GE COMPLETES EMERGING MARKETS SULLAIR ROTARY

METEM ACQUISITION EYE LNG SCREW COMPRESSORS

MAY 2016

WWW.COMPRESSORTECH2.COM/SUBSCRIBE/
n Customer:
Vertically integrated global
petrochemical company, Texas.
n Challenge:
Build a world-scale olefin plant to
process plentiful, low-cost shale gas.
n Result:
Three trains of reliable, efficient
Elliott steam turbines and compressors
ensure the customers competitive
advantage in world markets.

They turned to Elliott

for a long-term partnership and long-term service.
World-scale olefin processors turn to Elliott for steam turbines and compressors
that deliver unmatched reliability, efficiency and value over the life of their investment.
Who will you turn to?

C O M P R E S S O R S n T U R B I N E S n G L O B A L S E R V I C E The world turns to Elliott.

www.elliott-turbo.com
ARIELS TORQUE REFERENCES
AT YOUR FINGERTIPS
With the all new Ariel Torque Guide App
May 2016

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

Featured Articles
12 GE Completes Metem Acquisition

14 Test Facilities Improve Compressor Reliability, Performance Predictability

24 Active Magnetic Bearing System For Large Machines

30 GE Tested, REP Approved

Cover Designed By
34 RMS Expands Its Footprint
Alyssa Loope
42 Analysis: Valve Performance On Booster Primary Compressor For LDPE
COMPRESSORtech2 (ISSN 1085-2468)
Volume 21, No. 4 Published 10 issues/year
(January-February, March, April, May, June, 48 Inlet Cooling For Gas Turbines Driving Gas-Gathering Compressors
July, August-September, October, November,
December) by Diesel & Gas Turbine Publications,
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postage paid at Waukesha, WI 53186 and at addi-
tional mailing offices. Copyright 2016 Diesel & 4 Page 4 Australia Leads The LNG Export Race
Gas Turbine Publications. All Rights Reserved.
Materials protected by U.S. and international 6 Global Perspective Emerging Markets Eye LNG
copyright laws and treaties. Unauthorized dupli-
cation and publication is expressly prohibited.
Printed in the USA.
8 About The Business Domestic Oil & Gas Downturn Continues
While Political Stances Threaten Its Survival
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THINK GERMAN,
ACT LOCAL.
LOOKING FOR AN ALL-IN-ONE BLUESTROKE
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FROM CONCEPT TO SERVICE, ANY APPLICATION.
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Located in Brazil, NEA's team works as the single-contact
provider for: Sales, Engineering, Packaging and Service.
This includes care for the entire reciprocating compressor
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service. Hydrogen, technical and natural gases, LNG, air
and more, we are here to serve you.

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Amrica do Sul Ltda
Located in Belo Horizonte, Brazil
www.neuman-esser.com
Contact me for Central and South America:
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Direct line: +55 (31) 2126-9503

NEA GROUP Headquarters in Germany

 Page
4
CT2 Founder .......................... Joseph M. Kane

COMPRESSOR
A Member of the Diesel & Gas Turbine Publications Group

PUBLICATION STAFF

Australia Leads The

Associate Publisher ................... Mark Thayer
Associate Publisher ..............Roberto Chellini
Senior Editor ................................... DJ Slater
Senior Editor ................. Michael J. Brezonick

LNG Export Race

Associate Editor ............................... Jack Burke
Associate Editor ............................Chad Elmore
Associate Editor ...................................Art Aiello
Copy Editor ............................... Jerry Karpowicz

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

Advertising Manager .................. Katie Bivens
Circulation Manager ............. Margaret Pieper
Production Manager ................ Marisa Roberts
Graphic Artist ...........................Brenda Burbach
Graphic Artist .................................Carla Lemke
Graphic Artist ............................... Alyssa Loope
PUBLICATION HEADQUARTERS
20855 Watertown Road, Suite 220
Waukesha, Wisconsin 53186-1873
Telephone: (262) 754-4100 Fax: (262) 754-4175
CONTRIBUTING EDITORS
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Mauro Belo Schneider Rio Grande du Sul, Brazil
HOUSTON, USA
Mark Thayer, Associate Publisher
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Houston, Texas 77070
Telephone: (281) 890-5310
GERMANY
Lisa Hochkofler, Advertising Manager
Gabriele Dinsel, Advertising Manager
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73760 Ostfildern, Germany
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DE6 1LH, United Kingdom
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ITALY
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Roberta Prandi, Regional Manager/Editor
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Telephone: +39 0464 014421 Fax: +39 0464 244529
SWEDEN
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Telephone: +46 70 2405369 Fax: +46 122 14787
JAPAN
Akiyoshi Ojima, Branch Manager
51-16-301 Honmoku Sannotani, Naka-ku
Yokohama, 231-0824 Japan
Telephone: +81 45 624 3502 Fax: +81 45 624 3503
KOREA
D.S. Chai, Sales Manager
Dongmyung Communications Inc.
82 Pyeongchangmunhwa-ro, Jongno-gu
Seoul, 03011 Korea
Telephone: +82 2 391 4254
DIESEL & GAS TURBINE PUBLICATIONS
President & CEO .................... Michael J. Osenga
Executive Vice President ....Michael J. Brezonick
T
he country that introduced latex
gloves, vegemite and Crocodile
Dundee is now home to one
the largest LNG projects in the world.
Australias Gorgon project, located on
Barrow Island off the coast of north-
western Australia, shipped its first
cargo this spring, strengthening the
lead of the Land Down Under in the
global LNG export race.
The U.S. made headlines in February
when Cheniere Energy dispatched the
first shipment of LNG from its facility
at Sabine Pass, Louisiana, bound for
Brazil. But the sheer size and scope
of the Gorgon Project quickly negated
any strides gained by Sabine Pass.
The Gorgon project includes a do-
mestic natural gas plant, a carbon
dioxide injection project and an LNG
export facility. Its three liquefaction
trains have a combined capacity of
2.1 Bcfd (59 x 106 m3/d). The first train
was commissioned in March, with
the second and third trains to follow
at six- to nine-month intervals. The
Gorgon project, taking more than six
years to develop at a cost of US$54
billion, is the worlds most expensive
LNG project to date.
Ultimately, Asia is the LNG prize.
The U.S. will benefit from the US$5.3
billion Panama Canal expansion set
to open this year, cutting costs and
travel time from the U.S. Gulf Coast to
Asia by 11 days (See November 2014
CT, LNG Vessels Will Run Through It,
p. 38). But the infrastructure required
to meet Asias thirst for LNG is lacking
in the U.S.
Including the first train from Gorgon,
Australias LNG export capacity current-
ly stands at 6.2 Bcfd (157 x 106 m3/d).
If the additional LNG capacity currently
under development is fully operational
as planned by 2019, the countrys LNG
exports capacity would likely increase
to the largest in the world, at 11.5 Bcfd
(325 x 106 m3/d), equivalent of one-third
of global LNG trade in 2014.
Three projects in eastern Australia
have been fully or partially commis-
sioned since 2014. Queensland Curtis
commissioned its two trains in 2014-
15, Gladstone commissioned its first
train in October 2015 and Australia
Pacific sent its first cargo in January
of this year. All three projects process
coal bed methane into LNG and have
a current combined capacity of 2.3 Bcfd
(65 x 106 m3/d). Once fully completed,
they will have a combined capacity of
3.4 Bcfd (96 x 106 m3/d).
Gorgon LNG is the first of the four
new projects off the northern coast of
Western Australia to be partially com-
missioned. Three other projects in the
northwest Prelude, Wheatstone and
Ichthys are still under construction.
These three projects have a combined
capacity of 2.8 Bcfd (79 x 106 m3/d)
and are expected to come online be-
tween 2016 and 2018.
Most new Australian liquefaction
capacity is already contracted on a
long-term basis to countries in the Asia
Pacific region. Among destinations for
Australian LNG, Japan accounts for the
largest share of contracted liquefaction
output, with contracts for 79% of output
from the existing liquefaction projects
(in operation prior to 2014) and 35%
from the new projects, according to the
U.S. Energy Information Administration
(EIA). China is the second-largest des-
tination, with 15% of contracted LNG
from the existing liquefaction projects
and 23% from the new projects.
The U.S., mired in red tape and fa-
cility delays, is quickly losing ground
to Australia in the race to become a
global LNG supplier. CT2
WHAT IS THE POWER OF ONE?
The power of one is what happens when many individuals join forces toward
a common goal. Its the greatness that can be achieved through a shared
purpose. For Compressor Products International, its the global footprint,
manufacturing efficiencies and product innovations that arise from the
unification of the 16 companies weve acquired since 2007. For our customers,
its the power of a single phone call for all of your oil & gas compressor needs.
Together, we are stronger. Together, we are CPI.

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CPIstrong.com | 1-800-675-6646
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Global Perspective
Emerging Markets
BY ROBERTO CHELLINI
ASSOCIATE PUBLISHER Eye LNG > Flexible and cost-competitive LNG
terminals provide regasification to
P
roliferation of innovative and cost-competitive lique-
fied natural gas (LNG) terminal solutions within the
Asia-Pacific region will facilitate more-efficient LNG
deliveries to its emerging markets. Many of those markets
are forecast to see substantial growth in LNG import re-
quirements over the coming years.
Singapores marine and offshore engineering firm SembCorp
Marine has increased its stake in near-shore LNG terminal
specialist Gravifloat AS to 56%, or US$27.5 million. In ad-
dition, it secured the right to raise its share by an additional
44% to take full ownership through an equity purchase at
the same price.
The acquisition places SembCorp in a good position to
capitalize on the growing need for flexible LNG solutions
in the Asia-Pacific region. Many of the emerging markets
are projected to see considerable growth in gas demand
and have proposed plans to increase LNG imports over the
coming years.
Nontraditional LNG import markets in Asia such as
Bangladesh, Myanmar, Pakistan, the Philippines, Thailand
and Vietnam could add in excess of 15 new LNG re-
gasification facilities, or at least 1.3 Tcf (36.8 x 109 m3) of an-
nual import capacity. Weak LNG prices for at least the next
five years and robust demand for gas will support long-term
investments in LNG, which in turn will create opportunities
for suppliers to sell into these markets. Given that many of
these projects are either in the proposed phase or pend-
ing final investment decision, BMI Research (BMI) believes
there are opportunities for Gravifloat to offer a cost-efficient
alternative to procuring LNG.
Gravifloats near-shore terminal can be situated at water
depths as shallow as 50 to 65 ft. (15 to 20 m), and be
constructed in two to three years. The design utilizes a
modular concept, which allows for flexible adjustment of
capacity, as well as stepwise expansion of storage, power
MAY 2016
emerging Asia-Pacific markets
generation module and berthing platforms, based on need
and investment plans.
Its lower cost structure increases its attractiveness rela-
tive to a conventional onshore import terminal, especially
as firms operate with smaller capex budgets amid the cur-
rent low oil price environment. Furthermore, Gravifloats
flexibility to cater to a wide range of market sizes offers it a
competitive edge over standard floating facilities, as over-
supply in the regional LNG market drives investors away
from large-scale LNG projects.
Some countries have already moved to explore the possi-
bility of installing Gravifloat terminals to meet rising demand
from the power sector. For instance, Thailand is currently
mulling over plans for a US$45 million LNG-based power
plant in Ben Dam Bay, Con Dao, which will include an LNG
depot, a port and an 18 MW LNG power plant. Myanmar is
also reviewing a proposal from Gravifloat to construct a 127
MW LNG-fueled power plant offshore the Thilawa Special
Economic Zone.
A sustained period of weak LNG prices will create an envi-
ronment whereby countries and companies that perhaps did
not have sufficient financial resources are able to consider
investing in LNG for the long term. BMI forecasts the price
of Asian benchmark Japan Korea Marker (JKM) to remain
below US$5/MMBtu over the period from 2016 to 2020,
lower than the US$13/MMBtu average over 2013 to 2015.
The low prices will place buyers in a strong bargain-
ing position to secure favorable long-term contracts.
Furthermore, floating storage regasification units will
be cheap as shipyards are looking for business amid
a slowdown in the shipbuilding industry. Lower costs of
LNG supply and infrastructure support the view that more
regasification projects will move forward on top of those
under construction, benefitting LNG suppliers who are
looking for export markets. CT2
6 COMPRESSORtech2
About The Business
Domestic Oil & Gas
Downturn Continues While
Political Stances Threaten
BY NORM SHADE Its Survival > Informative grass roots conversation is
needed to counter the negative oil & gas
U
.S. oil production is falling as low prices have stifled
new development. In the first week of April, Baker
Hughes reported that U.S. rigs drilling for oil and nat-
ural gas reached a new low of 443 (354 oil and 89 gas). U.S.
Energy Information Administration (EIA) data shows that
after a 23% decline from 2010 to 2014, crude oil imports ac-
tually started increasing again in late 2015. Total 2015 imports
were slightly higher than 2014, and January 2016 imports
soared to 20% higher than the same period last year.
But natural gas production continues to climb due to the
large inventory of drilled wells yet to enter production and to
the amazing productivity of new Marcellus and Utica Shale
wells. The EIA reports that gas storage at the traditional end
of the heating season was 54% higher than the five-year
average, highest ever for that point in the season. This has
kept the Henry Hub price below $1.90/MMBtu.
In the midst of the worst U.S. oil and gas downturn in
decades, environmental advocates, government agencies
and politicians continue to push agendas that endanger the
very survival of the industry that drives the gas compres-
sion market. Uninformed, misinformed or misguided presi-
dential candidates are proposing severe restrictions, and
even bans, on fracking.
In March, an EIA report said that over half of the energy
production in the U.S. comes from fracking, pointing out
that the industry has allowed the United States to increase
its oil production faster than at any time in its history. Yet,
some politicians and environmental activists ignore this
fact and push to essentially destroy the U.S. oil and gas
industry. Although green energy development should not
be discouraged, the practical matter is that it cannot meet
demand for decades. And even green energy has environ-
mental consequences, a fact rarely reported by the press
and ignored by the anti-hydrocarbon lobby.
Speaking at the Gas Compressor Associations Expo
in March, Dr. Ken Morgan, director of the TCU Energy
Institute, explained that solar and winds arent as green
Norm Shade is senior consultant and president emeritus of ACI
Services Inc. of Cambridge, Ohio. A 46-year veteran of the
gas compression industry, he has written numerous papers
and is active in the major industry associations.
MAY 2016
messaging from environmental advocates
and strategically friendly as generally portrayed. Solar cells,
batteries, and turbine generators rely on components that
contain rare earth metals found outside North America. Not
only is that a strategic concern, significant environmental
issues have been reported from mining and manufacturing
them, especially in China.
For example, solar, thought to be the greenest of energy
sources, has some serious baggage. A November 2014
National Geographic article, How Green Are Those Solar
Panels, Really? pointed out that the fabrication of solar pan-
els requires toxic chemicals and uses large amounts of water
and electricity. The Silicon Valley Toxics Coalition (SVTC),
a San Francisco-based nonprofit that has tracked the envi-
ronmental impact of the high-tech industry since 1982, re-
ported that the solar industry is focused more on survival and
growth than on tackling the dirtier side of an otherwise clean
energy source. These problems undercut solars benefits.
Well-organized opponents of oil and gas are energetic,
passionate and increasingly effective at influencing public
opinion and politicians. Yet we, as individuals in the oil and
gas industry, do little to counter their messaging and make
our story heard. Talking only among our business associ-
ates is not enough. And, although some of the nastier en-
vironmental facts associated with green energy should be
more widely publicized, negative messaging risks turning
most of the public off from listening to us.
Instead, we should concentrate on constantly educating
the public on the positives of fracking and domestic oil and
gas production to sustain the U.S. and North America en-
ergy needs for the foreseeable future. The benefits jobs,
low costs and security are obvious to all of us, but the
average citizen rarely hears that message except in some
paid advertisements.
As this column has advocated, its up to us to direct
our friends, relatives and neighbors to factual information
that favors our industry, encouraging positive conversa-
tion. There are many good information sources including
the American Petroleum Institutes (API) Energy Nation
(www.energynation.org) and the Interstate Natural Gas
Association of Americas (INGAA) new Energy Link (www.
ingaa.org/energylink). Make yourself and your extended
network familiar with them! CT2
8 COMPRESSORtech2
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Events & Meetings

Altronic_HHsprd_Mar16_CT2.indd All Pages

Boldface indicates shows and conferences in which COMPRESSORtech2 is participating

MAY Abuja, Nigeria JULY

May 24-26 +234 706 911 7347 July 25-27
Eastern Gas Compression www.cwcnog.com SGA Operating Conference
Roundtable Houston
Pittsburgh June 13-17 +1 (972) 620-8505
+1 (412) 372-4301 ASME Turbo Expo www.southerngas.org
www.egcr.org Seoul, South Korea
+1 (800) 843-2763 AUGUST
May 31-June 1 www.asme.org/events/turbo-expo Aug. 23-25
Gas Africa Power-Gen Natural Gas
Sandton, Gauteng, South Africa June 21-23 Columbus, Ohio
+27 11 234 1196 Power-Gen Europe +1 (918) 831-9160
www.ingadaevents.co.za www.power-gennaturalgas.com
Milan, Italy
+44 1992 656 637
JUNE SEPTEMBER
www.powergeneurope.com
June 1-4 Sept. 12-15
Caspian Oil & Gas Turbomachinery Symposium/
Baku, Azerbaijan June 21-23 Pump Users Symposium
+44 207 596 5147 Sensors Expo & Conference Houston
www.caspianoil-gas.com San Jose, California +1 (979) 845-7417
+1 (617) 219-8300 http://turbolab.tamu.edu
June 7-9 www.sensorsmag.com/sensors-expo
Global Petroleum Show Sept. 13-15
Calgary, Alberta, Canada June 21-23 Gas Compressor Short
+1 (403) 209-3555 Developing Unconventional Gas (DUG) Course Conference
www.globalpetroleumshow.com East Conference & Exhibition Norman, Oklahoma
Pittsburgh +1 (405) 325-3136
June 13-16 +1 (713) 260-6492 www.ou.edu/outreach/engr/
Nigeria Oil & Gas Conference www.dugeast.com gascompressor_home.html

MAY 2016 10 COMPRESSORtech2

Rebuild.
The Altronic Flashguard 2.0 Secondary Spark Plug Lead System
gives you the ability to fully rebuild spark plug leads in the field.
Incorporating custom Teflon extensions, including special
extensions for the Caterpillar 3300 and 3400 engines, multiple
wire styles, a range of primary and secondary connections, and
an assortment of lead accessories, you can cost-effectively
specify a lead for manufacture by your local Distributor, or
locally by your own personnel. In either case, leads can be
serviced/rebuilt when necessary with moderately priced, easily
installed replacement components, including new O-rings, wires,
boots, or grommets/terminal pins acquired directly from your
Distributors inventory or your own.
This system offers accessibility, reliability, and the performance
that are critical to minimize downtime, while driving the
necessary cost-control and serviceability that are so crucial to
twenty-first century operation.
Contact your Altronic Distributor for all the details.

HOERBIGER Engine Solutions

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

2/17/16 9:44 AM

For a complete listing of upcoming events, please visit our website at www.compressortech2.com/events/

Sept. 13-15 Sept. 20-23 Oct. 17-19

Wyoming Natural Gas Fair InnoTrans 2016 Saudi Arabia International Oil & Gas
Casper, Wyoming Berlin Exhibition (SAOGE)
+1 (307) 258-4708 +49 30 30 38 2376 Dammam, Saudi Arabia
https://wyogasfair.org www.innotrans.de +39 06 3088 3030
www.saoge.org
Sept. 14-15 OCTOBER
International Rotating Equipment Oct. 2-5 Oct. 24-27
Conference Gas Machinery Conference Rio Oil & Gas
Duesseldorf, Germany Denver Rio de Janeiro
+49 69 66 03 12 82 +1 (972) 620-4026 +55 21 2112 9079
www.introequipcon.com www.gmrc.org www.ibp.org.br

Sept. 14-15 Oct. 10-13 NOVEMBER

European Forum for Reciprocating International Seminar Rotor Dynamics Nov. 2-4
Compressors (EFRC) & Bearings EP Shanghai 2016
Hofburg, Vienna, Austria Cologne, Germany Shanghai
+49 69 6603 1286 + 49 2267 6585-0 + 852 2811 8897
www.recip.org www.arla-online.com www.epchinashow.com

Sept. 20-22 Oct. 11-13 Nov. 7-10

Power-Gen Asia HHP Summit 2016 ADIPEC
Seoul, South Korea Chicago Abu Dhabi, United Arab Emirates
+44 1992 656 656 +1 (888) 993-0302 +971 2 6970 518
www.powergenasia.com www.hhpsummit.com www.adipec.com

MAY 2016 11 COMPRESSORtech2

 n This closed-loop at Solars gas compressor test facility is powered by a dedicated
Titan 130 gas turbine driver on a universal driven-equipment skid that enables full load
testing in a hydrocarbon or inert gas closed-loop.

Test Facilities Improve Compressor

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

S
ince the introduction of its first centrifugal compres-
sor in the early 1960s, Solar Turbines has steadily
developed its compressor product line that now
covers a wide range. The compressors are optimized to
match the speed and power ratings of its Saturn, Cen-
taur, Taurus, Mars, Titan (all registered names of Solar
Turbines) gas turbines. They can be matched with electric
motor drives as well.
MAY 2016
Solar continues to invest in its product development ef-
forts through its two ISO 9001:2008 certified campuses in
San Diego. Its gas compressor test facility (GCTF), which
began operation in 2009, is part of a substantial invest-
ment in new product development, as well as providing
customers with expanded options for shop testing.
The three-bay GCTF facility at Solars Kearny Mesa
continued on page 16
14 COMPRESSORtech2
INNOVATION STANDARD IS
THE TRUSTED LEADER IN
N AT U R A L G A S C O M P R E S S I O N C O N T R O L S
Murphy by Enovation Controls continues to
invest in products that help you get the
most our of your business and reduce
unscheduled downtime.

We are creating new ways

to help you grow by:
Continuing
to innovate

Developing
fit-for-purpose
products

Bundling end devices that you need

to save you more

By continuing to add diagnostic capability, performance

improvements and unrivaled support, we will work diligently
to make the Murphy choice the easy choice. With more than
75 years in the industry, Murphy is the smart choice, too.

FIND OUT HOW WE CAN HELP YOU GROW YOUR BUSINESS

Contact us for solutions and services.

Phone: 918-317-2641 www.fwmurphy.com/newstandard
 complex is used for research, devel-
opment and production, including new
and aftermarket testing of compres-
sors in accordance with ASME PTC-
10 Type I and II.
In the first two bays, a dedicated
Titan 130 gas turbine engine and an
8 MW variable speed electric motor
drive (VFD) equipped with univer-
sal driven-equipment skids enable
full load testing in a hydrocarbon or
inert gas closed-loop up to 3500 psig
(241 bar).
The third test bay can accommo-
date full compressor package closed-
loop string testing up to 30,000 hp
(22.3 MW). Testing of Solar compres-
sors at the GCTF facility provides
mechanical integrity, accurate mea-
surements and aerodynamic perfor-
mance. It also ensures rotordynamic
stability and low vibration that meet
or exceed API requirements.
In addition to testing new compres-
n A significant amount of development and production compressor testing has taken
sors, the GCTF facility is available to
place at Solars closed-loop test facilities, which accommodate ASME PTC-10 Type I and
test customers gas compressors af-
II testing. One of the closed-loop facilities is driven by a dedicated 8 MW variable speed
ter overhaul or restage. At its Harbor
electric motor (top). The extensive data gathered during these tests (bottom) is fed into
Drive complex, Solar has an addi-
the companys prediction database to improve analytical models and to improve compres-
tional closed-loop test facility, which
sor durability and reliability.
is also used for Type II compressor
testing, with a dedicated Centaur 40
gas turbine driver.
In the closed-loop facilities, produc-
tion or aftermarket compressors can
be shop tested under load to repro-
duce the aerodynamic design point.
Field gas properties can be simulated
through a variety of gas mixtures. Per-
formance verification with shop tests
before site commissioning is critical
to many customers.
Solar is aware of customer require-
ments for availability and durability of
compression equipment, which is why
the company emphasizes significant
development testing prior to compres-
sor qualification.
At development, the compressors
are run on natural gas to their speed
and pressure limits, pushing beyond
their normal operation in the field. A
magnetic exciter is used to directly
measure damping in the rotor-bearing
system. This allows verification of ro-
tordynamic stability under actual op-
erating conditions at high speeds and
continued on page 18
MAY 2016 16 COMPRESSORtech2
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 operate the unit being tested, while measuring and evaluating its performance.
The system establishes specified test conditions, constants and operating
limits. Test data are monitored by video displays as instructed by the test
agenda, selecting various parameters for display, checking values and limits,
and generating reports as needed. When acceptable performance levels are
achieved, the test technician initiates a command to a computerized real-
time data acquisition system that captures all instrumented points, initiates
automatic performance computations and prints the results for review for a
permanent test record.
Closed-loop testing is used for development purposes and is often specified by
customers of mission-critical compressor applications. These applications justify the
higher cost of more extensive closed-loop factory validation of compressor aero-

COMPRESSOR LUBRICATION SYSTEMS

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MAY 2016
cilities, two open-loop test facilities
are used to test every Solar Turbines
compressor prior to shipment to eval-
uate mechanical and aerodynamic
performance in accordance with test
procedures and acceptance criteria as
outlined in applicable test specifica-
tions. The suction and discharge noz-
zles are connected to an open-loop
configuration that uses atmospheric
air. The two open-loop test facilities
have dedicated drivers a Centaur
50 and a Saturn 20 gas turbine.
Mechanical testing is performed first.
The dry gas seals are tested statically
with nitrogen. After preliminary checks
and static seal testing, the unit is operat-
ed at break-in speed, then at maximum
continuous speed. Key mechanical pa-
rameters such as seal gas leakage and
separation seal air flow, oil flow, and vi-
bration levels are measured and evalu-
ated against established limits.
continued on page 22
20 COMPRESSORtech2

Sloan_WhenMachinesStop_Mar16_CT.indd 1 2/22/16 3:56 PM

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

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2

After the mechanical tests, aerodynamic testing on air oc-
curs. The primary objective of the test is to confirm the accu-
racy of the individual stage characteristics used for predicting
compressor aerodynamic performance at the air-equivalent
design speed.
Accuracy is determined by comparing the overall head
vs. flow speed line from choke to surge and the surge line
position against prediction when operating at a speed
equivalent to the specified site design speed. Surge points
are determined at various speed points to validate the
surge flow estimate for the entire operating speed range.
Extensive instrumentation, together with the facility data
acquisition and reduction system, validates mechanical
and aerodynamic performance.
A separate aero test facility (ATF) allows for testing
scaled single stages while making detailed measurements
in order to improve prediction capability and help under-
stand component performance. In this facility, exclusively
dedicated to development testing, Solars engineers can
test entire compressor stage impellers, diffusers, return
vanes and volutes.
Many different types of compressor stage components
can be tested in the ATF. These stages can either be
scales of existing production stages or experimental stag-
es. For each test article, flange-to-flange performance is
determined. Static and total pressures are measured at
various locations throughout the stage to determine over-
all stage performance as well as the performance of each
individual component.
This process extends our aerodynamic design knowl-
edge, Schor said, adding that the ATF tests are used to
validate and establish limits of 1-D and 3-D design codes,
MAY 2016
n Solars aero test facility (ATF) enables
testing of scaled single centrifigal com-
pressor stages while making detailed
measurements in order to improve pre-
diction capability and help understand
component performance.
evaluate and understand stage component (impeller, return
vane, etc.) losses, establish guidelines for aerodynamic pa-
rameters, and gather data to help design the next generation
of compressors.
The objective of the facility is not only to design and test
stages with the best efficiency for direct application to a pro-
duction stage, but also to extend our knowledge of critical
parameters, Schor said. For example, a stage can be de-
signed deliberately with a sub-optimal surge margin and, by
analyzing test data and predicted data, correlations can be
derived as to what critical parameters, such as diffusion or
flow angle, are responsible for the adverse effect on com-
ponent stability.
This extends the prediction capabilities of the design
software and improves the ability to design stages with the
best compromise between head, efficiency and flow range.
Throughout its compressor line, Solar Turbines makes use
of pre-designed, pre-engineered and pretested components
rather than customized stages. Since standardized aero
components are used in Solar compressors rather than a
completely customized design, far more effort can be spent
in careful optimization. The impellers for Solar pipeline com-
pressors have complex 3-D blades with inducer inlet sec-
tions. The optimization process makes extensive use of 3-D
modeling components, using computational fluid dynamics
(CFD) tools, scaled model testing at Solars ATF, and full size
testing in its closed-loop test facilities.
These modern computational tools, together with the
expanded test capabilities, have been used to design
compressor stages with high efficiency and a wide oper-
ating range, said Manoj X. Dutt, manager, marketing &
product strategy. CT2
22 COMPRESSORtech2
2016 EDITION XX WWW.CTSSNET.NET CTSS
 Active Magnetic
Bearing System For
Large Machines > Siemens Introduces Simotics Active Magnetic
Bearing technology for wear-free operation in
large-machine applications
I
n order to limit the wear of moving components, covering
their surfaces with an oil film is a conventional practice.
For more than a century, this has been the only way to
avoid friction between moving metal components. Oil con-
sumption can be expensive and, in some cases, pollute the
environment or the fluid used by the machine.
An alternative system, applicable to all rotating machines
(specifically high-speed and large-dimension machinery) is
active magnetic bearings. While not new, this systems big-
gest drawback was its control system. The analog tuning
procedure could take several weeks, sometimes months.
With the advent of digital control systems, this procedure
has been reduced to a few hours and has created new op-
portunities in the design and implementation of all types of
rotating equipment, such as compressors, electric motors/
generators, gas and steam turbines.
With its Simotics Active Magnetic Bearing (AMB) tech-
nology, Siemens has introduced an AMB system for large
machines, such as high-speed, high-voltage motors or in-
dustrial turbines and compressors. The rotors for such ap-
plications are held suspended in the center of the bearing
without any friction or wear. To achieve this, sensors record
the position of the shaft 16,000 times a second and a regu-
lator adjusts the magnetic field to keep the rotor hovering
MAY 2016
BY ROBERTO CHELLINI
n Simotics Active Magnetic Bearing (AMB) tech-
nology for wear-free operation in large-machine
applications. The system is built around standard
controller and converter units from the Sinamics
family of products from Siemens. The illustration
shows a special split bearing as used in a feed-
pump drive turbine at the Jnschwalde power
plant in Germany.
precisely in the bearing center. Even rotors weighing sev-
eral tons, spinning at maximum speed, can be held in a
position window that has the diameter of a human hair.
The Simotics AMB technology allows the use of standard
components from the Siemens portfolio, such as Sinamics
and Simotion control and converter units. In the context of
Totally Integrated Automation (TIA) and Integrated Drive
Systems (IDS), Simotics AMB technology is a highly effi-
cient and matched solution for large machine applications,
the company said. Simotics AMB technology seamlessly
integrates into the Siemens TIA concept, as all compo-
nents in it are mutually compatible and system tested. The
Sinamics standard control components are used both in
the IDS in the drive train to control the magnetic bearings
as well as in the main converter. The PC-based Simotion
P320-4 controller forms a customer-specific, configurable
human machine interface for system monitoring, communi-
cation with the higher-level plant controller and for auxiliary
commissioning functionalities.
Simotics AMB technology is already in use. At NAM/Shell,
two 23 MW high-speed compressor drive trains running at
6300 rpm in the Netherlands Groningen gas field utilize Si-
motics AMBs; as well as at Germanys Jnschwalde power
plant in a 10 MW steam turbine running at 5700 rpm. CT2
24 COMPRESSORtech2
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FEATURED
PRODUCTS
Protection Relays flexibility. Using the expanded communications capabilities,
Woodwards new HighPROTEC-2 protection relays are the HighPROTEC-2 interfaces with Woodwards engine
designed to protect electrical buses and equipment. These and turbine controls and generator set controllers to form
medium-voltage protection relays for generators and a complete control and protection solution for generator
power distribution applications monitor the electrical con- systems. Programming and operation menus, available in
dition of equipment and discon- seven different languages,
nect the power source quickly reside in each unit.
when a problem or potential prob- A graphic display shows
lem is detected. the HighPROTEC-2 con-
Nine separate HighPROTEC-2 nection architecture along
products target different electrical with real-time operating val-
applications, including electrical ues and messages, alarms,
feeders, mains decoupling and and fault data. A PC-based
line protection, as well as electri- service tool simplifies con-
cal generators, transformers and figuration and includes pa-
motors. Users can configure each rameter plausibility checks
product to address the specific and an ANSI menu struc-
aspects of a given application. ture. It includes a display
This flexibility reduces the num- screen editor and event,
ber of product variations that oc- trends, and disturbance re-
curs when matching a solution to corders and counters to aid
unique application requirements. Broad voltage and cur- operation and troubleshooting. The HighPROTEC-2 has
rent inputs (0-800V ac and 1A/5A), wide range input power, worldwide certifications including CE, UL, CSA, EAC and
parameter configuration, and communication protocols marine certifications.
(DNP3.0, IEC 61850, Modbus, Profibus) provide application www.woodward.com/hpt-2

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OKLAHOMA CITY DALLAS GILLETTE HOUSTON LOS ANGELES TORONTO DENVER
 n GE Oil & Gas completed a full-load engine test
of its 16 MW industrial gas turbine last September.
GE Tested, REP Approved > 16 MW gas turbine slated for
Russian installation
A
t its Florence, Italy, facilities last September, GE Oil
& Gas completed the full-load engine test of its 16
MW industrial gas turbine for mechanical drive com-
pressors and power generation.
The test confirmed turbine efficiency, power output and
emissions levels, GE said. Efficiency and power were high-
er than analytical forecasts, while emissions came in lower
than expected, according to the test results.
MAY 2016
BY ROBERTO CHELLINI
Russian licensee REP Holding assisted with the engine
development, which involved validating the engine require-
ments and main design parameters. REP Holding also con-
tributed to the preliminary and detail design, as well as the
crafting the low-pressure turbine, and designing the engine
package for the Russian market.
A gas generator full-load test also took place before GE
shipped the module to REP Holdings Nevsky facility in
30 COMPRESSORtech2
 (among other equipment) in order to map performance, temperatures and
secondary flows.
The measurements will be used to finalize the digital engine model, as well
as fully characterize the performance of each machine component and define a
baseline thermodynamic cycle. The latter will constitute the starting point to further
increase the turbine power output and efficiency, while also improving emissions.
In order to test the complete GE train configuration, a dedicated test stand was
constructed with a gearbox from GE Lufkin and an electric generator from GE
Power Conversion.
The instrumented unit will remain on its test stand in Florence for research and
development purposes throughout 2016, the company said.
continued on page 32

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St. Petersburg, Russia. At the facility, and comprehensive service. No
the licensee performed further joint matter the challenge you have
testing on the gas turbine as well as with your compressor, the Tulco
subsequent field installation at a com- team will have a solution.
bined heat and power plant.
Two months later in Florence, GE
Oil & Gas finished the assembly of
a fully instrumented unit, which went WWW.TULCO.COM
through its validation and character-
ization test campaign. The engine was (800) 375-2347
heavily instrumented with research
and development strain gauges, tem-
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MAY 2016 31 COMPRESSORtech2
 n GEs 16 MW industrial gas turbine was

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

GE Oil & Gas is working on the pro-

duction of three gas generators for
REP Holding, which will be used in
St. Petersburg. REP Holding will com-
plete the manufacturing of the low-
pressure turbine modules and engine
packages to create the T16 gas tur-
bine engine; it is called the NovaLT16
for the Russian oil and gas market.
The three units will be used to drive
REP Holding centrifugal compressors
as part of the modernization of Rus-
sian pipeline infrastructure. The job,
which will see industrial gas turbines

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replacing aged turbo-compressors,
requires more than 4000 GT units.
The modernization is expected
to improve transportation efficiency
(amount of natural gas consumed vs.
transported gas and availability) with
longer maintenance intervals and a
smaller environmental impact, GE Oil
& Gas said.
In 2014, GE Oil & Gas announced
an all-GE pipeline configuration of
its 16 MW unit, with a dedicated GE
Oil & Gas designed package and
BOP, developed in collaboration with
TransCanada Corp. and launched as
NovaLT16.
GE Oil & Gas is working to produce
one complete turbo compression train
for installation along a Canadian pipe-
line in Alberta. CT2

MAY 2016 32 COMPRESSORtech2

FEATURED
PRODUCTS
has expanded its line of measure-
ment and control instrumentation
with the addition of the model TCA-
MS-K-1. This Single Channel Type K
Thermocouple Amplifier Module con-
verts the low output voltage signal
from a Type K thermocouple probe
to a single independent linearized 0
to 5 Vdc output voltage. According to
the company, this output is ideal for
interfacing to instrumentation equip-
ment including data loggers, tem-
perature indicators, chart recorders
and controllers.
Product features include a Type K
thermocouple input; temperature
repaired motors prior to their installation. Split rings come in mating halves that measuring range from 32 to 2282F
simplify field installation around the shafts of in-service/coupled motors. (0 to 1250C); analog output of 0 to
The Aegis Pro SLR Ring is specially designed with O-ring barriers that prevent 5 Vdc; and a response time of 1 ms.
the ingress of dust, debris, and excessive contamination that could lessen con- http://thesensorconnection.com
tact of the rings conductive microfibers with the motor shaft. The Aegis Pro-MR
combines a PRO Bearing Protection Ring with a shaft voltage-monitoring ring in
a single unit.
Specially designed universal mounting brackets allow installation of Aegis Pro
Series Rings on large motors. These brackets attach to Pro Series Rings with
screws and have slotted legs that allow mounting to the motor with a bolt circle
of 2.64 to 7.79 in. (67.05 to 197.8 mm) greater than the shaft diameter. They are
provided with 0.5, 1.0 and 1.5 in. (12.7, 25.4 and 38.1 mm) standoff spacers to
provide sufficient clearance for shaft shoulders, slingers, or other end bell protru-
sions. Mounting bolts, flat washers and lock washers are also included.
www.est-aegis.com

The Sensor Connection

The Sensor Connection, a division of Harold G. Schaevitz Industries LLC,
RMS Expands
Its Footprint > Rotating Machinery Services Inc. provides full range
of turbomachinery repair and upgrade services
n The RMS service facility consists of three 10,000 sq.ft. (929 m2) bays that include a rotor assembly shop (left), large-capacity machine
shop with quality control room, and an assembly shop (right) with a full range of lifting, moving and storage equipment.
I
n 1998, a group of experienced turbomachinery engi-
neers with a strong aftermarket engineering background
founded Rotating Machinery Services Inc. (RMS) in
Bethlehem, Pennsylvania. Now in its 18th year, the compa-
ny has steadily grown its business, becoming a major force
in providing turbomachinery aftermarket engineering and
repair services to the refining, chemical, gas transmission,
power generation and steel industries. Earlier this year,
RMS opened a satellite engineering office in Appleton,
Wisconsin, specializing in the support of the former A-C
Compressor line of centrifugal compressors.
RMS performs a wide range of services on turbomachin-
ery, including reliability improvements, performance optimi-
zation, repair, component replacement and the supply of
upgraded/overhauled surplus equipment. The company
has experience with repowering turbomachinery pack-
ages and has also supplied new custom-designed equip-
ment skids and lube oil systems. Its experience includes
axial and centrifugal compressors, fluid catalytic converter
(FCC) and nitric acid expanders, gas turbines, aeroderiva-
tive power turbines and steam turbines.
RMS provides a full range of turbomachinery services,
giving users a complete alternative to the OEM (original
MAY 2016
BY NORM SHADE
equipment manufacturer), said Jerry Hallman, company
president and co-founder. We have a total focus on existing
compressor equipment, as opposed to OEMs, which have
their resources focused on new equipment. We can provide
superior engineered solutions to long-standing problems
that the OEM is unwilling or unable to solve. We also focus
on orphaned equipment that is no longer fully supported
by an OEM. And we provide customers with open access
to RMS experts.
Types of projects include rerates for improved performance;
engineered overhauls of rotors and complete machines;
mechanical redesigns and upgrades; reapplication of sur-
plus equipment trains; component repairs; new parts sup-
ply including rotor blading, disks, shafts, stators, casings,
bearings and seals; and field service that ranges from in-
spection and turnaround support to providing supervisors
to full turnkey responsibility.
We take pride in our ability to refurbish turbomachinery
to a condition that ensures long-term trouble-free operation
for our customers, Hallman said. Our assemblers, inspec-
tors, machinists and field service supervisors have an aver-
age of 25 years of experience in their respective fields and
continued on page 36
34 COMPRESSORtech2
Everywhere.
Providing solutions for oil and gas applications upstream, downstream and in-between.

We are where you need us.

Welcome to a new era of innovation and technology.
As you have come to expect, Dresser-Rand provides
safe, reliable and efficient rotating equipment for nearly
every application in the oil and gas market.
But theres more.
The new Dresser-Rand business now has expanded
resources and more experience as a member of the
global Siemens family. The Dresser-Rand business
combines one of the industrys most extensive
portfolios of rotating equipment with a universe of intelligent
solutions and one of the worlds largest technical support
and service center networks. We offer more choiceswhere
you need usall from a single supplier.
So what can you expect from us? High-quality products
and services, combined with local support around the
clock, wherever you are, for the applications that matter
to you.

dresser-rand.com
 take great pride in our facility and our
ability to handle our customers prop-
erty with the greatest efficiency and
Experience, Reliability, Integrity... attention to detail.
Hallman said that RMS is affiliated
with respected millwright service orga-
nizations throughout the country, and
RMS supplies field supervision for
each crew to ensure proper execution
of every project.
Our organization is made up of
uniquely experienced engineers and
technicians, said Robert J. Klova, PE,
vice president, chief engineer and co-
founder. We leverage our experience
with the latest engineering technology.
Experience in all types of custom-en-
gineered turbomachinery separates
the optimum solution from the run-of-
the mill. Strong design and analytical
engineering form the backbone of ev-
erything we do. Engineering makes
the difference, and we focus on con-
tinuous development of the next gen-
The AXH manufacturing complex consists of
six plants, totaling 559,100 SF on 67 acres. eration of turbomachinery engineers
to serve customers future needs.
RMS has analytical capabilities in
structural analysis, aerodynamics,
(918) 283-9200 Fax (918) 283-9229 www.axh.com rotor dynamics and metallurgy using
the latest analytical tools.
The RMS service facility consists
MAY 2016 36 COMPRESSORtech2
 ...
LOW... ...RATING
n The capabilities of RMS experienced en-
gineering staff include expertise in all major
types of custom-engineered turbomachinery
and a full range of analytical expertise with the
latest analytical tools in rotordynamics, struc-
tural analysis (e.g., turbine disk, left), aero-
dynamics (e.g., centrifugal stage flow path,
center) and performance (e.g., steam turbine
blade erosion, right).

of three 10,000 sq.ft. (929 m2) bays that
include a rotor assembly shop, machine
shop with quality control room, and an
assembly shop. The rotor shop, which
is serviced by a 25 ton (22.5 tonnes)
overhead crane, houses multiple in-
dicating stands and stacking pits, two
Schenck balancing machines with
respective capacities of 40,000 and
17,000 lb. (18,140 and 7710 kg), an
electrical runout (glitch) system, a va-
riety of hydraulic coupling and tie-bolt
stretching equipment, and a Bracker
hydraulic rotor tenon peening system.
The machine shop houses multiple
large machine tools including a 5 in.
(127 mm) bar CNC horizontal boring
mill, a 60 in. (1524 mm) swing CNC
vertical boring mill, a Mazak 300M
CNC turning-milling center, a 52 in.
(1321 mm) swing by 236 in. (5994
mm) between centers engine lathe,
and a 90 in. (2286 mm) swing vertical
boring mill, as well as a variety of small
manual lathes, knee mills and grind-
ers. The temperature-controlled, qual-
ity control room houses a number of
granite tables, coordinate measuring
equipment with scanning capabilities,
positive material identification equip-
ment and two precision air bearing
MAY 2016
low-rating.hoerbiger.com
rotary table inspection stations. The
machine shop is equipped with 25
and 15 ton (22.5 and 13.5 tonnes)
overhead cranes.
The assembly shop has six large
assembly cells, a weld shop, nonde-
structive test (NDT) area with mag-
netic particle and wet magnetic particle
booths, an abrasive blast room and
multiple abrasive blast cleaning cabi-
nets. This shop is supported by a 35/15
ton (31.5/13.5 tonnes) crane with 27
ft. (8.2 m) hook height and multiple jib
cranes. Also in this area, RMS field ser-
vice operations maintain a 20 ft. (6.1 m)
fully equipped sea container/shop and
gang boxes, ready for immediate dis-
patch to customer sites.
RMS capabilities are evidenced
by its list of successful turbomachin-
ery projects. A recent major project
was an ammonia/water turbine gen-
erator set, developed from a surplus
steam turbine for a process cus-
tomer in Pakistan. RMS provided the
complete train of equipment, with
new controls and auxiliaries, includ-
ing the application of dry gas seals
for ammonia containment. To sup-
port the project, RMS had to develop
continued on page 38
37
n RMS provided this complete ammonia/water turbine gen-set for a process customer in Pakistan. Developed from a surplus steam
turbine, it provided the complete train of equipment, including controls and auxiliaries and the application of dry gas seals for ammonia
containment. To support the project, RMS had to develop performance analysis capability for ammonia and steam mixtures.

n RMS provided this complete machinery

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

performance analysis capability for

ammonia and steam mixtures.
The company has special expertise
in fluid catalytic cracker (FCC) and ni-
tric acid expanders. Nitric acid is the
basic material for the production of
fertilizers, explosives and chemicals.
In 2014, an I-R E520 nitric acid tail
gas expander experienced a high-
pressure seal failure. RMS engineer-
ing supervised the change-out of the
damaged expander with a spare unit
that had been sitting idle following a
multiyear run. The spare expander
had experienced high of 2 to 3 mils
(51 to 76 m) and unstable shaft vi-
brations during its prior run. Improved
cold alignment, bearing changes, and
careful setup resulted in low and
stable vibration of less than 1.06 mils
(27 m), the lowest historical level for
this expander.
MAY 2016 38 COMPRESSORtech2
n An axial compressor rotor is ready for
return to a customer after an engineered
overhaul in RMS shop.

In 2008, RMS provided a complete and expander assemblies, enabling

machinery train for a nitric acid plant.
Starting with a surplus train, RMS
completely designed the axial com-
pressor and rerated the turbine, pro-
viding a new lube oil console as well.
It also rerated the customers existing
expander during a turnaround.
In 2012, RMS was contracted to
support the emergency breakdown
of a European refinerys FCC power
recovery train. A failed Elliott hot gas
expander was at the heart of the
breakdown. RMS was able to restore
the main axial compressor to service
on motor only within a 10-day period.
The company then received another
contract for a root cause analysis
of the failure and for rebuilding the
damaged expander using an existing
spare rotor. During the inspection pro-
cess, RMS determined that the entire
intake casing assembly was no longer
suitable for service. It was able to de-
liver a new intake casing assembly, in-
cluding first- and second-stage stator
housings in an expedited 16 weeks
from date of order. RMS field service
team travelled to Europe to support
the installation of the intake casing
an early startup.
Last year, RMS was offered a
unique challenge to urgently replace a
Cooper-Bessemer RC20 compressor
rotor that suffered a heavy rub failure
caused by impellers contacting the
diaphragms. The impellers were re-
verse engineered through mechanical
and FaroArm inspection methods in
four weeks. RMS engineers analyzed
the inspection information, and new
CAD models were created. Utilizing
forged material from in-house stock,
RMS was able to complete five-axis
machining of the impellers and a fin-
ished product, including overspeed
testing, in less than eight weeks. The
engineering and manufacture of a
new shaft, balance piston and shaft
sleeves were completed in 12 weeks,
so that the entire replacement rotor
assembly was assembled, balanced
and shipped in 13 weeks, one week
ahead of the agreed-upon 14 weeks.
RMS also performed a rotordynamics
analysis and developed performance
curves for the design.
In addition to service and repair,
continued on page 40

n RMS provides engineering and support to users

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

MAY 2016 39
 n RMS refurbishes and upgrades process (left) and pipeline centrifugal compressors including new custom-engineered
aerodynamic assemblies (right).

solving turbomachinery problems with engineering analyses and improved designs and pipe locations, and lead time was
has always been an RMS focus. For example, a 1968 vintage GHH horizontally over 30 months. RMS custom designed
split centrifugal compressor in a toxic gas service had experienced chronic joint and manufactured two new 300 series
leakage over many years. The end user tried various fixes including purchasing stainless-steel drop-in replacement
a spare compressor with a thicker casing; yet the sealing problem could not be compressors with upgraded barrel type
consistently eliminated. Finally, the end user was faced with the need to replace the casings to solve the split line leakage
machines entirely. However new compressors would not match the existing layout problem. The complete units utilized
new RMS casings and diaphragms with
the customers existing rotors, bear-
ings and inner seals. Dry gas seals and
a new common oil system were also
included as part of the upgrade. The
new compressors were installed in the
spring of 2014, completely eliminating
the chronic leakage problems.
FCC expanders can experience sig-
nificant erosive wear due to catalyst
particles entrained in the flue gas.
Using computer fluid dynamics (CFD)-
aided state-of-the-art aerodynamic
design, RMS developed a number of
unique features that have significantly
improved blade and disk lives. These
include low-erosion rotor and stator
airfoils, blade platform seals, and a
unique overlapping platform design
upgrade that shields the rotor disk
from the harmful effects of catalyst
laden flue gas. The low erosion design
doubled the life of the rotor disk and
blades to six years at one customer
site. RMS significant experience in all
aspects of FCC expander design, ser-
vice and support has earned it a strong
and growing place in the FCC expand-
er aftermarket, where numerous refin-
eries rely on us to support their FCC
power recovery trains, Klova said. CT2
MAY 2016 40 COMPRESSORtech2
LITERATURE
Compressed
Technical Services
Stark Industries brochure
outlines its Compressed
Technical Services offering.
CTS designs and manu-
factures compresor system
packages for industrial gas.
Compressors, oil-removal
systems and air-storage
solutions are enumerated
along side the companys
services offering.
www.starkindustries.com
Cooling
Solutions
The Fuzzys Radiator bro-
chure lays out the products,
services and technologies
used by the Texas panhan-
dle company. Fuzzys cool-
ing solutions include radiator
packages, heat exchangers,
fin fan packages, radiator
cores, charge air coolers,
gaskets, cooling coils, hydro
blasting, soda blasting and
repair services.
www.fuzzysradiator.com
Gemini
Upgrade Parts
TrueRock released bro-
chures to highlight the fea-
tures and benefits of its line
replacement/upgrade parts
for Gemini compressors.
The brochures feature the
H Series aluminum pis-
ton rod (pictured) and the
M/H Series variable volume
clearance pockets.
www.truerocksupply.com
Stop by Booth 301/400 at the EGCR for more information
Preservation
Coatings
A-76 Technologies supplies
the A-76 line of preserva-
tion coatings and lubricants,
offering corrosion prevention
and lubrication in high-
humidity, high-salinity envi-
ronments. A green variation
contains no volatile organic
compounds, helping custom-
ers reduce emissions.
www.a76tech.com
Analysis: Valve Performance On Booster
Primary Compressor For LDPE >
Production of critical parts, maintenance strategies
help to optimize availability, minimize costs
n Booster primary compressor.
T
he production of low-density polyethylene (LDPE)
requires special compressors to obtain the pres-
sure necessary for the product.
The booster primary compressor brings the pressure
from low value up to the suction of the hyper compressor
that feeds the reactor.
Great attention is paid to all details of the plant in order to
achieve maximum operating time. The valves represent an
important component that strongly influences the reliability
of compressors and the plant.
The booster primary compressor requires stringent ca-
pacity control, further increasing its complexity.
An analysis of the design, production and performance
aspects of the booster primary compressor follow.
Plant features
The booster primary machine is a six-cylinder, mul-
tiservice compressor, which combines the function of
the booster and primary on one frame manufactured by
Nuovo Pignone (now GE Oil & Gas). The motor oper-
ates at 4000 hp (2983 kW) at 327 rpm. The machine has
Jimmy Salmon is a senior principal engineer with 40 years of con-
tinuous service in LDPE maintenance, reliability and production.
Enzo Giacomelli is a consultant for Dott.Ing.Mario Cozzani Srl.
MAY 2016
BY JIMMY SALMON AND ENZO GIACOMELLI
a capacity of 16,000 lb./hr (7000 kg/hr) for the booster and
56,000 lb./hr (25,000 kg/hr) for the primary.
The boosters suction pressure is slightly above the at-
mospheric one, collecting the gas from the plant recovery
system. The discharge of the primary reaches 3600 psi
(25 MPa) to feed the hyper compressor. The hyper com-
pressor, designed and manufactured by GE Oil & Gas, is
an eight-cylinder machine that raises the pressure to full
reactor pressure. The three cylinders are double acting on
the booster, which reaches a pressure of 3278 psi (22.6
MPa). The compressor has 24 Nuovo Pignone-designed
valves manufactured by Cozzani.
The primary compressor operates up to 3771 psi (26 MPa)
and has two cylinders with a tandem arrangement (second-
stage inboard and third-stage outboard). Additionally, the pri-
marys first stage is double acting with 2+2 valves, while the
two second and third stages are single acting and positioned
on the same cylinder with a tandem arrangement. The sec-
ond stages have one suction valve and one discharge valve
per cylinder, while the third stages have one combined suc-
tion and discharge valve per cylinder. All the cylinders are
equipped with plastic piston and packing rings.
The cylinder lubrication is made with a mineral oil with
lubricity additives. It is the same one that is applied for the
booster/primary and hyper compressor.
42 COMPRESSORtech2
Valve applications (temperatures, pressures and vibra- same cylinder is essential to assess
The set of 30 valves is equipped tion). In operation, we monitor process performance and keep operations run-
with metal rings in all stages of boost- and oil temperature and pressure, as ning until a failure can be predicted.
er and primary. The capacity control well as machine vibration. Following the 1996 valve change,
requires the use of finger-type, one- the next change occurred in 2002 for
step unloading systems as well as Valve performance all of the valves. In 2006, the primary
continuous bypass control. Because The valves are critical compressor third-stage valves were changed dur-
the gas involved is not corrosive, the components. Their performance has ing re-ringing of the third-stage cylin-
material of the seat and guards is been checked by pressure and tem- ders, as the cylinders were already
alloy steel AISI 4140. perature analysis. The attention to any largely dismantled. All other valves
The valve bolts for the seat/guard deviation from the design parameters remained in service.
system were provided with a threaded and homogeneity of the valves of the continued on page 44
connection, including a surface treat-
ment for longer life. Castle-type lock-
nuts were used to prevent the assembly
from loosening in service. These nuts
also include an anti-friction surface layer
to reduce damage during maintenance.
Simulation programs have real-
ized the design on the full operat-
ing range. The machines have been
manufactured to meet quality control
procedures. The critical parts, such
as springs and rings, are designed to
withstand fatigue stress.

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

MAY 2016 43 COMPRESSORtech2


n Ring valves after disassembly.
In 2013, as part of the proactive replacement plan, the
booster and first-stage primary valves were reconditioned.
The final reconditioning efforts took place in Cozzanis
service center in Magnolia, Texas, with the coordination
of the compressor manufacturer and supervision from the
valve manufacturer.
MAY 2016
EGCR_May16CT_HalfHorizNonBld.indd 1
44
Most valves have lives of six to 13
years. The primary third-stage valves
were removed with lives of four to 13
years. The last valves placed in ser-
vice now have nine years and are
still operating. The valves were
in good condition during each
inspection. While slight wear oc-
curred to some seating surfaces,
it wasnt enough to cause per-
formance issues. There was also
slight wear in the bottom of some
spring recesses.
The rings were in good condition, with
no cracks or broken pieces. The springs
were intact, with none of them broken or mis-
shaped. Every reconditioning was made accord-
ing to the recommended procedure.
Conclusions
The original valves installed in a booster primary com-
pressor have performed well from one proactive switch to
the next during the 32-year window. All replacement parts
have been designed to the original more than 30-year-old
design. Although potential design improvements could be
made, such as plastic rings, the original work suited this
application. CT2
COMPRESSORtech
4/14/16 2:24 PM
2
COMPRESSOR

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PRIME
MOVERS
Gasmet Technologies
Gasmet Technologies has acquired Quantitech Ltd.
Headquartered in Finland, Gasmet Technologies is a
global manufacturer of gas monitoring instruments and
systems for industrial and environmental applications in-
cluding continuous emissions monitoring, process control,
engine exhaust gas, greenhouse gas monitoring and car-
bon capture.
Quantitech Ltd. provides advanced environmental and
process monitoring instrumentation in the U.K. and Ireland.
Following the acquisition, Quantitech will remain at its
Milton Keynes, U.K., location, trading under the same name
and continuing to supply the same range of products.
Burckhardt Compression
Burckhardt Compression will acquire a 60% stake in
Shenyang Yuanda Compressor Co. Ltd., a Chinese recip-
rocating compressor manufacturer. Shenyang Yuanda re-
portedly had sales of about US$111 million in 2015 with
650 employees.
Shenyang Yuanda, established in 1997, is focused on
the development, manufacturing and service of recipro-
cating compressors. Burckhardt said the acquisition helps
MAY 2016
them gain local market reach in new market segments,
expands its product portfolio to cover market requirements
and gives them direct access to a well-established local
supply chain.
BP
BP and China National Petroleum Corp. (CNPC) have
signed a production sharing contract for shale gas explo-
ration, development and production in the Neijiang-Dazu
block in the Sichuan Basin, China. The contract is BPs first
shale gas production sharing contract in China and covers
an area of approximately 579 sq.mi. (1500 km2). CNPC will
be the operator for this project.
This production-sharing contract is the first achievement
from BP and CNPCs framework agreement on strategic
cooperation that was signed last October during the visit
to the U.K. by Xi Jinping, president of The Peoples Re-
public of China. In addition to unconventional resources,
the framework agreement covers possible future fuel re-
tailing ventures in China, exploration of oil and LNG trad-
ing opportunities globally, and carbon emissions trading
as well as sharing of knowledge around low carbon energy
and management practices.
Wasco Engineering Services Singapore
Wasco Engineering Services Singapore (WESS) has
signed an agreement to serve as LeROI Gas Compressors
authorized packager and distributor.
As a LeROI packager and distributor, WESS will have
product and service offerings that include vapor recovery,
well unloading, fuel gas compression, flare gas capture and
wellhead compression.
WESS network includes the Middle East, South East
Asia and Australia. LeROI controls more than 60% of the
U.S. compression market, the company said.
Enerflex Ltd.
Enerflex Ltd., a supplier of products and services to the
global energy industry, opened its new service facility in
Adelaide, Australia. The facility is the latest addition to
Enerflexs global branch network and the seventh loca-
tion in Australia.
The 21,528 sq.ft. (2000 m2) facility, located at Gilman, will
provide Enerflexs complete product and service offerings
including compression, process and electric power equip-
ment sales, aftermarket service and support, and integrated
asset management for the Southern Australia region.
The facility includes a workshop focused on equipment
overhauls, project optimization, upgrades, retrofits, and
general asset management, as well as a regional training
facility and a parts warehouse.
Correction
The minimum suction pressure for MAN Diesel & Turbo bar-
rel compressors was incorrectly stated in Standardized Refin-
ery Compressor Packages in the March 2016 issue (page
75). The correct minimum pressure is 50 psig (3.5 bara).
46 COMPRESSORtech2
 Now established and manufacturing
in the US German Experts in Sealing
Technology for Reciprocating
Compressors, Rotary Systems and
Renewable Energies

Exclusive Sealings
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We proudly present the
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The gas tight design reduces the loss of

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info@stasskol.com
www.stasskol.com
STASSKOL GmbH STASSKOL Inc.
Maybachstrasse 2 Suite 100,
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Germany Katy, Texas 77449
USA
+49 3925 288100 +1 713 2445050
Inlet Cooling For Gas Turbines
Driving Gas-Gathering
Compressors > Hybrid indirect evaporative chilling
systems help optimize performance
BY GARY HILBERG

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

A
s natural gas usage continues to grow, due to its to gain significant incremental gas flow from its exist-
clean, cost-competitive and efficient nature, the ing facilities was very compelling. Pemex worked with
demand for larger capacity compressors has in- Everest Sciences of Tulsa, Oklahoma to evaluate the
creased. Many operators use gas turbines to drive their potential benefits of providing inlet chilling the exist-
compressors due to their power density, ease of opera- ing Solar Taurus 60 gas turbines at its Pardon facility.
tions and low emissions. continued on page 50
One challenge with modern gas
turbines is that they lose signifi-
cant output and efficiency as air Chilled Turbine Chilled
Output (HP)Turbine Output (HP)
temperatures rise, forcing users
to accept lower capacity or add Titan 130 19802S
incremental equipment to com-
pensate for this loss. Figure 1 Mars 100 15000S

shows the performance of sev- Mars 90 T1300

eral leading gas turbines used to
drive compressors. Taurus 70 10300
For one integrated oil and gas
Taurus 60 7800S
firm, Petrleos Mexicanos S.A.
de C.V. (Pemex), the opportunity Centaur T6200

0 5000 10,000 15,000 20,000 25,000

Gary Hilberg is president of Everest
Sciences. Contact him at: ghilberg@ Chilled 47F (8.3C) Ambient 100F (37.8C)
everestsciences.com.

MAY 2016 48 COMPRESSORtech2

 t o g e t y o u r c o m pre s s o r
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the parts it manufactures are OEM parts, however to the best of its knowledge, OEM specifications are adhered to on all of
the parts manufactured.
 n Inlet cooling optimizes gas turbine performance by cooling the
gas turbine inlet air and providing more mass flow for combus-
tion and increasing the efficiency of the gas turbine compressor.

Unit 5 Performance & Reliability Test January 2016

Unit 5 Performance & Reliability Test Jan 2016
130 400

120 360

110 320

100 280
Temperature / F

90 240

Power / kW
80 200

70 160

60 120

50 80

40 40

30 0
0

0
0

:0

:0

:0

:0

:0

:0

:0

:0

:0

:0
:0

:0

:0

:0

:0

00

06

12

18

00

06

12

18

00
12

18

00

06

12

18

27

28

28

28

28

29

29

29

29

30
26

26

27

27

27

Date & Time

TI-01 XI-02 TI-05 TI-06 Plant Power
Ambient Air Relative Humidity Air Leaving ESID Final Leaving
(primary air) T1 Air Temperature T2

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MAY 2016
Modulift_JanFeb16_CT.indd 1 50 COMPRESSORtech
1/13/16 5:23 PM
2
 ability to gain 15 to 25% incremental
power continuously over a 12-month
period is a key advantage of modular
inlet chilling solutions. Future projects
with Pemex are expected to complete
quickly now that all parties are famil-
iar with the technology.
A key benefit of hybrid indirect
evaporative chilling is the automated
and reliable operations of the chilling
solution, providing a consistent inlet
temperature and system gas flow
even as the ambient temperature
varies, as shown in Figure 2. Gas
flow is a key metric for all gas trans-
portation companies. For the Pemex
Pardon plant, this reduction in inlet
temperature increased the per unit
gas flow from 30.0 MMcfd (8.5 x 105
m3/d) to 33.4 MMcfd (946 m3/d) in
the coldest month of the year; in the
summer it is expected that the per-
unit gas flow will increase by an ad-
ditional 10%. CT2

Gas
Compressor
This evaluation showed a significant Synthetic
value proposition, and Pemex is-
sued an international request for Lubricants
proposals in 2014. Everest and its
local partner Equipos Industriales del
Golfo (EIGSA) received the contract Synthetic Lubricants
to supply three hybrid indirect evap-
orative chilling systems to Pemex in Save Money and
November of 2014, with operations Protect Equipment
starting in early 2015.
The hybrid indirect evaporative chill-
ing systems tsolution is highly efficient Come See Us at the
due to its use of indirect evaporative EGCR Show
cooling operating in series with me- Booth #523
chanical chilling. For most applications,
this solution provides the efficiency of
Summit synthetic gas compressor lubricants are formulated and
evaporative cooling without using in-
cremental water, while still providing field tested to eliminate many of your serious gas compressor
the consistent inlet air temperature of problems. Each gas compressor application has its own unique
mechanical chilling.
set of operating parameters and issues. Summit offers a variety
Inlet cooling optimizes gas turbine
performance by cooling the gas tur- of synthetic lubricant base stocks to solve these issues. Summit
bine inlet air and providing more mass Synthetic gas compressor lubricants will increase productivity with
flow for combustion and increasing
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the efficiency of the gas turbine com-
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ing equipment optimizes the overall
facility, leveraging the existing staff, Free technical support. Call us we can help!
and reduces the overall operating
cost on a US$/hp-hour basis.
For the Pemex Pardon project, the
modular equipment was factory pack-
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Summit
Quality Service Expertise
the site for installation by EIGSA. The
two hybrid indirect evaporative chilling 800.749.5823
systems were installed in late 2015 www.klsummit.com www.sublimedescaler.com 903.534.8021
and commissioned in early 2016. The
MAY 2016 51 COMPRESSORtech2
 2
3 Scheduled Downtime MARK THAYER, PUZZLEMASTER

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

7 5
6
I Before E, Except
Atheism Leisure
D T V D Z C O U N T E R F E I T S I E H
Beige Neighborly
D R H E C N A L L I E V R U S S H E I K
Being Neither
Y P E G I P S T E I N I B C F E I S T Y Blueish Onomatopoeia
E A S I I N R B E I N G E N I E F F A C Caffeine Poltergeist
I C Y O D E S O E F O R F E I T E D B P Codeine Preignition
N L A D V L H T T S W M B E N I E D O C Counterfeit Proteins
Deigned Reign
G P T E U E S N E E Z I N O I E D L R H
Deionize Reinforce
W R H D R N R I E D I D E I T Y T E R L
Deity Rottweiler
N E E A I E Z E E I S N U O L E E R F Y Dreidl Seismic
T I I E I U N N I E T F S R R Y P U O R Dyeing Seizures
S G S G R E G I I G M H O G T G O S R E Eighty Sheik
E N M E H I O S E Z N B E H H F C I E L Einstein Sleigh
Either Sovereign
D I S E E T M P E W H I E R S F S E I I
Feisty Stein
R T U D I I L I O G S I V E I R O L G E
Foreigner Surveillance
I I Y N C G T E I T R N I R E E D S N W Forfeited Their
E O B E V G H E S L A T G E U I I L E T Freight Unveil
W N Y G E E N T O S H M L I L G E E R T Heifer Veins
R E F I E H I O Y E T T O G B H L I D O Height Weightless
F P S E D P M L R A T I M N Y T A G B R Heirloom Weiner
Heist Weirdest
P T Z B E C R O F N I E R E O M K H M T
Kaleidoscope Zeitgeist
 U.S. Energy Corp 1k x 1" 3/11/03 11:06 AM Page 1

Marketplace
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UNITED STATES ENERGY CORPORATION
1600 MISSILE WAY, ANAHEIM, CA 92801
(714) 871-8185 (714) 871-9229 FAX
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MAY 2016 53
Advertisers Index
*Further information on this companys products can be found in the 2015 Edition of the Diesel & Gas Turbine Sourcing Guide
(at www.Dieselandgasturbineguide.net) and/or 2016 Compression Technology Sourcing Supplement (at CTSSnet.net).

ACI Services Inc. ...................................................................41 * KB Delta Compressor Valve Parts, Mfg. ...................28-29, 49

ADIPEC 2016 ..........................................................................53 Modulift ...................................................................................50

Air-Cooled Heat Exchangers ................................................36
MOTORTECH GmbH ..............................................................18
Altronic, LLC .....................................................................10-11
Murphy by Enovation Controls ................... 15, Fourth Cover
* ARIEL CORPORATION ............................................................1

Armco Compressor Products Corp. ....................Third Cover Neuman & Esser Group ..........................................................3

BG Service Co., Inc., The ......................................................43 PROGNOST Systems GmbH ................................................25

* Burckhardt Compression AG .................................................9 Shinkawa Electric Co., Ltd. ...................................................40

Compressor Products International ......................................5
Sloan Lubrication Systems ..................................................20
Cook Compression ................................................................13
STASSKOL GmbH .................................................................47
* Cozzani, Dott.Ing. Mario Cozzani S.r.l. ...................................7

DCL International Inc. ...........................................................26 Sullair ......................................................................................39

* Dresser-Rand .........................................................................35 Summit Industrial Products ..................................................51

E Instruments International ..................................................46 Sumy NPO PJSC ................................................................33

Eastern Gas Compression Roundtable ...............................44
SYNTHOSOL ..........................................................................27
* Elliott Group .......................................................Second Cover
* Testo, Inc. ...............................................................................32
Exline, Inc. ..............................................................................19

Girtz ........................................................................................21 Tulco Oils ...............................................................................31

HOERBIGER ...........................................................................37 Zahroof Valves Inc. ................................................................17

Cornerstones Of Compression story continued from page 56

Rotor Diameter Max. Discharge Pressure Full Load Capacity Range

Series in. mm psig bar cfm m3/min

PDX10 4.01 102.0 200 13.8 72 to 176 2.0 to 4.0

PDX12 5.02 127.5 200 13.8 163 to 295 4.6 to 8.4

PDH12 5.02 127.5 400 or 500 27.5 or 34.5 108 to 385 3.1 to 10.9

PDX16 6.43 163.2 200 13.8 258 to 555 7.3 to 15.7

PCC16 6.43 163.2 400 27.5 223 6.3

PDX20 8.03 204.0 200 13.8 423 to 996 12.0 to 28.2

PDR20 8.03 204.0 200 13.8 547 to 1289 15.5 to 36.5

PCC20 8.03 204.0 400 27.5 298 to 441 8.4 to 12.5

PDR25 10.04 255.0 200 13.8 554 to 1674 15.7 to 47.4

PCC25 10.04 255.0 400 27.5 583 to 857 16.5 to 24.3

PDX32 12.65 321.3 200 13.8 962 to 2329 27.2 to 66.0

PDR32 12.65 321.3 200 13.8 1732 to 3292 49.0 to 92.2

PCC40 16.06 408.0 300 20.7 3527 100.0

n In addition to being a leader in portable and industrial air compression markets, Sullair provides the widest range of rotary screw
compressors available for natural gas applications.

in 1966. The new Sullivan Machinery Co. was the first in the
U.S. market to completely rely on rotary screw compressor
technology. By 1968, after Sullivan had established itself in
markets that use portable compressors, the company intro-
duced stationary rotary screw compressors to the industrial
air market. Later that year it changed its name to Sullair,
which became a public corporation in 1972.
Responding to market demand for clean and dry air in
specialized applications, Sullair developed air treatment
systems for its compressors and, in response to customer
needs, developed a line of proprietary compressor fluids
and related products that enabled it to become a dominant
supplier in the air compression market. Over the next two
decades, rotary screw compressors would almost com-
pletely displace reciprocating compressors in portable and
industrial air compression applications.
In the early 1970s, the Sullair C series was developed
for refrigeration applications, being offered in a complete
turnkey package. This made Sullair one of the very few
companies with full lines of screw compressors optimized
for both air and refrigeration applications.
In 1971, Sullair screw compressors were first adapted for
natural gas compression, making it one of the first manufac-
turers to enter this new market. Over the ensuing decades,
Sullair gas compressors have been commonly applied for
vapor recovery, gas gathering, landfill gas recovery, coal
bed methane, wellhead compression, sweet and sour pro-
cess gas and fuel gas boosting.
Sullair OEM gas compressor models, commonly called
gas ends, are the PDR, PDX and C series. Together, they
represent the broadest range of natural gas screw compres-
sor types and options of any manufacturer in the market, with
MAY 2016
thousands in operation and with some units running for well
over 20 years.
The PD series offers a range of geared and direct drive
options to deliver flows up to 3292 cfm (93.2 m3/min) and
pressures up to 600 psi (41.4 bar) as well as spiral and slide
valve options for capacity control. The PC series are direct
drive units capable of flows up to 3527 cfm (99.9 m3/min)
and pressures up to 400 psi (27.6 bar), featuring an econo-
mizer port and slide valves for capacity control.
An oil-free dry screw compressor line was introduced in
1979, and a full line of pneumatic air tools was introduced in
1985 to complement the companys portable air compressor
line. Sullair has remained a pioneer of air compressor technol-
ogy, delivering the first 500 psig (34.5 bar) two-stage portable
compressor in 2003, as well as encapsulated compressors
and vacuum systems. Today, the Sullair line of portable com-
pressors ranges from 185 to 1600 cfm (5.2 to 45.3 m3/min)
with output pressures from 100 to 500 psi (6.7 to 34.5 bar),
being designed for years of use in extreme field conditions. Its
line of single-stage air compressors ranges from 5 to 450 hp
(3.7 to 335 kW) and two-stage compressors range from 100
to 600 hp (75 to 447 kW).
Operating behind the scenes in many cases, Sullair com-
pressors are used in thousands of common applications as
well as many unique applications that most wouldnt expect
like fountains in Las Vegas and parades in New York City.
In 1984, Sullair was purchased by Sundstrand Corp.,
which became part of the United Technologies Hamilton
Sundstrand business unit in 1999. In 2012, it became part
of Accudyne Industries Inc. In 2015, Sullair celebrated its
50th anniversary, noting that it has manufactured well over
300,000 rotary screw compressors since its beginning. CT2
55 COMPRESSORtech2
 C ornerstones Of Compression

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

Sullair Rotary Screw

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

I
n 1965, Donald C. Hoodes departed Joy Manufacturing
Co., a Pittsburgh-based manufacturer of mining and
reciprocating compressor equipment. In Michigan City,
Indiana, he founded a privately held company, taking the
name of Sullivan Machinery Co. As president, Hoodes
brought with him Roger Gustafson, Borje Vagenius and
C.J. Joseph as vice presidents. Their shared interest was
the relatively new rotary screw compressor technology that
was emerging for air compressor applications. That same
year, the new company acquired a license from Svenska
Rotor Maskiner AB (SRM) of Sweden to market rotary
screw compressor technology.
Starting with Ingersoll Rand in 1958, Joy in 1960 and
Gardner Denver in 1963, interest in screw compressor
technology was rapidly growing in the U.S. Interestingly, of
those three well-established air compressor companies, Joy
ultimately elected to stick with reciprocating and later cen-
trifugal compressor technology for its air compressors, which
opened the door for Hoodes new enterprise.
The Sullivan Machinery Co. name was previously con-
nected with Joy. In fact, Sullivan Machinery dates back
to 1868 when the New England company was formed to
MAY 2016
manufacture a newly invented diamond-channeling machine
for quarrying stone, especially marble. In 1901 it purchased
another company in Chicago that expanded its products
and services in prospecting, mining, oil field exploration and
industrial construction. In 1923, Sullivans rapidly expanding
business completed a new factory in Michigan City.
Through the years, many innovations in machinery for
the basic industries were attributable to the dedication of
Sullivan engineers. Early in the 1900s, Sullivan rock drills
and channeling machines dug 185 ft. (56.4 m) deep wheel
pits at Niagara Falls, New York, excavated 15 mi. (24 km) of
rock for the Chicago Drainage Canal and countless Sullivan
rock drills helped carve out the Panama Canal. In 1928,
Sullivan reciprocating compressors supplied high-pressure
air for rock drills penetrating the backbone of the Cascades
for the Great Northern Railway tunnel. And during World
War II, Sullivan Machinery Co. was cited for its contribu-
tion in war production equipment and services. In 1946, Joy
Manufacturing acquired Sullivan.
Hoodes and his team moved quickly to produce its first
150 cfm (4.25 m3/min) portable rotary screw air compressor
continued on page 55
56 COMPRESSORtech2