SureSeal System to flex with facepiece movement, resulting in a higher fit factor and improved user comfort.
We Manufacture and Remanufacture the World’s Largest Crankshafts Ellwood Crankshaft Group Irvine, PA, USA 16329 Hermitage, PA, USA 16148 1-800-247-1326 or 724-347-0250
[email protected] www.ellwoodcrankshaftgroup.com SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
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COMPRESSOR TechTwo
Featured Products COMPRESSORTechTwo Additionally, a fifth strap improves sealing capabilities by adding another point of connection to the smaller Kevlar head harness. The tightening buckles are positioned so they won’t torque the seal and cause leaks if over-tightened. Scott said that an important feature of the SureSeal System is its deeper, lower-profile seal that offers a more robust interface with protective suits, hoods, shrouds and helmets. Additionally, a smaller Kevlar head harness eliminates bunching and discomfort under helmets and hard hats. For proper and quick donning, a reflective positioning tab is located on the back of the head harness. As with all of Scott’s AV-series facepieces, the AV-3000 facepiece with the SureSeal System honors Scott’s TopDown Convertibility design concept, which allows a single facepiece to be used for all NFPA/CBRN/NIOSH respiratory applications. The SureSeal System is available on all new AV-3000 facepieces and can be retrofitted to AV-3000 facepieces currently in use.
pacity of 212,000 to 388,000 cfh (6000 to 11,000 m 3/hr) and suction pressure ranging from 11.6 to 21.8 psia (0.8 to 1.5 bara). Discharge pressures can range from 21.8 to 54.4 psia (1.5 to 3.75 bara). Nash, a division of Gardner Denver, manufactures liquid ring vacuum pumps, compressors and engineered systems serving the chemical, petroleum, power, paper, mining, environmental and food industries. Nash also provides global service and technical support for its products through its locations around the world. SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
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Vacuum Pumps and Compressors
GD Nash has introduced its new 2BE4 series vacuum pumps and compressors. Nash said that the 2BE4 series provides the same long life and reliable operation for which its 2BE3 series is known, but benefits from its effort to upgrade and perfect that series. Features of the new design include optimized inlet and discharge porting for enhanced performance, the use of cylindrical roller bearings for improved load ratings and increased reliability (a bearing upgrade that can be applied to existing 2BE3 series units), optional lobe purge piping to remove entrained solids and prevent erosion, elimination of the need for inlet bypass piping in most installations, a choice of ductile iron or stainless-steel construction and a configuration that allows it to be a drop-in replacement for existing 2BE3 installations. The 2BE4 series feature a suction ca-
Subsea Power Converter Power Supply manufacturer Schaefer Inc., has announced a new power con verter designed for use in subsea mineral exploration or other deep-sea applications. Based upon Schaefer’s C3700 power converter, the robust design provides up to 1100 W of power with an adjustable, tightly regulated 24 Vdc output. Schaefer can also engineer units to accept a high voltage input (up to 5000 Vdc) or to supply higher-output voltages and/or output power. No minimum load is required for stable operation. The converter is optimized such that seawater can be used as the input return path; and it has convection cooling over a wide temperature range of -4° to 167°F (-20°C to 75°C). All dissipated heat is efficiently conducted through a single flat aluminum surface that can be mounted to the subsea structure. Overtemperature shutdown with alarms, featuring automatic recovery, is inherent in the design. Additional features and comprehensive protection circuitry includes remote sensing, Power-OK, DCOK, current limiting, short-circuit protection, overvoltage protection and overload protection. Schaefer said that the use of industrial grade components yields a highly efficient, space-saving solution while increased mechanical strength and tropical protection facilitates reliable operation in extreme environments.
R ug ge d R el ia bl e A cc ur at e
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PTNAUTIA Anchor
Mess
Azimuth
OIM
Ballast
OOE
Caisson
OTL
Catering
Platform
Chiksan
PSTL
Compressor
Quarters
Concrete
Rig
Coxwain
Riser
Crane
Rotation
Deck
Roughneck
Derrickhand
Roustabout
Drill
ROWPU
Fixed
Safety
Flare
Scaffolder
FPSO
SemiSubmersible
Freefall
Spar
Galley
Stabilizer
Genset
Stores
HeavyLift
Superstructure
Helipad
TensionLeg
Jackup
Thruster
Kit
Toolpusher
Lifeboat
Topsides
Locker
Trim
Visit www.compressortech2.com for answers.
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Literature Library — COMPRESSORTechTwo Manufacturing and Repair Laser Alignment
Compressor Elements offers literature on its compressor-related machining, manufacturing and repair. The company manufactures and repairs a complete line of compressor parts, maintains a warehouse inventory of new replacement parts, and sells used and refurbished compressors.
Information on Express Alignment (XA) from Fixturlaser is available in a 12-page brochure that explains the wide range of standard technical features in the Fixturlaser XA system. Those include CCD technology, line laser, large detector surfaces 1.18 in. (30 mm) and pre-mounted fixtures. Also described are the 3-D color animation displays, wireless data transfer capability and the automatic Express Mode that speeds the measurement and alignment process. SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
continued on page 76
Continuous Monitoring •Early Warning •Critical Shutdown • Peace of Mind
SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
Rotor Dynamics Analysis The Turbomachinery Research Consortium of the Turbomachinery Laboratory at Texas A&M Uni versity offers a brochure on its XLTRC 2 rotor dynamics software suite. XLTRC2 is a suite of fast, accurate and userfriendly codes for executing a complete lateral and torsional rubber dynamic analysis of rotating machinery including pumps, compressors and turbines. XLTRC2 runs on most versions of Windows with Microsoft Office 97 or later. SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
Magnetic Bearings
Advances In Magnetic Bearings is the title of a white paper included in a company capabilities folder from Synchrony. In addition, the folder includes multipage overviews of selected Synchrony products, including its Fusion and NovaGlide brands of magnetic bearings and the NovaDrive 400 and NovaGen 400 oil-less drivetrains. The company also manufactures high-speed motors and generators for a wide range of industrial applications. SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
A Diagnostic Solution that can PREVENT MOST SHUTDOWNS! SENTINEL II is unique there is nothing else like it! A modular concept that allows Can your current shutdown panel catch you to custom tailor a shutdown/diagnostic/control system this before it causes severe damage? to your company’s mechanical condition and economic goals. From simple shutdown protection...to complete diagnostics...including performance information and SCADA communications, SENTINEL II provides “peace of mind” that your SENTINEL II can! compression equipment: A broken piston retaining ring is just one type of failure Sentinel II can diagnose. • Is meeting company profit goals • Is mechanically sound enough to run safely • Is likely to be in environmental compliance • Is properly loaded at all operating conditions SENTINEL II gives you confidence for today, flexibility for tomorrow, with fast payback.
DYNALCO
3690 N.W. 53rd Street • Fort Lauderdale • Florida 33309 U.S.A. Toll Free (US) (800) 368-6666 • www.dynalco.com SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
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Advertisers’ Index MAY www.compressortech2.com
Company Name
Page Number
Company Name
Page Number
Company Name
Page Number
ACI Services, Inc. ..................................... .29
E Instruments Group ................................. .60
LMF Leobersdorfer Maschinenfabrik AG ......7
ADIPEC 2010 ............................................. .78
* Elliott Company ....................... .Second Cover
Lincoln Crankshaft & Machine Ltd. ........... .79
AXH air-coolers ......................................... .66
* Ellwood Crankshaft Group ......................... .68
MAN Diesel ................................................. .9
Altronic, Inc. ............................................. .2-3
EmeraChem, LLC....................................... .53
MIRATECH Corporation ............................. .11
ARIEL ......................................................... .27
EMIT Technologies, Inc. ............................. .1
MOTORTECH GmbH ................................. .35
BG Service Co., Inc., The........................... .57
Enerproject SA ........................................... .44
BETA Machinery Analysis ......................... .23
Exline, Inc. ................................................. .76
BORSIG ZM Compression GmbH ............. .65
Flexware, Inc. ............................................. .68
* Burckhardt Compression AG ............... .43, 49
Foley Equipment......................................... .76
CC Technology ..................................... .20-21
* GE Oil & Gas ............................................... .5
CECO, Compressor Engineering Corp. ......61 * CPI, Compressor Products International ... .17 Cameron’s Compression Systems Group ................................. .40-41 Canfield Industries, Inc./
GPSA, Gas Processors Suppliers Association ............................. .73 Harsco Industrial - Air-X-Changers ........... .31 * HOERBIGER Kompressortechnik Holding GmbH................................... .32-33
Murphy, FW ............................... .Fourth Cover * Neuman & Esser Group ............................. .39 PROGNOST Systems, Inc. ................. .36-37 Progressive Equipment Inc. ....................... .63 PROS Company, The ................................. .50 Rawson Energy Services (RES) ............... .16 Robt. L. Rowan & Assoc., Inc. ................... .77 Rottler Manufacturing ................................. .19 Stitt Spark Plug Company ......................... .51
In The News ................................................72
Summit Industrial Products ....................... .30
* Cook Compression ..................... .Third Cover
KB Delta Mfg, Inc. ..................................... .55
Superbolt Inc. ........................................... .66
Cummins Inc. ............................................. .45
Kiene Diesel Accessories, Inc. ................. .59
TMEIC GE ................................................. .56
CRYOSTAR SAS ....................................... .46
Kobelco EDTI Compressors, Inc. ............. .15
* Tech Transfer, Inc. ................................. .24-25
* Dresser-Rand ............................................. .47
Kobe Steel, Ltd. ......................................... .15
Testo, Inc. ................................................... .48
LCEC, Louisiana Chemical
Ultrachem, Inc. ........................................... .75
Spartan Scientific ................................... .60
DYNALCO ........................................... .59, 71 ECOM America ......................................... .69
Equip. Co., LP......................................... .50
Wesco Valve and Manufacturing Company....67 * Further information on this company’s products can be found in the 2009 Edition of the Global Sourcing Guide (at GSGnet.net ) and 2010 Compression Technology Sourcing Supplement (at CT2SS.com).
SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
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Marketplace — COMPRESSORTech
Two
EXPLOSION PROOF AC&DC ENGINE STARTING SYSTEMS • STARTER MOTORS • ALTERNATORS • SWITCHES • CLASS I, DIV. 1&2, GROUP D UNITED STATES ENERGY CORPORATION 1600 MISSILE WAY, ANAHEIM, CA 92801
A Midwestern manufacturing company seeks an experienced individual for a position of Sales Engineer/Manager for advancing a product line for the stationary & high speed engine market
(714) 871-8185 • (714) 871-9229 FAX WWW.USENERGYCORPORATION .COM
Houston-based Writer/Editor CompressorTech Two is seeking a Houston-based
Writer/Editor with 2-5 years' experience on newspa- per or B2B magazine staff with proven research and interview skills, familiarity with publishing processes and fluency with Microsoft Office applications. The
Candidate must be familiar with the operation of engines used in the natural gas compression, power generation and marine markets. Responsibilities of the position include managing and expanding the product, marketing, sales, application engineering, field trou-
bleshooting and profitability of the product line. The position will report directly to the Vice President of Marketing & Sales and work closely with customer service personnel, production managers and customers. Extensive travel is required.
ideal candidate will be disciplined, self-motivated, outgoing, curious and mentally agile. Fluency in Spanish is a definite advantage. This position is full time and offers competitive compensation and
Requirements: degree preferred plus minimum of 3 years of technical sales experience or equivalent.
excellent benefits. Please express your interest by e-mail only to
[email protected]. Include attached PDF files of 1) your resume, 2) at least three published examples of your relevant work and 3) a list of three credible references.
We offer a competitive salary, relocation package, benefits including heath, life, disability, and 401K plan. Email resume c/o
[email protected] REF: CT0410CJ
Engineering Data Book/CD Set The worldwide authoritative resource for technical and design information pertaining to the gas processing industry and its approved practices and procedures. 12 TH
2004
TheGPSADataBook 12th Edition providesupdatesto all26 sections, including:
water treating systems and electrical
ORDER ONLINE AT www.GPAglobal.org/GPSA; or call GPSA at 918-493-3872 (USA) SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
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Great Expectations Gas Projects Offshore Venezuela
I VZU B NTU G PY LT A? Recent Developments May Reshape the Natural Gas Export Market in Latin America By Roberto Chellini
To date, major producers and exporters of natural gas in Latin America have been Mexico, serving the consumer markets in the North (United States), and Bolivia, exporting its gas to several countries located in South America. Venezuela has been a major exporter of oil and heavy hydrocarbons (from the Orinoco Belt) but not of natural gas, although its proven natural gas reserves amount to 170.9 Tcf (4.84 x 10 12 m3), representing 2.6% of world gas reserves (BP Statistical Review of World Energy, June 2009). Geopolitical reasons have prevented international oil companies from investing large amounts of money in Venezuela to develop the necessary infrastructures needed to export this source of energy. However, as reported by Business Monitor International in several issues of its Daily Oil & Gas Alert, the situation might be changing. In April, according to the Venezuelan Energy Minister Rafael Ramírez, a Japanese company offered Venezuela a US$1 billion loan to develop the large Mariscal Sucre offshore gas project. In MAY 2010
addition, the state-run Petróleos de Venezuela (PdVSA) is holding bilateral talks over funding for the $8.3 billion Mariscal Sucre development after a recent project tender failed to attract bids. Apparently, the unnamed Japanese concern is prepared to advance the loan. Ramírez added that the government was “looking for a large-scale firm” (such as Gazprom) to help de velop Mariscal Sucre’s reserves. The much-delayed Mariscal (Marshall) Sucre complex is one of several gas projects in the shallow waters bordering Trinidad & Tobago that PdVSA is hoping will propel Venezuela into the ranks of the world’s major gas producers. The project comprises the Dragón, Patao, Mejillones and Río Caribe gas fields, and according to the government holds 14.7 Tcf (416 x 10 9 m3) of gas. Under PdVSA’s development plans, gas from Mariscal Sucre will supply the local market, with the surplus to be liquefied for export. An LNG plant would be built at the Gran Mariscal de Ayacucho industrial facility in Sucre 74
State and comprise two trains, each with a send-out capacity of 4.7 MM tons per annum (tpa) or 6.48 x 10 9 m3. A final investment decision on Mariscal Sucre LNG is due by year-end 2010, and operations are expected to start in 2014-2015, beyond the original 2013 start-up date. Combined production at the fields is expected to reach 438 Bcf (12.4 x 10 9 m3) of gas per annum and 20,000 barrels per day of condensate. PdVSA puts the costs of the upstream section of the project at $2.7 billion, while the total price tag is supposed to be around $8.3 billion. To attract funding, in January 2010 PdVSA offered a 40% stake in the project to foreign investors, shortlisting Gazprom, Japanese firms Marubeni, Mitsui, Mitsubishi and Itochu, and several Western international oil companies for the tender. The licensing round, however, received no bids. Thus, PdVSA is now trying to secure investment from Gazprom and Japanese conglomerates on a bilateral basis. While it is Caracas, Venezuela’s growing ties with Moscow, Russia, that have been grabbing the headlines over the last year, its investment links with Tokyo, Japan, are more ad vanced and arguably as valuable to the struggling Latin American country. The wide-ranging preliminary agreements signed with Tokyo covered the potential participation of Japanese conglomerates in upstream and downstream Venezuelan projects, including loans for the upgrade of the Puerto la Cruz and El Palito refineries and a joint feasibility study of the Junín 11 Block in the Orinoco heavy oil belt. In addition, PdVSA signed a Memorandum of Understanding (MoU) with four Japanese firms over their participation in the Mariscal Sucre LNG terminal. Under a preliminary deal signed earlier, Mitsubishi and Mitsui hold 2.5% each in the first proposed train of the plant and Itochu and Mitsubishi have 10% and 5%, respectively, in the second train. Following his visit to Tokyo, President Hugo Chávez announced that the trip yielded $33.5 billion worth of agreements. A $1 billion loan, however, would mark the first concrete investment under the deals. The loan, which is yet to be confirmed by the Japanese side, could come from any of the four Japanese signatories of the Mariscal Sucre MoU. In return for funding, the Asian in vestors will be looking to secure LNG supplies for their domestic market. The amount of Mariscal Sucre’s gas available for export, however, is in question, and that uncertainty is believed to have been the main reason COMPRESSOR TechTwo
Gulf of Venezuela Gas Exploration Repsol and Eni’s Stake
behind the failure of the project bidding round. Apparently, severe power shortages caused by Venezuela’s prolonged drought have led the government to raise the amount of Mariscal Sucre’s gas used for internal consumption. This would severely damage the economics of the LNG plant by forcing companies to sell gas at government-imposed domestic prices. At present, gas from Venezuela’s non-associated onshore gas fields is sold for around $0.9 per million BTU, way below international prices. At such low prices, even the politically driven Gazprom will struggle to justify its investment in the project. Unless the government is prepared either to raise wholesale gas prices or to free up more supplies for export, it is unlikely that Mariscal Sucre will be able to attract the required investment. Moreover, given Caracas’ track record of contract alterations, any agreements reached with the IOCs now run the risk of being overridden during Venezuela’s next energy supply crisis. In North Venezuela, Spain’s Repsol YPF and Italy’s Eni announced, on April 12, that the Perla field in their 50:50-owned Cardón-IV exploration block in the Gulf of Venezuela may have 30% greater gas reserves than initially estimated in October 2009. The reserves upgrade announcement was made following the drilling of the Perla-2 well at a depth of 197 ft. (60 m) in the shallow waters of the Gulf of Venezuela. The results of Perla-2 mean the partners have re vised up the field’s gas reserve estimates to approximately 8.8 Tcf to 9.9 Tcf (250 x 10 9 m3 to 280 x 10 9 m3). Production targets will also require upward revision, and the field’s location in relatively shallow waters will help to lower future production costs, boosting the project’s economics. The
company also stated that two new Perla development wells will be drilled in mid-2010. Under their contract, Repsol and Eni will have to transfer a 35% stake in the project to state-controlled PdVSA, leaving the two European firms with a 32.5% stake each. When the Perla gas discovery was announced in late 2009, it was Venezuela’s largest natural gas discovery and the biggest gas find in Repsol’s
corporate history. The reserves upgrade at Perla is a further boost to the prospects for Venezuela’s gas sector. At 170.9 Tcf (4.84 x 10 12 m3), Venezuela has Latin America’s largest proven gas reserves, but upstream attention has focused for decades on the country’s large oil reserves and its importance as one of the top oil exporters to the U.S. market. As a result, non-associated gas production remains low and gas distribution infrastructure is limited. The government has ambitious plans for the sector, however, and has set a target to raise national gas production to 4.6 Tcf (130 x 10 9 m3) by 2013, from 1.1 Tcf (31.5 x 10 9 m3) in 2008. To support these goals, the government and PdVSA are hoping to de velop a national gas infrastructure and LNG export capability. In spite of the upgrade of the Perla field’s reserves, however, PdVSA would have to dramatically ramp up capex to achieve its gas output targets. Follow us on
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CALL ON EXLINE
Literature Library — COMPRESSORTechTwo Thrust Bearings Design Guide
Oil-Flooded Rotary Compressors
FOR ALL YOUR MAINTENANCE NEEDS 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.
Your Single-Source Field Services Solution
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:
[email protected] ©2006I Exline, Inc. EXLI-2033
Kingsbury offers a design guide that contains three sections that will guide the user to a proper thrust bearing selection. Section I covers the fundamentals of equalizing fluid film thrust bearings. Section II reviews design features and accessories for monitoring performance. Section III contains systematic guidelines for matching your application with the ideal bearing.
SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
LeROI Gas Compressors from Rotary Compression Technologies Inc. has prepared a handy summary of the features, benefits and specifications of its HG20 Series of geared and nongeared singlestage oil-flooded rotary compressors. Also included are details of options available for gas gathering, wellhead boosting, fuel gas boosting, vapor recovery, inert gas boosting or landfall gas handling.
SEE DIRECTLINK AT
SEE DIRECTLINK AT
WWW.COMPRESSORTECH2.COM
WWW.COMPRESSORTECH2.COM
Bearing Selection Guide
Valve Performance Simulator
A product selection guide from Waukesha Bearings describes a variety of bearing designs. The guide also provides examples of typical applications in which each type frequently sees service. Information is provided for tilting pad thrust, tilting pad journal, polymer-lined and solid polymer, active magnetic, fixed profile, ceramic and vertical bearings as well as horizontal bearing assemblies.
A new service from Klaus helps eliminate expensive, time-consuming, iterative pilot model valve testing offers recommendations to meet changing field conditions, support new OEM designs and offer API 618-compliant valve reports. The company’s proprietary ValveSim software uses computational fluid dynamics (CFD) to test valve performance in a 3-D, digital “virtual flow loop.”
EXCHANGE
GAS COMPRESSION
ENGINES
®
For more information contact Foley Rebuild Center today!
FOLEY REBUILD CENTER SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
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SEE DIRECTLINK AT
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COMPRESSOR TechTwo
Literature Library — COMPRESSORTechTwo Personal Locator Device
Energy Transfer Products
Air Starters
A detailed, 28-page document summarizing the company’s range of products and support capabilities is available from Rexnord. Summaries of Rexnord product lines including Falk and Rexnord gear drives; Rexnord, Link-Belt and MB brand bearings; Rexnord and Falk coupling products; Rexnord FlatTop and other heavyduty, engineered steel chain and roller chain.
A four-color brochure from TDI Tech Development offers a n o v e rv i ew o n t h e c o m pany’s TurboTwin air starters. The piece presents the features and benefits of its turbine air starters, an overview of available models and information on the availability of detailed, industry-specific catalogs featuring TurboTwin air starters.
SEE DIRECTLINK AT
Cummins Inc. has prepared a d o c um e n t o u t li n i ng t h e Cummins Scheduled Rebuild Program that is designed to maximize critical uptime. Included is an explanation of how your Cummins distributor can help you schedule an optimum engine rebuild date. Also included is information on the levels of service available and warranty information.
WWW.COMPRESSORTECH2.COM
SEE DIRECTLINK AT
SEE DIRECTLINK AT
WWW.COMPRESSORTECH2.COM
WWW.COMPRESSORTECH2.COM
WWW.COMPRESSORTECH2.COM
m2m Data Corp. offers information on the iSafety features in the Spot Personal Locator device, which contains a satellite communicator and GPS receiver in a small package that can be worn on the person. The literature describes the numerous features of the device and explains its simple, three-button operation.
Gas Engine Rebuild Service
SEE DIRECTLINK AT
continued on page 78
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COMPRESSOR TechTwo
Literature Library — COMPRESSORTechTwo Compressor Specialists
Bolting Expertise
Compression Leasing Services Inc. offers a library of brochures and information on its wide range of services to the compression industry. The subject matter of those publications includes the company’s gas packaging, sales, leasing, service, machine shop, fabrication and design capabilities. Also included is information on the firm’s construction air equipment.
An informative brochure designed to introduce the products, services and advanced technical capabilities of Alltite is now available. Subjects addressed include the company’s on-site calibration services and its catalog of sophisticated pneumatic, hydraulic and manual torque tools that are available for rent or sale. A description of the company’s diverse service capabilities is included.
SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
Industry News — COMPRESSOR TechTwo TransCanada Corp. TransCanada Corp. President and CEO Hal Kvisle will retire effective June 30, 2010. Russ Girling , currently COO, will succeed him as president and CEO on July 1, 2010. Kvisle will assist Girling with the transition through Aug. 31, 2010, and will be available as an advisor thereafter. “Executive development and succession planning are important responsibilities of the board of directors,” Barry Jackson, chairman of the board of directors. “Russ has demonstrated outstanding vision and leadership over his 16 years at TransCanada. He has had exposure to all aspects of our business and has consistently shown an unwavering commitment to the company’s long-term success. His strategic thinking ability, commercial acumen, bottom-line focus and people/leadership skills will serve the company well in the years ahead. We are confident in our choice of Russ as Hal’s successor and look forward to TransCanada’s future under his leadership.” Kvisle joined TransCanada in 1999 as executive vice president and became CEO in 2001. In 2008, he was named Canada’s Outstanding CEO of the Year. Incoming President and CEO Russ Girling joined the company in 1994 and, prior to his appointment as chief operating officer in July 2009, held a number of leadership positions including: president, pipelines; CFO and executive vice president, corporate de velopment; and executive vice president, power. He is the current Chairman of the Interstate Natural Gas Association of America (INGAA). SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
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COMPRESSOR TechTwo
Literature Library — COMPRESSORTechTwo Tools and Supplies Enco has released its 2010 catalog, which contains over 75,000 products in 14 categories. The company also offers over 100,000 items online at www. use-enco.com . New offerings in 2010 include a broader selection of the products for which the company has been known since 1940 — cutting tools, measuring instruments, vises, fasteners, clamps, machinery, chucks and power tools.
Mat Systems An overview of the economic and environmental advantages of the C-Lock interlocking mat products available from Canadian Mat Systems Inc. of Edmonton and Alberta, Canada, are outlined in a color brochure. The piece lists a range of applications for which the company’s products can help expand work activity outside regular seasonal constraints while helping to protect the environment and reduce mitigation and remediation costs. SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
Engineering, Procurement and Construction Willbros USA Inc. has prepared material providing a succinct overview of the engineering, procurement and construction services firm’s offerings to the energy industry. Highlighted is the company’s emphasis on interoperability, scalability and advanced analysis in which GIS and integrity program management are used to compile data that can be analyzed to understand how each element of a project affects other elements.
LC&M…taking the load!
LC&M are pleased to announce the recent purchase and installation of our new 11,000mm CNC Orbital Crankshaft Grinding Machine, offering you, our customers… Enhanced quality
SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
Faster turnaround More competitive prices
Manufacturing Crankshafts Ellwood Crankshaft Group (ECG) has published literature featuring the history and crankshaft range of the company. The forging capabilities allow ECG to produce more than 10,000 crankshafts between 13 and 23 ft. (4 and 7 m) in length. Market segments include stationary power, compressors, locomotives, power generation and marine. SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
We are the UK’s leading manufacturer of large crankshafts, from forging to finish grind - maximum capacity 11,000mm long by 25 tonnes in weight. We also specialise in crankshaft and turbine shaft repair, refurbishment and regrind.
Tel: +44 (0) 1522 522 855 Fax: +44 (0) 1522 522 856
Email:
[email protected] Web: www.lcmandm.co.uk
Lincoln Crankshaft & Machine Ltd Bay 18 Beevor Street Lincoln, LN6 7DJ, England SEE DIRECTLINK AT WWW.COMPRESSORTECH2.COM
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About the Business
PW INN ND CN … SDDD … SPX HYD TN … TNN SY LD. … P U SY … TBNY SY … OFF MDD E CNF. & E … LN RD G CNDNN CNF. … A C. … MN ENY Edited By Phil Burnside
Power Ignition and Controls has
been named the exclusive distributor fo r Stoddard Silencers for the provinces of Alberta, Saskatchewan and British Columbia, Canada. Stoddard Silencers is a Canadian manufacturer of silencer products designed to control the potentially harmful effects of noise pollution in industrial environments. Stoddard Silencers specializes in the design and manufacture of silencers for engines, rotary blowers, vents, compressors, vacuum pumps and turbines in industrial applications. SPX Hydraulic Technologies, a business unit of SPX Corp.’s Industrial Products and Services segment, has acquired U.K.-based Torque Tension Systems Ltd. (TTS), a global supplier of hydraulic torque wrench and tensioner tool products. Transaction terms were not disclosed. Torque Tension Systems Ltd. had annual revenues of approximately US$7.65 million in 2009. The company’s hydraulic bolting product lines include Dura-Lite hydraulic torque wrenches, LDF Torque wrenches, subsea bolt tensioners, hydraulic nut splitters, flange pullers and flange spreaders. In addition to serving the power and energy market, TTS’s tools are utilized in the petrochemical, automotive, chemical, railways and shipbuilding industries. The company has additional offices in Australia and Malaysia. SPX Hydraulic Technologies is a global manufacturer of high-force hydraulic pumps, cylinders, jacks, pullers and tools, serving customers around the world. With brands that include Globe, Hytec, PowerTeam, Stone and SPX Rail Systems Clamplock. In a significant change to the machinery event calendar, Texas A&M University’s Turbomachinery Laboratory has moved the date of the International MAY 2010
Pump Users Symposium , tradition-
Energy have entered into a US$2.7
ally held in February, to run concurrently with the fall Turbomachinery Symposium . As a result, the 2011 event — the 27 th International Pump Users Symposium — will be held in parallel with the 40th Turbomachinery Symposium, Sept. 12-15, 2011. Some details resulting from the schedule change have not been settled. One definite change will be the due date for abstracts for prospective presentations at the 2011 Pump Users Symposium. The original deadline was May 3, 2010, but organizers have announced a new deadline of Sept. 27, 2010, which coincides with the previously announced abstract due date for presentations planned for the 2011 installment of the Turbomachinery Symposium. The Advisory Board of the Offshore
billion merger agreement that G. Steven Farris, Apache’s chairman and CEO said will provide “an exciting new platform for growth in the deep water [Gulf of Mexico] and complements our strengths in the Gulf Shelf and the Permian Basin.” Mariner’s deepwater portfolio includes nearly 100 blocks, seven discoveries in de velopment — including interests in Lucius and Heidelberg — and more than 50 prospects. In February, Mariner produced 63,000 boe per day from the Gulf Shelf and deepwater, the Permian Basin and unconventional onshore plays. At the close of 2009, Mariner had estimated proved reserves of 181 MMboe (47% liquid hydrocarbons) as well as unbooked resource potential of 2 billion boe. Mariner also has more than 240 blocks on the Gulf Shelf and more than 200,000 net acres (80,900 ha) across several emerging onshore plays. Days earlier, Apache announced that it will acquire Gulf Shelf assets from Devon Energy Corp. that add production of 19,000 boe per day with year-end 2009 estimated proved and probable reserves of 83 MMboe across 158 blocks. The properties gained in that US$1.05 billion deal are projected to produce 9500 bbl of liquid and 55 MMcfd (1.56 x 10 6 m3/day) of natural gas (net) after closing, which is expected in June. Apache is the largest held-byproduction acreage owner and the second-largest producer in Gulf waters less than 1200 ft. (366 m) deep. The acquired assets comprise 477,000 net acres (193,035 ha) across 158 blocks. The fields have 80 platforms and 211 production caissons in waters to 450 ft. (137 m) deep.
Middle East Conference & Exhibition is accepting abstracts for pre-
sentations at its 2010 conference, which will be held Oct. 12-14, 2010, in Dohar, Qatar. The event addresses the technological challenges associated with de veloping resources safely and economically. Abstracts between 150 and 300 words are due by May 18, 2010. They must be submitted using the online form at www.offshoremiddleeast.com. Th e 2011 Laurance Reid Gas Conditioning Conference, scheduled for Feb. 20-23, 2011, in Norman, Oklahoma, U.S.A. has issued a call for papers. Authors should submit a 250 word abstract including title and all authors by June 11, 2010, along with an e-mail address and contact information. Consideration of abstracts will begin on June 17, and final paper selections will be made on Sept. 13. Detailed information can be found on the events website at www.lrgcc.org. Apache Corp. an d Mariner 80
COMPRESSOR TechTwo
Turnkey Compressor Reliability
Recognizing opportunities for improved compressor reliability is one thing. Implementing them is another. Doing both is Cook Compression. Cook Compression is your source for turnkey engineered solutions – including diagnostics, machine analysis, project engineering, state-of-the-art products, emissions expertise, machine upgrades, field services, contracting work, repairs, maintenance and much more.
We’re everything you need to make reliability… a reality.
Turnkey Reliability www.cookcompression.com
©2010 Cook Compression
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