SIEMENS GOES DIGITAL NEW SEALING ELEMENTS SAY HELLO TO NEA X

DUISBURG SITE BURCKHARDT TESTS NEW BUSINESS UNIT

MAY 2018
A KHL Group publication
WWW.COMPRESSORTECH2.COM/SUBSCRIBE

ALSO IN THIS ISSUE:

GCA EXPO ROUNDUP

ENERPROJECT UNITS FOR

NEUTRON ACCELERATOR

THE B&S ENTREPRENEURIAL

ADVENTURE
IS WHO WE ARE
Ariel’s meticulous quality
assurance workforce is what
makes us the number one
authority in natural
gas compression.
MAY 2018

SIEMENS GOES DIGITAL NEW SEALING ELEMENTS SAY HELLO TO NEA X

DUISBURG SITE BURCKHARDT TESTS NEW BUSINESS UNIT

MAY 2018
A KHL Group publication

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

Product Focus
15 Ariel Releases KBK:T
Compressor Frames
39 Condition Monitoring
WWW.COMPRESSORTECH2.COM/SUBSCRIBE

Consultants
ALSO IN THIS ISSUE:

Site Reports
GCA EXPO ROUNDUP

ENERPROJECT UNITS FOR

21
NEUTRON ACCELERATOR

THE B&S ENTREPRENEURIAL

ADVENTURE
37 Enerproject Stays In The Loop
44 Cold Calculation
CT2 05-2018 Front Cover jb JG.indd 1 20/04/2018 16:28:12

Conference Review
COMPRESSORtech2 (ISSN 1085-2468) Volume
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6 Don’t Be Shy To Tell Your Story 39
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Meddling In U.S. Energy Policy
Follow @COMPRESSORtech2 on: 11 Gas Lines
12 Events & Meetings
27 Prime Movers
35 Media
55 Scheduled Downtime
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29
 EDITORIAL
PUBLICATION STAFF
comment FROM THE EDITOR
Publisher:
Associate Publisher ................... Mark Thayer
Michael J. Brezonick

Don’t Be Shy
Senior Editor ................................... DJ Slater
mike.brezonick@khl.com
Senior Editor ................. Michael J. Brezonick
Tel: +1 262-754-4112
Associate Editor ........................... Klinton Silvey
Cell: +1 262-366-9452

To Tell Your Story

Associate Editor ............................... Jack Burke
Senior Editor:
Associate Editor ............................Chad Elmore
DJ Slater
Copy Editor ............................... Jerry Karpowicz
dj.slater@khl.com
Digital Publishing Manager ........... Paul Damon
Senior Editor:
Advertising Manager .................. Katie Bivens
Jack Burke
BY DJ SLATER

I
Circulation Manager ...................... Sue Smith
jack.burke@khl.com
Graphic Artist ...........................Brenda Burbach ’ve always been fascinated by the stark differences between being a
PRODUCTION
Graphic Artist .................................Carla Lemke
Production & Circulation Director: newspaper reporter and the editor of COMPRESSORtech2. The former is a
Graphic Artist ............................... Alyssa Loope
Saara Rootes position I held for four years in a small northern Wisconsin city called Wausau.
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saara.rootes@khl.com During my tenure in Wausau, there was never a shortage of phone calls, e-mails
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Production Manager - KHL Americas: were quick to return the inquiry. They understood the importance of getting their
CONTRIBUTING EDITORS
Brenda Burbach
Norm Shade – Cambridge, Ohio message in front of as many eyeballs as possible.
brenda.burbach@khl.com
Mauro Belo Schneider – Rio Grande do Sul, Brazil
Design Manager: Yet after years of working at COMPRESSORtech2, it’s still startling to see how
Patrick Crow – Austin, Texas
Jeff Gilbert that’s sometimes not understood.
HOUSTON, USA There are companies that “get it”. They call or send an e-mail with their news
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readers learn about something new that may help them do their jobs better and
helen.knight@khl.com
GERMANY we end up with more interesting, newsworthy content.
Office Manager: Advertising Manager
Lisa Hochkofler, Yet some companies don’t seem to understand this process. They don’t return
May HydeTel: +49 711 5062 4982 the phone call or e-mail, even when it’s in response to news they issued. Some
may.hyde@khl.com
Gabriele Dinsel, Advertising Manager
worry that talking about a new product will give some advantage to a competitor.
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DE6 1LH, United Kingdom as a new hire to as large as a new compression product that will change the world.
Gabriele Dinsel All of it has merit, but we can’t publish what we don’t know.
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Tel: +44 20 31 79 29 79
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even though you didn’t exhibit at the trade show to
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through of that new product on the show floor.
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& CHIEF Manager
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CNGS
Compressed Natural Gas Solution
A new concept combining gas and oil sealing
High reduction of gas and oil leakage for your compressor

STASSFURT HOUSTON
GERMANY USA
www.stasskol.de SEALING EXPERTS SINCE 1920
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Houston, Texas 77047
Tel: 1-832-710-4700
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of storage space.
www.mhicompressor.com/en
Monitoring Government
Report Exposes Russia’s
Meddling in U.S. Energy Policy
The Reds subtly helped the Greens oppose pipelines
BY PATRICK CROW
f you suspect that Russia nefariously worked to
I influence the U.S. elections in 2016, you will have
little difficulty believing further disclosures in a recent
congressional report.
The staff of the Science, Space and Technology
Committee in the U.S. House of Representatives has alleged
Russia has fanned the flames of controversy regarding some
American pipeline projects and compressor stations.
“This report reveals that Russian agents created and
spread propaganda on U.S. social media platforms in an
obvious attempt to influence the U.S. energy market,” said
committee chairman Rep. Lamar Smith (R-Texas).
“Russia benefits from stirring up controversy about
U.S. energy production,” he said. “U.S. energy exports to
European countries are increasing, which means they will
have less reason to rely upon Russia for their energy needs.
This, in turn, will reduce Russia’s influence on Europe to
Russia’s detriment and Europe’s benefit.
“That’s why Russian agents attempted to manipulate
Americans’ opinions about pipelines, fossil fuels, fracking
and climate change. The American people deserve to know
if what they see on social media is the creation of a foreign
power seeking to undermine our domestic energy policy,”
Smith said.
The report claimed that from 2015-17, Russian sources
initiated 9097 posts or tweets on Twitter, Facebook and
Instagram regarding U.S. energy policy or a current energy
event. During that period, the Internet Research Agency
(IRA) had an estimated 4334 accounts on the social media
triad. St. Petersburg-based IRA has been described as a “troll
farm” that the Kremlin established to propagate propaganda
for social and traditional media outlets. The U.S. Justice
Department has charged IRA, two other companies and 13
Russian nationals with fraud regarding their activities during
the 2016 presidential campaign.
The committee report said Twitter’s data shows that
Patrick Crow is an Austin, Texas, writer and a former COMPRESSORtech2
editor. He has reported for oil and gas publications since 1967 and has
written extensively about energy issues before Congress, federal agencies
and the courts.
COMPRESSORtech2
more than 4% of all IRA’s tweets were related to energy
or environmental issues, “a significant portion of content
when compared to the 8% of IRA tweets that were related
to the election in the U.S.” IRA targeted pipelines, hydraulic
fracturing, fossil fuels, climate change, oil company profits
and other energy issues. Many of the cyber subterfuges
encouraged Americans to protest or petition against oil
and gas pipeline construction projects, including Dakota
Access Pipeline, Keystone XL, Bayou Bridge and Enbridge
Line 5.
Other U.S. agencies have reported similar transgressions.
In January 2017, the Office of the Director of National
Intelligence released a report accusing Russia of trying to
influence the U.S. election. That investigation found “clear
evidence that the Kremlin is financing and choreographing
anti-fracking propaganda in the U.S.” It said the Kremlin-
sponsored RT (formerly Russia Today) news agency was
behind the mischief.
“It is likely reflective of the Russian government’s concern
about the impact of fracking and the U.S. natural gas
production on the global energy market and the potential
challenges” to Russian energy companies, the office said.
Last March, the U.S. Department of Homeland Security
accused Russia of cyber attacks against nuclear power plants
and water and electric systems in 2015. And U.S. Sen. Ben
Cardin (D-Md.) also issued a study on Russian energy
intrigues. The senator serves on the U.S. Commission on
Security and Cooperation in Europe.
Cardin’s brief claimed that Russia funneled US$95
million to environmental groups that sought to persuade
European governments to ban shale gas exploration or
hydraulic fracturing. The report said some green groups had
become “useful idiots” in the Kremlin’s campaign to keep the
Continent dependent on Russian gas supplies.
The House committee report concluded, “Regardless of
one’s political or ideological views surrounding U.S. energy
policy and climate change, the American people deserve to
be free from foreign political interference.”
Then it should follow that U.S. pipelines deserve
assurances that discourse regarding their projects hasn’t
been tainted by foreign interference. CT2
MAY 2018 9
What Makes a Refinery Refined?
Reliability and efficiency are everything.

10,000+
100,000+
MAN turbomachines are installed
worldwide. That’s more than 50 in
every country in the world

continuous working hours of flawless

operation: oil-free screw compressors

250+
from MAN Diesel & Turbo

years of engineering experience

makes innovation a MAN tradition

Compressors Steam Turbines Expanders Machinery Trains Gas Turbines Reactor & Apparatus After Sales

The more the global economy develops, the greater the need for efficiency in supplying the energy sources the world
relies on. With their legendary reliability, MAN Diesel & Turbo machinery and components are used throughout the
refinery and petrochemical industries. Applications range from hydrogen production and recovery to desulfurization,
fluid catalytic cracking (FCC), PTA, fertilizer and IGCC. Engineered to the most exacting standards, our axial, screw
and centrifugal compressors, steam turbines and reactors are built to ensure maximum availability in even the
toughest environments. Find out more at www.mandieselturbo.com
Gas Lines
Baker Hughes Rig Count
Michigan Leads In Underground
1200
Natural Gas Storage Capacity 1000
lthough it’s not a major player in production, Michigan

A has the highest amount of natural gas storage design

capacity in the country. But storage is important for
Michigan because the state relies heavily on natural gas for
800

600

400

winter heating needs and has several major pipelines that 200
connect to Canada and other Midwestern states, including 0
nearby population centers such as Chicago. Depleted production Jan-16 Jan-17 Jan-18
fields have also been converted into storage fields. Series2 Series1
The EIA has found that relatively little new underground natural Source: Baker Hughes

gas storage capacity was built in the Lower 48 states in the past
four years, however. EIA measures natural gas storage capacity
Henry Hub Natural Gas
in two ways: design capacity and demonstrated maximum
Spot Price (US$/MMBtu)
working gas volume (or demonstrated peak). In 2017, design
capacity grew by about 1%, and demonstrated peak fell by 1%. $5.00
Most of the incremental capacity in 2017 came from expansions
to existing facilities, and expansions were heavily concentrated in $4.00

the East region, where natural gas production has grown almost
$3.00
continually since 2009. Several facilities in Ohio and West Virginia
likely expanded in 2017 to accommodate increasing levels of $2.00
natural gas production in the Appalachian Basin. CT2
$1.00
Mar-16 Mar-17 Mar-18
Source: EIA

Brent Crude Oil Price

(US$/Barrel)

$75.00

$65.00

$55.00

$45.00

$35.00
Mar-16 Mar-17 Mar-18
Source: EIA

US Natural Gas Storage (Bcf)

5000

4000

3000

2000

1000

0
January December
2018 Five-Year High Five-Year Low
Source: EIA

Source: U.S. Energy Information Administration (EIA)

COMPRESSORtech2 MAY 2018 11

Events & Meetings
Boldface indicates shows and conferences in which COMPRESSORtech2 is participating

APRIL Oslo, Norway swenergyinstitute.org

April 29–May 3 asme.org/events/turbo-expo
Sour Oil & Gas Advanced Technology June 25–29
(SOGAT 2018) June 11–15 World Gas Conference
Abu Dhabi, UAE ACHEMA Washington D.C.
+971 2 697 9000 Frankfurt, Germany +44 20 7978 0019
sogat.org + 49 69 7564-750 wgc2018.com
achema.de
April 30–May 3 June 26–28
Offshore Technology Conference June 12–14 Sensor + Test
(OTC) Global Petroleum Nürnberg, Germany
Houston, Texas Calgary, Canada +49 (0) 5033 9639-0
+1 (972) 952-9494 +1 (888) 799-2545 sensor-test.de
2018.otcnet.org globalpetroleumshow.com
June 26-28
MAY June 19–21 Sensors Expo & Conference
May 22–24 Electrify Europe San Jose, California
Eastern Gas Compression Vienna, Austria +1 (617) 219-8300
Roundtable +1 (888) 299-8016 sensorsexpo.com
Pittsburgh, Pennsylvania electrify-europe.com
+1 (412) 372-4301 JULY
egcr.org June 19-21 July 30-Aug. 1
Southwest Energy Institute SGA Operating Conference
JUNE Short Course Industry Training Tampa, Florida
June 11–15 Liberal, Kansas +1 (972) 620-8505
ASME Turbo Expo +1 (620) 417-1170 southerngas.org

12 MAY 2018 COMPRESSORtech2

The future of control is in your hands!
DE-3000/3000+ and the TE-1000 Integrated Telematics Module for Gas Compressor Package Automation
Combining Altronic’s vast experience in control system development GSPNWJSUVBMMZBOZXIFSFJOUIFXPSME5IJTJODMVEFTGVMM
and production, with Enbase Technology’s advanced telematics and TZTUFNDPO¼HVSBUJPO TFUQPJOUBEKVTUNFOU BOESFNPUF
software engineering, produced a breakthrough automation platform monitoring via sophisticated telematics and predictive
that integrates local and remote engine and compressor control, BOBMZUJDT
NPCJMF¼FMEPQFSBUJPOT BOEDPOUSPMSPPNBOBMZUJDT)PX
The value of this new approach to gas compressor
Together, Altronic’s DE-3000/3000+ System plus the add-on/plug-in monitoring and control—one that combines a stable and
TE-1000 Telematics Module comprise an innovative gas compressor proven local control with a robust, seamless communi-
package platform that provides local, area, and simultaneous long- DBUJPOTZTUFN¯JTMJNJUMFTT
EJTUBODFNPOJUPSJOHBOEDPOUSPMBDDFTTUPUIFTLJE
Please contact the integration team at Altronic
5IF%&QMBUGPSNJTLOPXOGPSJUTRVBMJUZBOETUBCJMJUZ5IF or your local Altronic Distributor for further
seamless integration of the TE-1000 Telematics Module extends that information on how the DE-TE package can
wireless functionality and control via its on-board Wi-Fi server to any deliver a whole new level of value to you and to
FOBCMFE1$ UBCMFU PSTNBSUQIPOF"DFMMVMBSPSTBUFMMJUFNPEFNDPO- ZPVSHBTDPNQSFTTPSPQFSBUJPOT
nection offers the same access and control of the DE-3000 system

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

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

SEPTEMBER Sept. 18–20 Colorado Springs, Colorado

Sept. 11-13 Gas Compressor Short Course +1 (703) 276-0110
Southwest Energy Institute University of Oklahoma globalsyngas.org
Short Course Industry Training +1 (405) 325-0673
Liberal, Kansas pacs.ou.edu/gas-compressor NOVEMBER
+1 (620) 417-1170 Nov. 12–15
swenergyinstitute.org Sept. 18–20 ADIPEC
Power-Gen Asia Abu Dhabi, U.A.E.
Sept. 12–14 Jakarta, Indonesia +971 2 444 4909
+1 (918) 831-9160 adipec.com
EFRC
asiapowerweek.com
Madrid, Spain
recip.org Nov. 14–16
Sept. 30–Oct. 3
20th Korea Rotating Machinery
Gas Machinery Conference
Sept. 17–20 Symposium
Kansas City, Missouri
Gastech Exhibition & Conference Seoul, South Korea
+1 (972) 620-4026
Barcelona, +82-2-579-6271
gmrc.org
Spain krmea.or.kr/engmain/main.php
+44 (0) 203 615 5914 OCTOBER +1 (918) 831-9160
gastechevent.com Oct. 23-24 asiapowerweek.com
Black Sea Oil & Gas
Sept. 18-20 Bucharest, Romania DECEMBER
Turbomachinery and Pump +44 845 868 8234 Dec. 4-6
Symposium globuc.com/blackseaoilgas Power-Gen International
Houston, Texas Orlando, Florida
+1 (979) 845-7417 Oct. 28–30 +1-888-299-8016
tps.tamu.edu Syngas Technologies Conference power-gen.com

COMPRESSORtech2 MAY 2018 13

GE Power

Working Smarter, Not Harder

Join the growing list of operators choosing GE’s Waukesha*
VHP* Series Five Engines
Featuring:
• More power and lower cylinder head temperatures Same Hardware. Two Models. Two Ratings
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• Full power to 120° F Power 1,500 hp 1,900 hp
• Most fuel efficient VHP ever Fuel Derate 35 WKI (~2,350 Btu/ft )3
55 WKI (~1,350 Btu/ft3)
• 4,000-hour oil change and spark plug intervals with 4,800 ft @ 100° F 5,000 ft @ 100° F
Altitude Capability
ESM*2 controls 4,000 ft @ 120° F 4,200 ft @ 120° F
BSFC (Btu/bhp-hr) 7209 7063
• Upgrade kits available to bring Series Five performance
Fuel consumption presented in accordance with ISO 3046/1 with a
and benefits to installed engines tolerance of -0/+5% at maximum rating.
*Indicates a trademark of the General Electric Company

To learn more about the VHP Series Five visit: gepower.com/S5


■ The KBK:T frames feature
5 and 6 in (127 to 152.4 mm) strokes
and power ranges from 1840 to 5520 bhp (1327 to 5520 kW).
They are available in two, four and six throw variations.
Ariel Releases KBK:T Compressor Frames
New product features higher horsepower, rod loads
BY DJ SLATER
riel Corp. has expanded its
A family of compressors by
adding two new frames: the
KBK and KBT (KBK:T). The company
debuted the new frames in March
at the Gas Compressor Association
(GCA) Expo & Conference in
Galveston, Texas.
The KBK:T frames are the latest
compressor from the company in
nearly five years. In 2013, Ariel
released the JGF, a variation of
its JGC compressor with a 5 in.
(127 mm) stroke, 1400 rpm and
57,000 pound rod load rating,
according to the company. Prior to
that, Ariel brought its KBZ and KBU
compressor frames to the market
in 2010.
The KBK:T brings Ariel’s KB design
features to the company’s midline
compressors, which are considered
the “heart” of the company’s
lineup, said Joe Fernandez, Ariel’s
manager of application engineering.
Specification wise, the new frames fall
between Ariel’s existing JKG:T and
COMPRESSORtech2
JGC:D compressors in terms of gas
rod load ratings.
New Features
Available in two, four and six throws,
the KBK:T frames incorporate a variety
of new features to meet the needs of
the gas compression industry, Ariel
said. The frames primary application
is gas gathering and rental fleets. With
its size and power ratings, the KBK:T
frames provide more punch and
longer strokes for operators who need
the footprint of a JGK:T compressor.
“Our JGK:T frames have been a
mainstay in the industry for a long
time,” Fernandez said, adding that
Ariel has started seeing manufacturers
uprating their natural gas engines.
Customers also expressed their
desire to capitalize on these higher
power ratings in their JGK:T-sized
compressor packages. “There was
a need for more capabilities and
flexibility from those frames.
“The JGK and JGT are the gold
standard,” he said. “We enhanced
Product Focus
these frames without giving up their
reliability.”
The KBK frame features a 6 in.
(152.4 mm) stroke, a power range
from 1840 to 5520 bhp (1372 to 4116
kW), a 1200 fpm (6.10 m/s) piston
speed at its 1200 rpm rating. It is
suited for natural gas engines and
1200 rpm motors, according to Ariel.
The KBT frame has the same
power ratings as the KBK, as well as
a 5 in. (127 mm) stroke, 1250 fpm
(6.35 m/s) piston speed and 1500 rpm
rating. These specifications make it
ideal for 1400 rpm engines and 1500
rpm motors, which are typically found
outside of the United States, the
company said.
The KBK:T frames also feature
a 92,000 lbs (409,236 N) total rod
load; 46,000 lbs (204,618 N) tension
rod load; and 50,000 lbs (222,411 N)
compression road load.
To realize the increases in rod
load and power ratings of the KBK:T
frames, Ariel’s design engineers
thoroughly analyzed and redesigned
continued on page 16
MAY 2018 15
Product Focus
major components. In
2013, Ariel began extensive
fatigue testing of the critical
components that would be
used on the KBK:T frames,
Fernandez said. Five years
later, those components
feature a design that
enhances their stiffness and
strength.
The crosshead guides
have an angled design
and through-bolt support
fasteners that mirror the
same feature of the KB series of
compressor frames. The angled
design provides greater stiffness
and improved stability under higher
rod loads, the company said. The
piston, piston rods, crossheads and
connecting rods have also been
redesigned for increased strength.
([SHULHQFH5HOLDELOLW\,QWHJULW\
The AXH manufacturing complex consists of
six plants, totaling 559,100 SF on 67 acres.
‘Easy To Work On’
The KBK:T frames also use a new
cylinder line that incorporates KTCD
cylinder bodies with non-collared 2
in. (51 mm) diameter piston rods.
The cylinders also use an uncut ring
technology (BTUU style packing rings)
and CP valves.
■ The KBK:T specifications
Ariel also added a design
feature into the KBK:T frames
that answers the call of its
customers. The company
simplified the auxiliary end
piping by integrating the
frame oil thermostat into
the oil filter header. It also
adjusted the placement of
the pipes to provide improved
access for maintenance.
“We’ve always taken the
approach of making the equipment
solid and easy to work on for the guys
in the field,” Fernandez said. “A lot
of that thinking has gone into what
we’ve done with the new frames.
We listened to our customers, added
more value with the new frames and,
in turn, made their lives easier.”
Another design feature is the
backwards compatibility of select
components within the KBK:T
frames. Its crossheads, connecting
rods and bearings can be used on
the JGK:T frames, Fernandez said,
which is useful for fleets that already
have the JGK:T frames in their lineup
and want to add the new frames to
the mix.
“We made sure these parts
were backwards compatible so our
customers wouldn’t have to stock two
different parts for their frames,” he
said. “They will fit in the old and new
frames.”
The new frames can also
accommodate an optional internal
torsional vibration damper or auxiliary
end flywheel. ELP and dual chain
drives come standard.
So far, the response to Ariel’s latest
frames has been positive, with the
company already receiving a handful
of orders, Fernandez said. Though it’s
early, Fernandez said he anticipates
the KBK:T frames will gain the same
market acceptance as the JGK and
JGT frames.
“As we look at our entire lineup, this
)D[ZZZD[KFRP is the heart of it,” he said. “Where we
go from here? We’ll see.” CT2

16 MAY 2018 COMPRESSORtech2

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Siemens Embraces The Digital Way
Company’s turbocompressor site optimizing supply chain
process with digitialization

BY ROBERTA PRANDI

F
or years, Siemens’ operations
site in Duisburg, Germany,
has been known for its
manufacturing and testing capabilities.
The site develops and produces
turbocompressors and also boasts a
mega test center dedicated to large
compressor trains.
While Siemens will continue to
hone these strengths, the company is
moving on a path that officials say will
thrust the site into the future and help
keep it there. Siemens is digitizing its
internal processes for the benefit of
its associates and customers.
According to Siemens, digitalization
along the entire value chain will
enable the company to develop and
manufacture products more efficiently,
with higher quality and shorter delivery
times. Data are key to delivering
customer-focused solutions.

The Process
The digitalization process in Duis-
burg includes optimizing engineering
with rule-based processes and Art to
Port (the path from design into the
prodution machine); logistics with
full transparency in parts handling
and the use of tracking and tracing
applications; manufacturing with au-
tomatically generated routings and
computer numerical control (CNC)
programs; as well as testing and the
possibility of carrying out remote test-
ing for customers.
Marcus Brücherm, general manager
of Siemens’ Duisburg operation,
said the digitalization activities in
Duisburg, said digitalization has been

n Every compressor at the Duisburg,

Germany plant has its digital twin before
it’s even manufactured.
continued on page 22

COMPRESSORtech2 MAY 2018 21


going on for about two years, but the
process is far from completion.
A 20-person team handles the
digitalization project and is led by
Daniel Wentzel, head of Digitization
& Operations Support. His team is
supported by all Duisburg employees.
The Digi Showroom inside
the plant’s main building is one
example of how the process
works. The room showcases the
whole seamless computer-aided
design and manufacturing (CAD/
CAM) information data flow, starting
with core compressor engineering
and ending with shop floor data
management.
The room serves as a digital get-
together spot for customer visits and
employee meetings. Brücher said the
room acts as the perfect environment
to show specific digitalization
working topics and to get feedback
in a non-operational surrounding.
This approach has changed the
traditional management flow. Initially,
only management submitted ideas
for potential digitalization projects.
Now, employees from across the
supply chain propose their share of
new ideas
The use of the Digi Showroom
has been so successful that the
22 MAY 2018
Siemens’ digital value
chain embraces a
product’s entire life,
starting with research
and development and
moving on to sales with
digital equipment for
calculation and design.
company is discussing the possibility
of organizing ‘shows’ for employees
every six months.
“It is hard to call Digitalization a
project,” Wentzel said. “Digitalization
has so many facets and perspectives
of improvement – automatization,
data integrity and seamless domain
interfaces – that it is not just getting
things done project-wise, but rather
a philosophy and a cultural change
with lots of work streams being
orchestrated by the project team.
“Sure, there is a dedicated team for
Digitalization, but within all the specific
domains people contribute and spread
the word of this idea,” he said.
When asked how much of the
project has been implemented
n Siemens’ first 3D printed impeller for a
single-shaft turbocompressor.
already, Wentzel said, “Many tools and
processes are already in operation,
including: sales configurators with
precise solution calculation
that are re-usable for
downstream engineering
and planning processes;
integrated cost-calculations
and automated resource/
capacity simulation for
core-compressor; CAD/CAM
and integrated product lifecycle
management (PLM); effortless
real-time reporting for fast decision
making; and digital shop-floor
management.”
A Value Chain
Siemens’ digital value chain em-
braces a product’s entire life, start-
ing with research and development
and moving on to sales with digital
equipment for calculation and design,
and to engineering with the use of a
digital twin. The path leads on through
the Siemens Customer Management
(SCM) system and to manufacturing
and logistics, where location beacons
and radio-frequency identification
(RFID) tracking are used.
When a product is manufactured,
the digital value chain moves on to
quality processes and testing, with
the possibility of remote testing with
the customer. The path concludes
with project management and service.
“We want to deliver a service
for remote inspection and test
acceptance,” Wentzel said. “This
has quite a few benefits as the
customer can lower travel expenses
and inspections can be much more
convenient.
“The possibility of visualizing figures
and real-time data from the various
sensors, beside the camera stream,
offers an immersive experience in the
test activities,” he said. “The various
steps in a test procedure can at times
make the planning a bit scrubby, but
with remote testing, these time points
continued on page 24
COMPRESSORtech2
 are moved easily and the customer
can commit on a short notice,
without losing time and resources in
postponed process steps.”
Savings are obtained with the
application of rule-based modeling for
Engineering to Order (ETO), which
finds application not only in single
components, but also in assembly
structures. The result is a fully defined
CAD structure that reduces lead time
and complexity.
One example is the pinion shaft
part, where it was possible to achieve
a significant reduction in lead time
from the part engineering to the
customer’s order.
“A better lead time focuses on

COMPRESSOR LUBRICATION SYSTEMS

WHEN
MACHINES n The Siemens’ Duisburg facility in
STOP, Germany offers tailor-made compressor
packages and services.

PROBLEMS
START. reduction in process time wherever
possible. Early and reliable data
improves negotiations with suppliers,
allowing for earlier pricing commitments.
Let our certified lubrication technicians visit Some days are saved in delivery time,
your location and conduct a survey of all your thanks to improved resource planning,”
Wentzel said. “Even the idea of rough
lubrication systems. It’s a simple, time-saving machining components earlier than
evaluation that will give you peace-of-mind, needed and finishing later with more
and a well-running compressor. reliable data can improve the decision
making in terms of prioritization.
Rotating parts are naturally the
critical path in production, so many
calculations and evaluations have been
Sloan’s Service is the key to done especially in that area.”
flawless compressor operation.
Digital Visualization
Siemens implements some tools
to support various steps between re-
1.800.722.0250 search and development and after-
Sales@SloanLubrication.com
market service, such as augmented
SloanLubrication.com reality. Siemens utilizes a digital vi-
sualization platform called Hololens,
which can be used in the project con-

24 MAY 2018 COMPRESSORtech2

Sloan_WhenMachinesStop_Mar16_CT.indd 1 2/22/16 3:56 PM

ception phase to show results to cus-
tomers, but also on the shop floor to
find smart solutions for the handling
and positioning of complex and heavy
The oil & gas industry
remains a traditional
environment, Brücher
said, and as such,
digitalization efforts
are still in their early
stages.
parts. This improves safety for manu-
facturing personnel because compo-
nents that are difficult to handle – such
as a 40 ton piece set for machining
– can be reproduced in augumented
reality to find the optimal solutions for
handling, positioning and clamping.
Augumented reality is also an
interesting tool for aftersale service,
where personnel can receive efficient
and detailed instructions on the
various intervention steps.
“Augmented reality (AR) is at
its very beginning, but we are
already evaluating medium-term
developments in order to be
prepared,” Wentzel said. “AR can
support training purposes, be a guide
through assembly processes that are
done only twice a year, and can make
operators aware of safety issues in
the surroundings, such as with hot
pipes, high voltage cables, and so
on. It can speed up processes with
suppliers saving on travel costs and it
can realize new service concepts by
being connected with supervisors far
away from the site.”
Siemens has also built up experience
in additive manufacturing, which
is being considered and intensely
tested as part of the digitalization
process for manufacturing and
research and development in the
Duisburg plant. The ultimate target
is to replace part groups or complex
parts with components manufactured
with additive manufacturing, or for
the development work involving more
complex parts. At this point, Siemens
in Duisburg is working with other
plants and external partners.
The oil & gas industry remains
a traditional environment, Brücher
said, and as such, digitalization
efforts are still in their early stages.
Still, digitailization is vital to improve
efficiency at all levels.
“The focus of our digitalization
project is on customers, touching
both the processes for new builds
as well as those for aftermarket
sales and service,” Brücher said.
“Another key area is cost reduction,
which can be achieved thanks to a
better efficiency in the execution of
customers’ projects.” CT2

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 Prime Movers
L’Orange
Rolls-Royce and Woodward, Inc. jointly announced that
Woodward will acquire fuel injection specialist L’Orange
GmbH, part of Rolls-Royce Power Systems. The agreement
includes L’Orange‘s operations in Germany, the United
States and China, for an enterprise value of $859 million.
L’Orange supplies fuel injection technology for engines in
applications such as oil and gas processing, marine power
and propulsion systems, power generation and special-
application vehicles.
After the acquisition, L’Orange will be renamed Woodward
L’Orange and be integrated into Woodward’s Industrial segment.
The transaction has been approved by the boards of directors
of both Rolls-Royce and Woodward, as well as the Supervisory
Board of Rolls-Royce Power Systems. The transaction is
expected to close by the end of the second quarter of 2018,
subject to clearance from German antitrust authorities.
Simple, reliable
efficient
Cook Compression
The Cook Compression Ellesmere Port, U.K., facility recently
recorded 1075 consecutive days without a recordable incident,
and 1353 consecutive days without a lost time accident. Over FLSmidth’s Ful-Vane™ rotary vane
the course of 151,431 exposure hours in 2017, the facility also
compressors are designed for long life, low
went without any first aid cases.
Phil Avis, HSE and CI manager for the facility, attributes this operating costs, and minimal downtime.
safety record to the development of a robust safety culture that With only two bearings and no valves, pistons,
combines acute awareness of risks and hazards with continued
crankshafts, or helical screws, field maintenance
training and investment in the proper protections.
is easier than with other compressor technologies.
Part of Dover Corp., Cook Compression provides
engineered solutions to increase reciprocating compressor
Our B3000™ carbon fiber blades outlast the
reliability and performance, offering components, repairs, competition. In addition, the cylinder and rotor can
field mechanical services and turnkey project management. each be re-machined several times - resulting in a
number of Ful-Vane compressors still in operation
Alfa Laval since the 1940s.
Alfa Laval, a global provider of specialized
products in heat transfer, separation and • Vapory recovery from storage tanks, flares,
fluid handling, has appointed Jo Vanhoren casing and well heads
president and CEO. In addition, he was • Gas boosting to high pressure reciprocating
named president of Alfa Laval’s North compressors, engines and turbines
American cluster, which includes its sales • Recommended for LPG, natural gas, sour gas,
and service organizations in the USA and and biogases
Canada. Jo is based at the Alfa Laval • Durable carbon fiber blades extend cylinder life
facility in Richmond, Virginia, USA. Jo Vanhoren
• Total capacity control with VFD and/or gas
Vanhoren joined Alfa Laval in 1991
bypass
as a heat exchanger sales engineer for Alfa Laval Benelux.
• Single-stage to 3000 SCFM, two-stage to 1800
From 1996 through 2006, he held several progressive positions
within the Alfa Laval Benelux organization, ultimately becoming
SCFM
charged with sales and marketing of all Alfa Laval products and • Working pressures to 300 PSIG
solutions to the local markets. • Made in the USA for over 85 years
In 2007, he was named general manager for Alfa Laval’s Find out more at
Air Business Center and in 2012, Vanhoren was appointed www.conveyorspneumatic.com/gas-compressors
managing director of Alfa Laval Iberica (Spain and Portugal) or contact us at +1 610 264 6800.
and president of the Southern Europe cluster in 2017, which info-us@flsmidth.com
includes Iberica (Spain, Portugal), France and Northwest Africa,
as well as Adriatic (Italy, Greece, Israel, Malta, Monaco).

COMPRESSORtech2
 All trademarks, logos and symbols are exclusive objects to the right of their owners and are used for reference purpose only.
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 GCA Conference Review

n Thompson Speir, sales manager of WellCaddie, explains

his company’s remote monitoring services during the Gas
Compression Association’s (GCA’s) technology update session.

GCA Updated On Best Industry

Operating Practices
Galveston conference briefed on changes affecting
compressor operations
BY DJ SLATER AND PATRICK CROW

T
he Gas Compressor Association
(GCA) returned to basics at its
annual Conference and Expo
in Galveston, Texas on March 20-23.
Eight educational sessions explored
some of the problems and challenges
facing gas compression companies.
David McCoy, director of technical
services for Ariel Corp., spoke on
the importance of properly mounting
and aligning rotating equipment.
The talk covered seven essential
elements to avoid vibration and
pulsation problems. Of the seven,
he stressed the significance of
having a solid foundation, which
encompassed all aspects of the
design and soil testing.
“It doesn’t matter how well the
package is designed,” McCoy said. “If
it doesn’t have a good place to sit, it’s
not going to be right.”
The other essential elements
discussed were skid and baseplate
to foundation interface; main bearing
bore alignment; equipment mounting
to the baseplate; shaft alignment;
component and pipe alignment; and
spending the time to do a job correctly
on the first try.
“All too often, the commissioning
checks and equipment confirmation
is rushed and kind of an afterthought
to getting this equipment running
reliability for its life,” he said.
The proper categories
David Lepley, Altronic’s senior vice
president, head of business unit
applications, provided an overview of
the zoning and classifications as they
relate to hazardous environments.
He said a hazardous situation always
contains three elements –- an ignition
source, oxidizer and flammable
substance. Combined, those elements
can result in an explosion.
Lepley discussed the categorization
system for classes, divisions and
groups, all of which are common
designations used in gas compression
in North America. He also covered
the zone classification system
commonly used outside of the United
States. Temperature codes, global
standards and nationally recognized
testing laboratories (NRTLs) were
also discussed.
After identifying these classifications,
Lepley turned to the types of
continued on page 32

COMPRESSORtech2 MAY 2018 29

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and standard) used in hazardous
environments. The discussion
then shifted to non-incendive and
intrinsically-safe circuits before
moving to wiring practices and
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Going digital in the field n Chris Jungers of Alfa Laval ACE
Alison Mackey, the digital product discusses the evolution of air-cooled
manager for the reciprocating heat exchangers during a technology
compression division of Baker update session at the GCA Expo &
Hughes, a GE company, discussed Conference.
the state of the gas compression
industry and the importance of using
digital analytical products to monitor
critical machinery.
Mackey emphasized the impor-
tance of these digital assets by
sharing data from a recent case study.
The study used data from myPlant, a
Web-based platform that monitors
and diagnoses the performance of
gas engines installed in industrial and
municipal distributed power projects.
In several slides, Mackey said valve
failures across several units can
cost end-users between US$3000 to
$70,000, depending on the frequency
of the failures.
With connected machinery, capital
efficiency and profits improve, as
well as operating costs and resource
management, Mackey said. Other
benefits include knowledge retention
and distribution, especially when
a senior staff member retires;
obtaining a competitive advantage
in the marketplace; and automating
procedures.
Mackey said three factors drive the
demand for digital capabilities – aging
resources, market downturn and the
growing demand for data.
Goodbye old school practices
Pat Runnels of FW Murphy Production
Controls reviewed basic maintenance
practices for reciprocating internal
combustion engines.
He said engine operators face
multiple goals. “We want to maximize
run time, maintain unit reliability, keep
the cost of operations down, and
maintain emissions compliance.”
Often, he said, companies must
be willing to adapt: “The old school
COMPRESSORtech2

practices no longer apply.” One
example that he gave was preventive
versus predictive maintenance. He
said predictive maintenance was
in vogue 20 years ago, but has
faded and most companies stress
preventive maintenance now. He
said a blend of the two should be
considered.
GCA Conference Review
Runnells offered practical oper-
ating tips on maintaining catalysts,
checking fuel pressure, air/fuel
ratio controllers, electronic ignition
systems among others.
“In all of this, the key is to train your
guys in the field to know what to look n Product demonstrations, such as this
for.” Also, he said, technicians should one from Alfa Laval, were plentiful during
observe and gather data. “There’s no the GCA Expo & Conference.
continued on page 34
 GCA Conference Review
n More than 425 industry professionals attended
the GCA Expo & Conference.
such thing as too much information.
But there is such a thing such as not
enough information.”
Staying in compliance
Joe Avila, J-W Power Co.’s health,
34 MAY 2018
safety and the environment manager,
updated the conference on compliance
with the Occupational Safety and
n Attendees gather on March 20 at a
kick-off reception hosted by Ariel Corp.
Health Administration’s walking and
working surfaces standards as they
apply to gas compression.
OSHA’s 2017 general Walking-
Working Surfaces rule required
personnel fall arrest or ladder safety
systems to be installed on new fixed
ladders over 24 ft. (7.3 m) by Nov.
19, 2018.
Also under the rule, existing fixed
ladders longer than 24 ft. (7.3 m)
must be equipped with a cage, well,
personal fall arrest system or ladder
safety system. Operators must
replace cages and wells (used as
fall protection) with ladder safety or
personal fall arrest systems on all
fixed ladders by Nov. 18, 2036.
“We have to be responsible about
these safety measures. What is
safest might not always be required
by OSHA. On the other hand,
although our goal is to make it (the
work environment safe), no one
wants it to be gold plated,” Avila said.
He said simple changes often
can solve the problem at hand. For
instance, rather than build ladders
and walkways to provide access to
valves atop machines, operators
sometimes can move the valves to
ground-level.
GCA has scheduled its 2019
annual meeting for March 19-22 in
Galveston, Texas. CT2
COMPRESSORtech2

The latest literature from companies
in the gas compression industry
Boss Industries
Boss Industries has
released a brochure
outlining its Tycoon
series of vapor recovery
units (VRU). The Boss
GasVantage Rotary Screw
VRU are designed to allow
tank batteries to comply
with U.S. EPA Quad O
rulings, according to the
company.
www.bosscompression.com
Moore Fans
High efficiency axial flow
fans from Moore Fans
are designed for industrial
heat exchange and cooling
applications. Operating in
air-cooled heat exchangers
and cooling towers, Moore
fans are designed to keep
liquids cool in refineries,
process plants and gas
compressors.
www.moorefans.com
COMPRESSORtech2
Media
Summit
A brochure from Summit, a
part of Klüber Lubrication,
outlines its line of gas
compressor lubricants for
rotary screw applications.
Gas compressor
applications are different
from typical lubrication
applications, according to
the company.
www.klsummit.com
Bluetick
Straightflo Innovation
The revolutionary Straightflo™ valve is based on the
simple principle of moving gas from point A to point
B in the most efficient way possible. At the heart of
the every valve is the patented module design which
provides a direct flow path and more effective flow
area. The result is a high efficiency valve which
A brochure from
increases compressor performance,
Bluetick Inc. outlines the and your bottom line.
company’s digital oilfield
automation solutions.
Solutions include tank
battery monitoring,
compressor monitoring
and electronic flow meter
monitoring.
www.bluetickinc.com
WWW.ZAHROOFVALVES.COM
WWW.ZAHROOFVALVES.COM
SALES@ZAHROOFVALVES.COM
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+1 713.554.2678
+1 713.554.2678MAY 2018 35
 SPARTAN ENTERS THE ARENA

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 Site Report

Enerproject Stays In The Loop

Company provides refrigeration compression
units for Swedish neutron accelerator
■ A helium compressor package by Enerproject
has been installed at the Spallation Source facility
used for research on neutron sources in Sweden.
The neutron source needs a reliable cooling
system, which is operated with helium.

The two, oil-injected screw compressors are designed for

nerproject, a Switzerland-based compressor packager
continuous use, delivering 1869 cfm (3000 Nm3/h) at 310.4
psig (21.4 barg). Because the suction pressure is close to 0
psi (0 bar), the driver size is 1.2 MW.
“The project also aimed to, and successfully achieved,
limiting costs for the operation and maintenance,”
Notari said.
One of the project’s key requirement for these compressors
was related to high availability, as these units have to operate
for two years without interruptions. The delivery contract

E and engineering services provider, completed a gas

compression project for the European Spallation
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assistance by Enerproject. CT2

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COMPRESSORtech2 MAY 2018 37

 86 YEARS OF BRINGING THE
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Condition Monitoring Consultants
Neuman & Esser’s NEA X unit designed to assist operators
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euman & Esser has created
N its fourth strategic business
unit – NEA X – to tackle
the challenges of monitoring and
analyzing all aspects of critical
machinery to avoid unscheduled
downtime. NEA X serves a resource
for natural gas operations looking to
pair intelligent software offerings with
their machinery.
In the current gas compression
landscape, plant operators are faced
with the task of keeping their assets
operational and readily available,
yet don’t have the resources to
effectively supervise and maintain
their machinery’s performance. A
2017 study revealed that unplanned
downtime of critical machinery costs
companies an average of US$260,000
per hour.
Neuman & Esser sought to broaden
COMPRESSORtech2
its client services in this area, which is
why it created NEA X, with the goal to
give plant operators all the condition
monitoring prowess they’ll need to
optimize the lifecycles of their assets.
With proper condition monitoring
solutions, potential risks on critical
components of a compressor can be
unveiled earlier and in higher detail
before failure occurs. Sources of
failure can be detected with higher
accuracy and service teams respond
more quickly to avoid unplanned
downtimes, Neuman & Esser said.
Consistent condition monitoring
starts with collecting relevant process
data continuously and using it to
generate condition indicators to
identify a precise picture of the current
asset performance, the company said.
Intelligent analytics, based on NEA’s
knowledge in compressor engineering,
Product Focus
■ Figure 1: Condition Management
Cycle, Source: NEA X
deliver automated notifications in case
of risky parameter trends and wear-
out effects on critical components.
This keeps clients informed on their
machinery’s health and allows them
to take action to prevent costly issues.
With NEA X, supply chain
management can be enhanced by
applying the condition monitoring
cycle. Such implementation via NEA X
follows a six-step process.
Preparation of physical assets
Before implementing a condition
management strategy, a thorough
evaluation of current processes and
existing instrumentation of assets is
required. NEA X identifies potential
gaps to be closed to enable meaningful
data analysis.
Together with the plant operator,
individual targets are developed
continued on page 40
MAY 2018 39
 Product Focus

■ Figure 2: Six-Step Path to Condition

Management, Source NEA X

that support the requested scope of

analytics and diagnosis. Depending
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Data submission
In a pilot phase for one compressor
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Intelligent analytics
Building on data processing and
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 Product Focus

into a recommendation to the generated from system analyses and

client regarding identified service
requirements. The client, though,
makes the final decision on the extent
of the necessary maintenance work.
Maintenance
NEAC Compressor Service fulfills
work orders based on the insights
results from in-person consulting.
NEA X counsels its clients as a
partner during the whole process of
implementing a tailored condition
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states of an asset, as well as deviations
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analyses are possible when more
complex algorithms and machine
learning are implemented to enable
pattern-based anomaly detection.

Service Notifications
In case of anomalies in performance
patterns, threshold violations and
risky trend developments, intelligent
push-notifications indicate likelihoods
for failures on affected components
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The pilot phase should then be
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copyright © 2018 J-W Power Company

COMPRESSORtech2 MAY 2018 41

Product News
New Material For Sealing Elements
Burckhardt Compression presents new material for use in sealing
elements for reciprocating compressors
BY ROBERTA PRANDI
A
new family of materials for
sealing elements has been
developed by Burckhardt
Compression.
The Persisto family can cover re-
quirements for a wide variety of gases
in oil-lubricated as well as in dry-running
environments, Burckhardt said.
Burckhardt Compression said that
the Persisto family can offer superior
sealing properties even in complex
sealing applications.
n Wear coefficients for Persisto 850 (red), Persisto 851 (gray) and
typically used hydrogen sealing materials (blue) in a piston rod sealing in
hydrogen with a discharge pressure of 1160 psig (80 barg).
42 MAY 2018 COMPRESSORtech2
The company is testing the
materials in five reciprocating
compressors used for different
applications. The Persisto 850 and
Persisto 851 materials are based
on an alloy of polytetrafluorethylene
(PTFE) and polyphenylene sulfide
and were specifically developed for
dry-running applications in hydrogen
compression and have been tested
on a hydrogen compressor.
Burckhardt Compression said that in
this case, the alloy showed particularly
favorable properties for the sealing
function, permitting a higher load
and reducing creep in comparison to
conventional filled PTFE materials.
Sealings and rider rings made of
Persisto 850 and Persisto 851 showed a
good flexibility and good adaptability, the
company said.
The Persisto family is Burckhardt
Compression’s answer to the market
requirements for superior sealing in
reciprocating compressors. Despite
the availability of several high-quality
plastic compounds, the company
said in many cases these materials
have not been developed specifically
for compressor use, but have been
optimized for several different
applications, such as automotive or
chemicals, to be cost effective.
According to Burckhardt Com-
pression, the requirements for an
optimal dry-running material for
reciprocating compressors are:
favorable tribological properties for
minimal friction and low wear; high
degree of chemical resistance for
use with as many different gases as
possible; good mechanical properties
to cope with high load parameters;
good shape adaptability for optimal
sealing; and minimum abrasiveness
to avoid counter body wear.
These requirements are currently
not satisfied by any dry-running
material, especially for what regards
the compatibility with all gases and
gas mixtures, the company said. Also,
available materials often are filled
 Product News

difference of more than 2900 psig is not recommended for compressing

(200 barg) is high: Persisto 851 is
used in the pressure range up to 725
psig (50 barg).
The wear coefficients of both
Persisto materials are reported to
be significantly lower than those
of conventional polymer blends or
carbon- and fiber-filled PTFE grades.
Persisto 850 can be used in a wide
range of gases and gas mixtures but
oxygen-containing gases.
Apart from hydrogen, this new
development is meant for applications
with various hydrocarbons such as
carbon monoxide, carbon dioxide
or ammonia, including boil-off gas.
Thanks to its special composition, the
atmospheric dew point of the gases
can be significantly below -70°C, the
company said. CT2

See all our products online

klsummit.com
Visit us at E.G.C.R.
Booth # 420
n Persisto 850 (red), shown in a
heterogeneous combination of rings
within a Redura Rod Sealing System by
Burckhardt Compression.

with a proportion of abrasives such as

glass fibers or ceramics that can have
negative effects on soft counter body
materials such as grey cast iron.
In some cases, high-temperature
polymers offer good mechanical
properties but a high elastic modulus,
which leads to rigid sealing rings
with poor adaptability – an especially
negative status in the oil-free gas
compression of light gases at high
pressures, the company said.
Burckhardt Compression said Expertise +
that the Persisto family can offer
superior sealing properties even in
Service =
complex sealing applications, without Results
requiring the use of expensive
counter body materials of coating.
If the wear compensation of sealing
elements is based on shifts in
ring components, rather than their Fix Problems. Reduce Downtime.
elastic/plastic deformation, even Summit’s specialty gas compressor lubricants
high differences in pressure can be succeed where conventional lubricants fail. Our
realized with Persisto 850 without customers have discovered that using the right
failure by fracture. lubricant, backed by our experience and technical
According to the company, expertise, results in significant decreases in
lubricant-related operating and maintenance
discharge pressures of more than costs.
4350 psig (300 barg) can be sealed in
the oil-free compression of hydrogen.
( 800.749.5823
The permissible pressure load for info@klsummit.com
dry-running packings with a pressure Klüber Lubrication NA LP

COMPRESSORtech2 MAY 2018 43

Summit_EGCR Tag.indd 1 4/5/18 11:14 AM

Site Report
n Dawson Creek, Canada location
presented unique challenges to the team
for installation and commissioning of
equipment in a remote location.
Cold Calculation
Siemens’ Dresser-Rand LNGo-HP takes on frigid Canada
BY JACK BURKE
C
limate extremes take a toll
on machinery, so when
Siemens’ Dresser-Rand
business was brought in to design and
implement a natural gas liquefaction
system in Dawson Creek, Canada,
the company had to account for
some brutally cold temperatures.
That area in the northwest
part of British Columbia regularly
sees -40oF (-40oC) in winter, said
Michael Walhof, sales director for
Distributed LNG Solutions for the
Dresser-Rand business.
Siemens’ Dresser-Rand business
recently commissioned an LNGo-
HP (high-pressure) micro-scale
natural gas liquefaction system for
AltaGas Ltd. at the Dawson Creek
site. The modular, expandable LNGo
technology is designed to enable
44 MAY 2018
efficient installation in demanding
environments and will give the
Dawson Creek facility a capacity of
30,000 gal. (113,562 L) of liquefied
natural gas (LNG).
The LNGo technology is designed
to monetize stranded gas deposits
due to its relatively low capital and
operating costs, Siemens said. The
micro-scale LNGo solution can be de-
ployed in rough terrain or remote re-
gions, which can eliminate the need to
establish a gas pipeline infrastructure
or arrange for long-distance truck-
ing of LNG from centralized plants
to point of use. It can also function
as a decentralized solution where
the requisite pipeline infrastructure
is lacking, or as an onsite solution to
reduce or eliminate flaring of petro-
leum gas at, for example, oil rigs or
producing gas fields, Siemens said.
“Dawson Creek is a harsh
environment, it’s really an Arctic
environment,” Walhof said. “There
are many challenges that have to be
overcome when installing a plant in
these conditions. Everything from
maintaining the proper temperature
inside the process building, to
the safety of the workers in this
environment.”Walhof said he couldn’t
go into all the details of the solution
(the “secret sauce that we put
together”), but he did say Siemens
relied heavily on the global project
experience within the company
and local contractors to execute
the project and overcome all of the
challenges of the environment.
“Our experienced engineering
team and project management team
COMPRESSORtech2
 Site Report

modules which include two 1 MW
SGE-56SL Siemens gas engines
adapted to run on natural gas. The
drive motor for feed gas compres-
sor is an 800 hp (597 kW) Siemens
low-voltage induction motor. The
primary compressor uses a 550
hp (410 kW) Siemens low-voltage
induction motor.
The system takes pipeline natural
gas and separates it into a feed gas
stream and a waste gas stream.
The waste gas is used to fuel the
Siemens gas engine generator
sets which power the LNGo-HP
equipment. The feed gas is liquefied
in the process to produce LNG.
The plant, with a footprint of
26,910 sq. ft. (2500 m2), was
deployed directly at the site.
continued on page 46

came up with a solution to make the

project successful,” Walhof said.
“The experience that Siemens brings
to the table for projects like this really
shows off the difference with the
competition.”
He said the company is working on
a similar application in the Houston,
Alaska region.
“It has very similar conditions and
will have similar solutions to what we
did in Dawson Creek.”
The scalability of the LNGo system
PROCESS API 618
GAS
will enable AltaGas to adjust production
COMPRESSOR
Reciprocating Compressors
in line with demand and minimize
capital expenditures, Siemens said.
The LNGo-HP system also allows API 617
users to convert from diesel and other Integrally Geared
fuels to natural gas, which can result
in a reduced carbon footprint, lower Centrifugal Compressors
operational cost, and market price
stability, the company said. We, at BORSIG ZM Compression GmbH,
Siemens’ scope of supply at design and manufacture tailored compressors
Dawson Creek included one LNGo- for innovative process gas compression
HP system, site civil works, building solutions.
construction, mechanical and
electrical integration, commissioning,
startup, and operator training.
BORSIG ZM  To learn more, please visit
Compression GmbH www.borsig.de/zm
The LNGo system consists of

COMPRESSORtech2 MAY 2018 45

Borsig_API 618.indd 1 3/28/18 3:32 PM

Site Report

n Siemens’ Dresser-Rand
business LNGo micro-LNG
solution is modularized for
speed to market and ease of
construction once at site.

AltaGas said it is evaluating the
feasibility of building a network of
small and medium LNG facilities,
known as Regional LNG, to service
northern British Columbia, Yukon
and Northwest Territories. Facilities
would be in areas where gas supply
is economical, abundant, reliable
and near transportation access and
existing infrastructure owned by
AltaGas, its subsidiaries and end-
use customers.
Along with being in a demanding
climate, the Dawson Creek facility
is rather remote, which also
played to his company’s strengths,
Walhof said.
“What drove the project in our

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 Site Report

n The Dresser-Rand business’ LNGo-

HP system uses Siemens variable speed
motor drivers with Dresser-Rand MOS
compression equipment.

up and running, because it is a

direction was the quality that is
built into our product, the reputation
of Siemens and the Dresser-
Rand business and the ability to
support a project in that demanding
environment and they knew the
company was going to be there to
back up the product for many years,”
Walhof said.
“If it’s down, they need to
know that someone is going to
respond to get the plant back
remote location.”
The Dresser-Rand business had
done work with AltaGas in the past,
so they are very familiar with the
product line, he said.
In 2016, the Dresser-Rand
business commissioned its first
LNGo-LP (low-pressure) micro-scale
natural gas liquefaction system at the
Ten Man LNG facility in Pennsylvania.
There, the LNGo technology has
enabled the operator, Frontier Natural
Resources, to monetize stranded
gas assets at Tenaska Resources
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the Marcellus shale natural gas field.
CT2

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 techc
Solving Vibration Issues On Recips

orner
Keeping pulsations in check starts in the earliest stages of a gas
compression project

BY COSIMO CARCASCI AND

MARCO SACCO

Vibrations in rotating equipment

V
ibration is one of the main
and more common causes
of failure or unscheduled
shutdown on rotating equipment.
Reciprocating compressors in
particular are often affected by
vibration issues, since these
are inevitably generated by the
reciprocating motion and by the
pressure pulsations typical of these
machines.

Cosimo Carcasci is consultative service

leader at Compression Service
Technology (CST), Florence, Italy.
Contact him at: cosimo.carcasci@
cstfirenze.com. Marco Sacco is package n Figure 1: Generation of pressure
engineering manager at CST. Contact him pulsations in a reciprocating compressor
at: marco.sacco@cstfirenze.com.

48 MAY 2018 COMPRESSORtech2

201803CT_A4562_Airtec Filtration_third.indd 1 1/9/18 2:55 PM
 During the detailed engineering
phase of each new project, technical
countermeasures are generally
taken to avoid high levels of
vibrations, generated by the so-
called “shaking forces”: i.e.,
adequate foundation design,
balancing of forces and couples,
volume bottles, orifices and suitable
pipe supports.
Despite this, vibration problems
frequently show up even from
the very first machine start-up; in
many cases the cause is to be
found in not having paid enough
attention to the interaction between
the compressor and the rest of
the system.
For the reasons above, the
success of the project can be
significantly affected by assess-
ments and decisions regarding
methods of controlling pulsation
and vibration that must be taken
right from the earliest stages of
detailed engineering, if not, even
before, when establishing the
purchase specifications. The help
of a consultant with experience
in this field, who is accountable to
the end user, can play a key
role. Such a consultant has a
comprehensive and unbiased view
and has two important tasks: to
ensure the goals of a state-of-the-
art design and to ensure that critical
decisions about efficiency, safety
and reliability are made wisely,
independently and in the shortest
time as possible.
Theoretical aspects on pulsations
The basic law that links the pressure
pulsations, measured at the flange
of the compressor and without
resonance phenomena, to the
flow pulsations (generated by the
oscillatory nature of the compressor
motion) can be expressed as follow:
ΔP/P α ΔQ K/S c
Where:
ΔP is the pressure pulsation;
P is the medium pressure;
ΔQ is the flow pulsation;
K is the ratio of specific heats;
S is the section of the pipe;
c is the speed of sound in the
actual conditions.
To obtain reliable results from the
acoustical analysis it is very important
to have a deep understanding of gas
thermodynamics.
Gas properties are dictated by
composition, operating temperatures
and pressures. The only value on
which it is possible to intervene is the
diameter of the piping. The choice of
the pipe size can be determined by
the average velocity of the gas that
has to be achieved, but also by the
maximum pulse that is deemed to
be admissible at the flanges of the
various cylinders.
In addition to trying to minimize
pressure pulsations directly near the
source (the compressor cylinders),
it is also important to avoid the
geometry of the piping triggering
acoustic resonance phenomena.
This is a physical condition, as
well as the mechanical or electrical
resonance, which occurs when
a forced oscillating system is
subjected to periodical stress,
having the same frequency as the
system oscillation mode.
Typically, this situation causes a
significant increase in amplitude of
the oscillations, which corresponds
to a considerable accumulation of
energy within the stressed system
that can lead the system itself
to destruct.
The pressure pulsations can be
originated by the compressor flow
pulsations, but also by resonance
phenomena; in both cases they
should be kept as low as possible.
In this way it is possible to ensure
that the energy contained in the
continued on page 50

High Performance Industrial

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PO Box J, Marshall, TX 75671
COMPRESSORtech2 1-800-525-0143 | sales@sswesco.com MADE IN USA SINCE 1951 MAY 2018 49
pressure pulsations interacts as
little as possible with the plant
mechanical system, generating
less possible vibrations: it is the
so-called mechanical response of
the system.
Furthermore, if the natural
frequency of a mechanical part
of the plant (whether it is piping,
vessels, or support) coincides with
an exciting acoustic frequency, a n Figure 2: First stage suction piping pulsation spectra
mechanical resonance phenomenon
may occur. This situation brings compressors. The plant was speed and item B had a suction
the system to high vibration experiencing high vibrations on valve reverse flow control.
amplitudes and represents in most many parts of the plant piping, By means of the vibration
of the cases, the cause of cyclical which caused the failure of a few measurements, the most critical
fatigue failure. nozzles connected to pressure areas were identified and a
instruments. comparison was made with the
Case study During the survey, vibration and relevant pressure pulsations
A few years ago, CST was tasked dynamic pressure measurements (representing the exciting forces
with evaluating the causes of the were carried out on the two units. of the system). These values​
problems encountered in an ethylene The two compression units were were then compared to the limits
and hydrocarbons plant, related equipped with two different capacity calculated according to API 618
to two, three-stages reciprocating control systems: item A had variable standards.

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50 MAY 2018 COMPRESSORtech 2
 The compressors were not made the measured pulsations spectrum was the condition with the highest
to work simultaneously, so no and the blue point represent the vibrations in this area. Consequently,
interaction between the systems API618 limit. the insertion of a restriction orifice
was accounted, but the two different A further analysis was performed on of the suction pressure vessel
capacity controls had to be analyzed to calculate the generated pressure was the recommended solution, as
separately. Therefore, the site tests pulsations at partial loads, when well as some stiffening on the piping,
had to be performed considering the reverse flow control system was to better counter balance the high
both the speed range of compressor working. The result was that the fourth pulsations.
A and the reverse flow system of harmonic generated a pulsation peak The interstage piping system
compressor B. at ~75% load (see Fig. 3), which was instead vibrating mainly at a
A detailed vibration measure-
ments campaign was performed in
10 critical combinations of operating
conditions to determine the worst
one. Afterward, the pulsations Searching for the
BEST solution for your
were measured in this condition
and compared with the calculated
values.
Two main areas were found to
be subject to the highest vibration
values, exceeding the EFRC
recommended limits:
n First stage common suction
changing conditions?
piping, just after the separator,
which was vibrating at more than continued on page 53
60 mm/s, with a main frequency
of 43 Hz, corresponding to the
4th harmonic, mainly when
compressor B was running;
n Second stage common
suction piping, especially on
the highest area, which was
vibrating at almost 60 mm/s,
with a main frequency of 15
Hz, corresponding to the
2nd harmonic, mainly when
compressor A was running.
After identifying the main areas
with high vibrations, a different
analysis approach was used for
each one, due to the dissimilar
nature of the vibration. ACI is your compressor problem-
In the first stage suction piping solving experts for reapplication, revamping
area, most of the highest vibration
were above 43 Hz, therefore at a or upgrading existing compressor equipment.
rather high frequency, considering
that the first exciting harmonic was Contact us today to provide the best solution!
at less than 10 Hz.
The pulsation amplitudes at
these frequencies are generally low,
when the compressor is working at
100% load, but the measured pulsation
values revealed quite elevated values
even at higher harmonics; Fig. 2 shows www.aciservicesinc.com | (740) 435-0240

COMPRESSORtech2 MAY 2018 51

ACI_Searching ForSolutions.indd 1 4/10/18 9:46 AM
 n Figure 4: example of elevated piping
n Figure 3: generated first-stage pulsations, at different load steps system

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 The calculation of the mechanical
natural frequency of the main pipe
segments was performed using the
API688 Fundamental Analytical
Method (FAM), which is a first
approximation to calculate natural
frequencies for most standard
piping configurations. It was found
that the particular U shape of
an elevated pipe segment had
a very low mechanical natural
frequency, very close to 10 Hz,
mainly due to the distance between
supports and to a low stiffness
of the beams structure below
(see Fig. 5).
In this case the solution had
to be oriented to mechanically
continued on page 54

particular speed of compressor A

(regulated by VFD) and the lower
frequency of the vibration suggested
a different nature of the pulsations,
therefore leading also to a different
analysis approach.
The measured pressure pulsations
were aligned with the calculated
values at compressor flanges,
therefore excluding the possibility of
acoustic resonances; moreover, the
values were not high compared to
API618 limits.
Consequently, the problem was
believed to be mainly mechanical,
which means that the supporting
structures were not stiff enough to
sustain the shaking forces generated
by the pressure pulsations.
Elevated piping systems, like the
one shown in Fig. 4, can often be
susceptible to vibrations, if an adequate
mechanical modelling with the relevant
mode shape analysis is not performed
in the engineering phase.
Subsequently, from the analysis of
the geometry and the arrangement
of the elevated pipes in the plant,
possible resonances of a mechanical
type, which may occur at the two
main excitation frequencies, were
investigated.

COMPRESSORtech2 MAY 2018 53

SAMR_SmoothRotation.indd 1 4/17/18 9:43 AM

 n Figure 5: elevated pipes
subject to high vibrations
stiffen the supporting structure of
the elevated pipes, so a compromise
between low intervention time and
effective supports construction was
performed and a series of new clamp
supports and of reinforcing beams in
a few key points was recommended.
Conclusions
To avoid the occurrence of vibration
phenomena, it is necessary that
the design phase of reciprocating
compressors skids is supported
11th EFRC CONFERENCE
September 13 – 14, 2018
Madrid, Spain
l F e ature
Specia
Compressor Training – September 13, 2018
State-of-the-Art Design of Reciprocating Compressor Systems
For Programme and Online Registration: www.recip.org
tion
direc
Main bration
of vi
with particular attention to a proper
thermodynamic simulation of the
treated gas, to the generated
pressure pulsations in all operating
conditions (including capacity
control) and to a correct design of the
supporting system and plant layout.
Dealing with vibration problems
when the plant and the compressor
are installed, almost always requires
huge resources in terms of time,
investment and production losses.
Therefore, it assumes funda-
mental importance dealing
with the problem of
pulsations and vibrations
control already from the
early stages of detailed
engineering, if not even in
the phase of preparation of
the material requisition.
In this regard, according
to guidelines of the new
concept, the cooperation
of an expert in this field, generally
involved directly by the end user, is
recommended: the expert has the
task of analyzing the new installation
in the most comprehensive and
impartial manner as possible.
He also must ensure that
the objectives of a state of the
art design are followed, that critical
decisions with respect to efficiency,
safety and reliability, are taken with
awareness, caution and rapidity at
the same time. CT2
11th EFRC CONFERENCE
 2
3 Scheduled Downtime DJ SLATER, PUZZLEMASTER

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

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COMPRESSORtech2 MAY 2018 55
 ASME 2018
Turbo Expo
June 11 - 15, 2018 | Lillestrøm, Norway

ASME Turbo Expo held in Düsseldorf in 2014:

1345 papers presented

76 student poster presentations
3,051 attendees representing over 150 countries
118 exhibiting companies

Norges Varemesse, Norway Convention & Exhibition Centre in Lillestrøm, Norway

asme.org/events/turbo-expo
American Society of Mechanical Engineers (ASME)
 Cornerstones Of Compression

Rated Rated Power

Power Speed Cylinder Bore Stroke Year
Series hp (kW) rpm Configuration in. (mm) in. (mm) Introduced
Harbison 6 (4.5) unknown Horizontal, 4-cycle 6.5 (165) 10 (254) 1897
to 40 (30) to 14.5 (368) to 20 (508)
Automatic 15 (11) unknown Horizontal, 4-cycle unknown unknown 1899
to 50 (37)
Class E & 4 (3) unknown Vertical, 4-cycle 5 (127) 8 (203) 1908
Class K to 8 (6) to 7 (178) to 10 (254)
Type K unknown unknown Vertical, 2-cycle 8.5 (216) 12 (305) c.1910
to 10.5 (267) to 14 (356)
Class AA 15 (11) unknown Half-Breed, 2-cycle unknown unknown 1913
to 25 (19)
Class N Est. 60 (45) 200 Horizontal, 4-cycle engine- 16 (406) 22 (559) 1919
compressor
Class AB 4 (3) 350 Horizontal, 4-cycle engine- 5.5 (140) 7 (178) 1919
compressor
Class AE 40 (30) 350 Horizontal, 2-cycle 12.5 (318) 12 (305) 1920
Class AJ 20 (15) 350 Horizontal, 10 (245) 14 (356) 1923
to 40 (30) 2-cycle to 12.5 (318)
Class CG 50 (37) 250 Horizontal, 2-cycle 13 (330) 16 (406) 1934
Class CJ 30 (22) 350 Horizontal, 2-cycle 11 (279) 14 (356) 1938
to 40 (30) to 12.5 (318)
■ Many different Bovaird & Seyfang engine and engine-
introduced a few years earlier by Blaisdell Machinery Co., compressor models were introduced over a four-decade
also located in Bradford. The B&S Class N was a straight- period. Production ended in the early 1950s.
line frame with the four-cycle gas engine and air compressor
cylinders on a single-throw. With a 16 in. (406 mm) bore supplies curtailed in the winter when gas was used for
x 22 in. (559 mm) stroke, it produced an estimated 60 hp heating. When that happened, the gas engine could be
(45 kW) at 200 rpm. The heads for the 100 psig (6.9 bar) converted to the diesel configuration for winter and then
air compressor cylinders were produced by the Laidlaw converted back to gas in the spring. The AJ was popular
Division of the Worthington Corp., complete with Laidlaw among independent producers because of its simplicity and
feather valves. lower price than other engines.
The similar Class AB engine-compressor was developed The 50 hp (37 kW), 250 rpm Class CG was designed
at the same time. The 4 hp (3 kW), 350 rpm unit was initially in 1934 to meet the need for a larger and heavier engine.
developed to provide 200 psig (13.8 bar) starting air for the This 13 x 16 in. (330 x 406 mm) gas engine was more
Class N engine, although it also found its way into plant air sophisticated than other B&S engines, having an all-iron
applications. The simple design used a single piston for the crankcase with a bored crosshead. Multiple feather valves
engine and compressor. were used on the air intake. The Class CO was a diesel
The Class AE 40 hp (30 kW), 350 rpm two-cycle 12.5 x version of this size.
12 in. (317 x 305 mm) special drilling engine was introduced The 14 in. (356 mm) stroke, 30 and 40 hp (22 and 30 kW),
in 1920. By this time, two-cycle engines were becoming 350 rpm Class CJ was introduced in 1938 to replace the AJ,
widely used in many applications, and they subsequently but both were built concurrently for a period of time. The
comprised most of B&S’s production. frame and cylinder were quite different than the AJ. As was
common for B&S engines, both models had a galvanized
The Class AJ cometh frame cover for splash lubrication. The CP was a diesel
B&S’ most popular two-cycle gas engine was the Class AJ. version. These were the last B&S engines developed.
Introduced in 1923, it was built in four sizes ranging from In 1942, the Bovaird & Seyfang Manufacturing Co. was
20 to 40 hp (15 to 30 kW) at 350 rpm. All sizes shared the purchased by Dresser-Clark, which needed B&S’ plant
same 14 in. (356 mm) stroke frame design. Power cylinder capacity for government orders. Production of B&S pump
bores ranged from 10 in. (245 mm) to 12.5 in. (318 mm). A jacks, engines and compressors continued until the early
diesel version of this engine, the Class BP, was introduced 1950s, when the demand for such equipment dwindled.
in the 1930s. Dresser-Clark continued using the B&S plant for producing
When oil companies were forced to buy natural gas due two-cycle multi-cylinder Clark angle engine-compressors
to dwindling supplies, they would often have their gas until the 1970s. CT2

COMPRESSORtech2 MAY 2018 57

 Cornerstones Of Compression
Bovaird & Seyfang
Entrepreneurs benefitted from Western Pennsylvania
and New York oil and gas boom
BY NORM SHADE
he boom that followed the discovery of oil in Western
T Pennsylvania in 1859 led to many new enterprises
in the region. Among them was John L. Seyfang’s
Central Iron Works, founded in Shamburg, Pennsylvania
in 1871 to repair oil drillers’ tools. As the oil boom pushed
northward, Seyfang, with partner David Bovaird, moved
the business to Titusville in 1875. They soon expanded
to manufacturing oil field products and, in 1879, followed
the boom to Bradford. In 1891, their growing business
was incorporated as the Bovaird & Seyfang Manufacturing
Co. (B&S).
By 1895, the company was manufacturing steam engines
for oil field needs. Bovaird left that same year to start his own
company, and Seyfang retired in 1896, but the company
continued to prosper. Although not as well-known as
other equipment manufacturers, B&S played an important
role in the development of the Western Pennsylvania and
New York oil and gas fields. In addition to steam, gas and
diesel engines, B&S manufactured compressors and other
oil field equipment. Most of the products stayed within a
100 mi. (161 km) radius of Bradford, but B&S engines and
equipment eventually found their way into most major oil
producing areas of the United States.
B&S’ first gas engine series was named for its designer,
Albert Harbison. About 220 Harbison engines were
produced from 1897 to early 1904. The four-cycle engines
were built in six sizes, ranging from a 6 hp (4.5 kW),
6.5 in. (165 mm) bore x 10 in. (254 mm) stroke model to a
58 MAY 2018
■ This Bovaird & Seyfang Class N combination
gas engine and air compressor was introduced
in 1919. The 16 in. (406 mm) x 22 in. (559 mm)
stroke single-throw, straight-line machine, rated
at 60 hp (45 kW) at 200 rpm, produced 100 psig
(6.9 bar) air. The compressor head, complete with
feather valves, was manufactured by the Laidlaw
Division of the Worthington Corp.
40 hp (30 kW), 14.5 x 20 in. (368 x 508 mm) model. Although
designed primarily for oil field use, some were designated
for powering small factories. An operable 12 hp (9 kW) 1900
Harbison is displayed at the Coolspring Power Museum
in Pennsylvania.
The next B&S series, built under license from the Standard
Automatic Gas Engine Co. of Oil City, Pennsylvania, was
known as the automatic. From 1899 to 1901, 25 were
produced in sizes from 15 to 50 hp (11 to 37 kW). Several
other B&S engine designs were developed in the early
20th century and more than 1000 were produced, mostly
for powering pump jacks on oil wells. All were single-throw
horizontal or vertical configurations. The company’s first
two-cycle engine was the Type K, introduced in 1910.
Half-breeds and conversions
B&S, like so many other gas engine builders in the
region at that time, also made “half-breed” cylinders for
converting steam engines into gas engines. B&S introduced
its Class AA half-breed in 1913, built in sizes from 15 to
25 hp (11 to 19 kW).
As oil wells proliferated and matured, many oil well pump
jack engines were converted from steam to compressed
air, which was supplied from central compressors through
a network of iron pipes. In 1919, with compressed air
being used for pumping oil wells in the Bradford fields,
B&S designed the Class N combination engine and air
compressor. The Class N design closely resembled one
continued on page 57
COMPRESSORtech2
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