Download - Compressor Tech August September 2013

COMPRESSORDedicated To Gas Compression Products & Applications

pumptech Spotlight: turbomachineryissue south AmericA technology

August-september 2013

Dresser-Rand MarksDAtum milestone

MAN Expands industrial steam turbine line

Universal AET Acquires ojibway enclosure systems

Compression Quiet

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Power & Compression

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n Customer: Refinery, Louisiana, USA.

n Challenge: Increase reliable, on-site power generation within the plants existing carbon footprint.

n Result: An Elliott 36 MW FCC hot gas expander-generator converts refinery waste gas to electrical power.

They turned to Elliottfor green, reliable power.

The customer turned to Elliott because of our 50 years of experience and nearly 500 MW of installed capacity in FCC power recovery. Elliott TH expanders routinely operate 5 years and more between shutdowns, extending FCC maintenance cycles and reducing maintenance costs. Who will you turn to?

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The world turns to Elliott.

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Ariel reciprocating compressors from 100 to 10,000 BHP are utilized in the upstream, midstream, and downstream sectors. Our compressors are designed and built for long service life and ease of maintenance. Ariel is there every step of the way, offering you the best customer service in the industry. For all your compression needs, choose Ariel.

Learn more about unit F40,000 at www.arielcorp.com/unit40k

IF NOT, TALK TO US ABOUT YOUR COMPRESSION NEEDS. WELL SHOW YOU THE ARIEL DIFFERENCE.

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TechTransfer_CT2.indd 1 2/22/12 9:11 AM

TechTransfer_CT2.indd 2 2/22/12 9:11 AM

Robert X. Perez has just made a valuable contribution to the data avail-able for personnel involved in energy production and transmission and pro-cess operations.

Perez, a machinery engineer, has compiled an illustrated dictionary of es-sential process machinery terms. The book is being printed by Diesel & Gas Turbine Publications, which is the par-ent company of COMPRESSORtech2.

The 200-plus page dictionary will be helpful for compression industry pro-fessionals who need to communicate ideas or understanding design, perfor-mance and maintenance documents.

According to Perez, process ma-chines come in a wide variety of forms and perform many critical functions. They are designed to efficiently and reli-ably pump liquids, compress gas, move air, generate mechanical power, trans-mit mechanical power, convert me-chanical power to electrical power, etc.

Without such machinery, our pro-cesses would come to a grinding halt, which is why it is important that any-one working in these industries have a basic knowledge of the purposes and construction of machines.

The purpose of the dictionary is to be a tool for those working around machinery, but who are not machinery professionals. It will help them quickly locate frequently used process ma-chinery terms and definitions in order to make better decisions.

The dictionarys succinct format and portable size makes it an ideal field reference. This resource is per-fect for plant decision makers, mainte-nance personnel, process operators,

purchasing agents, or anyone need-ing to understand machinery terms.

The dictionary contains essential terms for a wide array of process ma-chines including: centrifugal pumps; rotary pumps; reciprocating pumps; centrifugal compressors; reciprocat-ing and rotary compressors; fans and blowers; electric motors; gas turbines; steam turbines; expanders; internal combustion engines and ancillary equipment and components.

In addition to specific equipment terms, the dictionary contains other related machinery topics in order to provide broad coverage of the process machinery field. Those include: lubri-cation; condition monitoring; vibration and rotordynamics; plus reliability and machine shop methodologies.

The book also has a quick refer-ence section listing frequently used acronyms. It contains a compilation of all of the acronyms contained within the dictionary, as well as commonly used acronyms within process ma-chinery applications.

Anyone with a recurring need for machinery information should find this dictionary to be a useful addition to their technical library. It already has demonstrated its value in the commu-nication business that deals regularly with energy and process industries.

The dictionary will be displayed at the COMPRESSORtech2

booth dur-ing the Turbomachinery Symposium in Houston in October.

So, while you are paging through this comprehensive dictionary, in a similar manner, may the Lord hold you in the hollow of His hand. CT2

A New Dictionary Of Process Machinery Terms

Page4JOe KAneCOmPReSSORtech2 Founder

President & CEO .................... michael J. OsengaExecutive Vice President ...michael J. Brezonick

PUBLICATION STAFFCT2 Founder .......................... Joseph m. KanePublisher .................................Brent D. HaightAssociate Publisher ..............Roberto ChelliniEditor ..........................................Patrick CrowExecutive Editor .............................. DJ SlaterSenior Editor ................. michael J. BrezonickSenior Editor ............................. mike RhodesAssociate Editor ............................... Jack BurkeAssociate Editor ............................Chad elmoreCopy Editor ............................... Jerry KarpowiczDigital Content Manager ...........Catrina BoettnerCirculation Manager ..................Sheila LizdasProduction Manager ............ marisa J. RobertsGraphic Artist .......................Brenda L. BurbachGraphic Artist ............................Carla D. LemkeGraphic Artist .......................... Amanda J. RyanGraphic Artist ............................... Alyssa Loope

PUBLICATION HEADQUARTERS20855 Watertown Road, Suite 220Waukesha, Wisconsin 53186-1873

Telephone: (262) 754-4100 Fax: (262) 754-4175CONTRIBUTING EDITORSellen Hopkins - midland, Texasnorm Shade - Cambridge, Ohio

mauro Belo Schneider - Rio Grande du Sul, Brazil

HOUSTON OFFICEBrent D. Haight, Publisher

Patrick Crow, editormike Rhodes, Senior editor

12777 Jones Road, Suite 225Houston, Texas 77070

Telephone: (281) 890-5310 Fax: (281) 890-4805GERMAN OFFICE

Lisa Hochkofler, Advertising managerGabriele Dinsel, Advertising manager

niemllerstr. 973760 Ostfildern, Germany

Telephone: +49 711 3416 74 0 Fax: +49 711 3416 74 74

UNITED KINGDOM OFFICEIan Cameron, Regional manager/editorLinda Cameron, Advertising manager

40 Premier Avenue Ashbourne, Derbyshire,

De6 1LH, United Kingdom Telephone: +44 20 31 79 29 79 Fax: +44 20 31 79 29 70

ITALIAN OFFICESRoberto Chellini, Associate Publisher

44, Via Delle ForbiciI-50133 Firenze, Italy

Telephone: +39 055 50 59 861 Fax: +39 055 57 11 55Roberta Prandi Via Fitta, 21a

I-38062 Arco, ItalyTelephone: +39 0464 014421 Fax: +39 0464 244529

SCANDINAVIAN OFFICEBo Svensson, Field editor/Business manager

Dunderbacksvagen 20612-46 Finspong, Sweden

Telephone: +46 70 2405369 Fax: +46 122 14787

JAPANESE OFFICEAkiyoshi Ojima, Branch manager

51-16-301 Honmoku Sannotani, naka-kuYokohama, 231-0824 Japan

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

CHINESE OFFICES.H. mok, Branch managerRm 1405, Kowloon Building

555 nathan RoadKowloon, Hong Kong

Telephone: +852 3118 7930 Fax : +852 3110 3572

COMPRESSORA Member of the Diesel & Gas Turbine Publications Group

CT252.indd 1 8/26/13 11:20 Am

Marine Engines & Systems Power Plants Turbomachinery After Sales

We build rock solid components for a broad range of applications in re neries and petro-chemicals. Whether for hydrogen production and recovery, desulfurization, uid catalytic cracking (FCC), PTA, Fertilizer or IGCC our axial, screw and centrifugal compressors, as

well as our steam turbines and reactors are built to achieve the highest level of availability.

Rede ning reliability today and tomorrow. Find out more at www.mandieselturbo.com

MAN InsideReliable solutions for the long run

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Follow Compressortech2 at www.compressortech2.com

MEMBER OF BPA WORLDWIDEPRINTED IN THE U.S.A.

MEMBER OF

Compressortech 2 ( ISSN 1085-2468) Volume 18, No. 7 Published 10 issues/year (January-February, March, April, May, June, July, August-September, October, November, December) by Diesel & Gas Turbine Publications, 20855 Watertown Road, Waukesha, WI 53186-1873, U.S.A. Subscription rates are $85.00 per year/$10.00 per copy worldwide. Periodicals post-age paid at Waukesha, WI 53186 and at addi-tional mailing offices. Copyright 2013 Diesel & Gas Turbine Publications. All Rights Reserved. Materials protected by U.S. and international copy-right laws and treaties. Unauthorized duplication and publication is expressly prohibited.

Canadian Publication Mail Agreement # 40035419. Return Undeliverable Canadian Addresses to: P.O. Box 456, Niagara Falls, ON L2E 6V2, Canada. E-mail: [email protected]. POSTMASTER: Send address changes to: Circulation Man ager, Compressortech2, 20855 Watertown Road, Suite 220, Waukesha, WI 53186-1873 U.S.A.

Featured Articles 16 The Next Generation Of Turbo Gearboxes 30 Universal AET Acquires Ojibway Enclosure Systems 32 MAN Expands Industrial Steam Turbine Line 40 Dresser-Rand, Honeywell Merge Turbo Control Systems 48 More Turbomachines Turning To Active Magnetic Bearings 52 Full-Load Test Of A CO2 Compressor 60 SEC Triples Capacity At Its Houston Complex 62 Downhole Compressor Technology Advances 66 Dresser-Rand Marks DATUM Milestone 70 Acoustic Walls Muffle Texas Compressor Station 76 The Cost Of Reducing Fan Noise 84 UE Compression Going Strong At New Location 88 Young Company Has Decades Of Experience 96 Gearing Up For The Big Crew Change

Spotlight: South America 24 South America: The Next Frontier 38 Tropicalization Is Common For Brazilian Packagers 46 Argentinas Shale Prospects Continue To Brighten

PUMPtech 28 Pumping Up The Offshore Market 42 A Case For VS4 Pumps

Departments 4 Page 4 A New Dictionary Of Process Machinery Terms 8 Global Perspective Infrastructure Sharing Could Help Indian Gas Flow 10 Meetings & Events 12 About The Business Pipeline Metamorphosis Begins In Northeast U.S. 14 Monitoring Government Mexico To Embrace Foreign Energy Companies 36 Recent Orders 36 Literature 41 Featured Products 47 Prime Movers 106 Snapshot GE Gets Contract For Snhvit Injection 108 Scheduled Downtime 109 Marketplace 110 Advertisers Index 112 Cornerstones Of Compression The Evolution Of Piston Rod Packing

COMPRESSORDedicated To Gas Compression Products & Applications

August-september 2013

Cover Designed By Marisa Roberts

CT2_AugSept_TOC.indd 1 8/26/13 1:30 PM

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AUGUST-SEPTEMBER 2013 8 CoMPRESSoRtech2

In a bid to reduce the development costs of offshore plays off Indias East Coast, Reliance Industries may share its infrastructure in the Krishna-Godavari Basin with state-controlled Oil and Natural Gas Corp. (ONGC).

On July 27, the two large Indian oil companies signed a memorandum of understanding to conduct a nine-month study on the details of the possible infrastructure sharing and the commercial terms.

Although ONGC has not publicly estimated its potential savings in capital expenditures, The Indian Express has re-ported that an internal company study had calculated the range at US$4 billion to US$4.5 billion. The cooperation also would enable Reliance to benefit from better utilization of its extensive offshore infrastructure investment.

The Krishna-Godavari Basin is home to Indias largest natural gas discovery, which Reliance made in 2002 on the deepwater KG-D6 gas block. Although technical challenges have resulted in disappointing production levels, Reliance plans to invest US$6.5 billion to restore output at the flagship offshore project an action that would be greatly helped by the governments upward revision to natural gas prices.

Reliance, Indias largest private upstream player, esti-mates that the additional investment could push production to more than 740 Bcfy (21 x 109 m3/y) nearly four times the 200 Bcfy (5.7 x 109 m3/y) average production rate from KG-D6 in April 2013.

ONGC is also expanding its presence in the prolific ba-sin. In March it announced two discoveries an onshore field with very high quality oil and a shallow-water gas/condensate find at its Saveri-1 well on block KG-OSN-2004. In July it spudded a Krishna-Godavari Basin well in 10,411 ft. (3174 m) of water, setting a world record in the process.

The firm planned to bring the offshore G-1 field on flow in August at an initial rate of 40 MMcfd (1.1 x 109 m3/d) from two wells. Production will peak at 92 MMcfd (2.6 x 109 m3/d).

ONGC has targeted the Krishna-Godavari Basin as a key growth area for the company. The G-4, KG-DWN-D and KG-DWN-E fields are expected to help boost its total natural gas

production by 212 to 318 MMcfd (6 to 9 x 106 m3/d) in mid-2017 or about 77.3 to 116.2 Bcfy (2.19 to 3.29 x 109 m3/y).

However, independently developing the necessary infra-structure to tap natural gas resources in the basin could be difficult. ONGC had planned capital expenditure of US$12.72 billion in fiscal 2012, but actual spending was nearly 60% higher.

Its capital expenditure is unlikely to fall anytime soon, particularly as it continues to expand its reach into offshore production. In March, ONGC decided to invest more than US$670 million to upgrade infrastructure along the Indian West Coast to facilitate offshore field developments. That was in addition to the US$673 million earmarked for the Mumbai High, Heera, Bassein and other offshore projects in the West.

The deal with Reliance would reduce the burden of ONGCs East Coast capital expenditure and could encour-age it to increase upstream field investments to further tap the resource potential of the Krishna-Godavari Basin. Two years ago the U.S. Geological Survey estimated that the basin could still hold 36.7 Tcf (1.04 x 1012 m3) of undiscov-ered mean gas resources and 950 million barrels of mean undiscovered liquids resources.

Indias heavily regulated energy environment remains a threat to the maximization of the hydrocarbon potential in the promising but technically challenging Krishna-Godavari Basin. Business Monitor International has reported that while the governments recent decision to double domes-tic natural gas prices was a positive development, the new price at US$8.40/MMBtu could threaten the profit margins for Indias electric power producers and risk power short-ages without a corresponding reform of electricity market prices. This situation might result in a reversal of the policy, particularly since an election is expected in 2014.

Yet without supportive natural gas prices, upstream players in the Krishna-Godavari Basin could find it hard to develop the regions resources even if the infrastructure is in place. CT2

Infrastructure Sharing Could Help Indian Gas Flow > BY ROBERTO CHEllINIASSOCIATE PUBlISHER

Global Perspective

ONGC, Reliance eye cooperation in Krishna-Godavari Basin

CT243.indd 1 8/22/13 3:54 PM

They may display a proud old name on the outside, but the driving force within the worlds best-engineered, most efficient, pipeline gas compressors is Rolls-Royce. The heritage name, Cooper-Bessemer, still carried by older machines, echoes the engineering excellence that has

earned Rolls-Royce an unparalleled reputation for quality. Today, in a business where productivity and dependability mean so much, the unsurpassed engineering experience of the past makes Rolls-Royce the compressor name of the future.

A proud past leads to a new future

Trusted to deliver excellence

Its all in the name...

Cooper-Bessemer is a registered trade name of Cameron Corporation, used under license by Rolls-Royce plc

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Meetings & Events*Indicates shows and conferences in which Compressortech2 is participating

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

SeptemberSept. 17-19*Gas Compressor Conference Norman, OklahomaTel: +1 (405) 325-3891Web: www.engr.outreach.ou.edu/gascompressor

Sept. 17-19Developing Unconventional Gas Eagle Ford Conference & Exhibition San AntonioTel: +1 (713) 260-6492Web: www.dugeagleford.com

Sept. 18-20*Wyoming Natural Gas Fair Jackson, WyomingTel: +1 (307) 234-7147Web: www.wyogasfair.org

Sept. 25-26ChemInnovations Conference & Expo Galveston, TexasTel: +1 (713) 343-1884Web: www.cpievent.com

Sept. 30-Oct. 3*International pump Users Symposium HoustonTel: +1 (979) 845-2924Web: www.turbolab.tamu.edu

Sept. 30-Oct. 3*turbomachinery Symposium HoustonTel: +1 (979) 845-7417Web: www.turbolab.tamu.edu

OCtOberOct. 2-4*power-Gen Asia BangkokTel: +1 (918) 835-3161Web: www.powergenasia.com

Oct. 6-9*Gas machinery Conference Albuquerque, New MexicoTel: +1 (972) 620-4026Web: www.gmrc.org

Oct. 7-10*Argentina Oil & Gas expo Buenos Aires, ArgentinaTel: +54 11 4322 57Web: www.aog.com.ar

Oct. 10-12China (Beijing) International Petroleum Technology Conference & Exhibtion BeijingTel: + 86 10 6273 0706 Web: www.ciptc-top.com

Oct. 22-24*Louisiana Gulf Oil & Gas exposition Lafayette, Louisiana Tel: +1 (337) 235-4055Web: www.lagcoe.com

Oct. 28-30Shanghai International Petroleum Petrochemical Natural Gas Technology Equipment Exhibition ShanghaiTel: + 86 21 36411666Web: www.sippe.org.cn/en

Meetings & Events

meetingsevents.indd 1 8/22/13 4:08 pm

Meetings & Events

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

Oct. 28-31International Rotor Dynamics Seminar Cologne, GermanyTel: +49 2267 6585-0Web: www.arla.de

Oct. 30-Nov. 1EP Shanghai 2013 ShanghaiTel: +86 10 5129 3366Web: www.epchinashow.com

NOvemberNov. 10-13*Abu Dhabi International Petroleum exhibition & Conference Abu Dhabi, United Arab EmiratesTel: +971 2 4444 909Web: www.adipec.com

Nov. 12-14*Power-Gen International Orlando, Florida

Tel: +1 (918) 831-9736Web: www.power-gen.com

Nov. 13-15Developing Unconventional Gas (DUG) East Conference & Exhibition PittsburghTel: +1 (713) 260-5209Web: www.dugeast.com

DeCemberDec. 5-8Basra Oil & Gas Conference and Exhibition Basra, IraqTel: +90 212 356 00 56 (1725)Web: www.basraoilgas.com

JANUArY 2014Jan. 21-23Offshore West Africa Abuja, NigeriaTel: +1 (713) 963 6283Web: www.offshorewestafrica.com

FebrUArYFeb. 4-7*Gas/electric Partnership Conference Cypress, TexasTel: +1 (713) 529-3216Web: www.gaselectricpartnership.com

Feb. 19-21Australasian Oil & Gas Conference Perth, AustraliaTel: +61 3 9261 4500Web: www.aogexpo.com.au

Feb. 24-27Nigeria Oil & Gas Conference Abuja, NigeriaTel: +44 20 7978 0000Web: www.cwcnog.com

mArCHmarch 19-21China International Offshore Oil & Gas Exhibition BeijingTel: +86-10-5823 6555Web: www.ciooe.com.cn/2014/en

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The U.S. shale plays continue to drive astounding pro-duction growth as infrastructure catches up with exploration and drilling. The Energy Information Administration (EIA) reported that domestic oil production in July totaled 7.5 mil-lion bbl/d, the highest monthly figure since 1991. Full year output is estimated to average 7.4 million bbl/d.

Despite the 2012 slump in natural gas prices, the North-east U.S. is forecast to double gas production by 2020. Re-search firm Wood Mackenzie says all current natural gas drilling in the U.S. is economic at prices above $4/Mcf.

So far, most of the Northeast gas is coming from the de-velopment of the Marcellus Shale. But gas drillers in Penn-sylvania are finding that the shallower Upper Devonian Shale is also lucrative. And, of course, the Utica Shale in eastern Ohio is just starting to ramp up production.

Oil output from the Utica will be dwarfed by gas, accord-ing to recent reports by the Ohio Department of Natural Re-sources. It said that Utica gas output averaged 0.035 Bcfd (9.9 x105 m3/d) in 2012, a pittance compared to the figures coming from the Marcellus. But the Utica was just getting started in 2012 as producers searched for the sweetest acreage, and output is still hampered by a lack of process-ing and pipeline infrastructure.

According to EIA data, Marcellus wells in Pennsylvania and West Virginia produce 7 Bcfd (2.0 x 108 m3/d). Thats more than 10% of all natural gas production and 25% of all shale gas production nationwide and its nearly double the Marcellus production of the previous year. A recent Stan-dard & Poors report said that the Marcellus could contain almost half of the current proven natural gas reserves in the U.S.

This powerful combination of resource, cost and location is altering natural gas prices and market trends across the nation. Gas that used to come all the way from the Gulf

Coast or western Canada to feed the energy-hungry North-east is now coming from Marcellus producers.

This has presented a major dilemma for interstate pipe-line operators. While flows through the existing long-haul pipelines to the Northeast are declining, regional pipelines must be added and compression systems reconfigured to support dramatic increases in production close to market areas especially the Marcellus shale.

Market analyst Bentek Energy predicts that by 2017 pro-duction centered around residue gas (from oil and liquids rich gas) production will lead to natural gas production in-creases of 8.4 Bcfd (2.0 x 108 m3/d) from the northeastern shales. It said that Marcellus production should reach 16 Bcfd (4.5 x 108 m3/d) by 2018.

Analysts predict that as much as 29 Bcfd (8.2 x 108 m3/d) of additional interstate transport capacity could be required through 2020, but most will be regional in nature. Natural gas liquids (NGL) and oil represent a large and growing fraction of total pipeline opportunity. An oversupply of NGL exists in the Utica and Marcellus shales, which is holding back production in the region.

Some relief will come with the first quarter 2014 comple-tion of the ATEX Express ethane pipeline that will connect the Northeast with processing facilities in the Texas Gulf Coast. And Kinder Morgan plans to convert an existing Tennessee Gas Pipeline transmission line to liquids by the fourth quarter of 2015, reversing the flow from northeast to southwest.

With continuing strong demand for shale gas compres-sors, Ariel Corp. has introduced a 5 in. (127 mm) stroke compressor to match 1400 rpm engines. The new JGF se-ries shares the same frame, running gear and cylinder se-lections as the successful JGC and JGD frames, but with a shorter stroke crankshaft.

The JGFs rod load rating of 57,000 to 60,000 lb. (25,850 to 27,211 kg) puts it at the top of the class for 5 in. (127 mm) stroke, 1400 rpm compressors. Previously, Ariel 1400 rpm compressor offerings were limited to 4.5 in. (114 mm) stroke with about 33% lower rod load rating than the new JGF provides. CT2

Pipeline Metamorphosis Begins In Northeast U.S. > By NORM ShADE

About The Business

Gas bonanza spawns new construction, compression

By NORM ShADE

Norm Shade is senior consultant and president emeritus of ACI Services Inc. of Cambridge, Ohio. A 43-year veteran of the gas compression industry, he has written numerous papers and is active in the major industry associations.

CT245.indd 1 8/22/13 3:59 PM

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Monitoring governMent

Reforms at Pemex could boost shale gas efforts

by PatRick cRow

Mexico To Embrace Foreign Energy Companies >


in a move that would have been unthinkable only short while ago, President Enrique Pea Nieto has asked congress to open Mexicos energy sector to foreign investment.that would end the 75-year monopoly that Petrleos

Mexicanos (Pemex) has held on most oil exploration, pro-duction and distribution in the nation.

to make the changes politically palatable, Pemex will re-main a state-owned company and foreign firms wont be allowed to own oil and gas reserves outright.

but foreign companies who partner with Pemex on proj-ects would get a share of any profits proportionate to their investments. in the case of U.S. firms, they could book the value of their contracts on the basis of the estimated amount of rights that they own, facilitating private financing.

in a televised address, President Pea Nieto reassured his nation that Pemex is not for sale and will not be priva-tized. Pemex will grow stronger and modernize.

if instituted, the reforms could be a major step toward developing Mexicos vast gas shale resources, opening op-portunities for more pipeline construction and more com-pression orders.

Mexican natural gas demand has been surging in recent years, forcing the nation to import a third of its gas through pipelines from the U.S. or via liquefied natural gas tankers from other nations (see COMPRESSORtech2, June 2013, p. 14).

an obvious solution to that problem has been for Pemex to exploit its scarcely-drilled shale gas zones. the U.S. En-ergy information administration has estimated Mexico has 681 tcf (1.9 x 1013 m3) of technically recoverable shale gas resources, the fourth largest in the world.

the Pea Nieto administration is clear that the energy policy changes, by encouraging joint ventures with interna-tional oil companies, would gain Pemex the technology and expertise to develop deep-water oil in the Gulf of Mexico and the complex shale fields.

in a parallel move, Pemex Director General Emilio Lozoya austin also announced the state company would establish a subsidiary for joint ventures within the U.S. again, the goal would be both to accumulate reserves and the expertise to develop shale gas and deep-water oil.

Energy Sec. Pedro Joaquin coldwell said Mexicos oil

output has fallen by 835 million bbl/d during the past eight years to the current 2.5 million bbl/d. He said the govern-ment intends to restore that to 3 million bbl/d by 2018.

we need capital, technology and knowledge, Joaquin coldwell said. we must associate with those who have them.

Pemex has long been the cornerstone of Mexicos econ-omy. it provides about a third of the governments income. according to the Pea Nieto administration, its energy liber-alization program could add a full percentage point to Mexi-cos economic growth within four years, and two percentage points by 2025.

Under the plan, the government would lower Pemexs roy-alties and license fees. to offset those losses, Pemex would begin paying income taxes on its production operations.

the national oil company would be reorganized into two divisions, one focused on exploration and production and the other on processing crude oil and natural gas into fuels and petrochemicals.

the detailed Pea Nieto proposal is due to go to con-gress in September. in order to permit private participation in a state-owned Pemex, articles 27 and 28 of the constitu-tion must be amended. that will require a two-thirds vote in both chambers of congress and then approval by a major-ity of the state legislatures.

aurelio Nuo Mayer, the presidents chief of staff, predict-ed the constitutional amendments and secondary legislation would be approved by the end of the year. No major road-blocks are in sight and both the major parties back the reforms.

Even though the powerful Union of Petroleum workers, which represents Pemex employees, may not enthusias-tically support the measures, it isnt expected to oppose them either.

Sec. Joaquin coldwell said no layoffs are expected at Pemex as the result of foreign participation. but they must occur eventually if Pemex is to function more like an inter-national oil company and less like a government entity.

Mexico citys Research center for Development report-ed earlier this year that Pemexs 151,000 workers produce 24.5 bbl/d per capita, less than any other Latin american oil company, and a third of the 76.4 bbl/d rate for Ecopetrols workers in colombia. Ct2

ct254.indd 1 8/22/13 3:59 PM

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Motortech.indd 1 7/18/13 11:33 AM

As the power and power density of rotating machines continue to increase, turbo gearboxes are approaching their limits in terms of safe and reliable operation. Some radical rethinking in gearbox design is needed if future machinery trains are not to be compromised by the capac-ity of their gear units.

Gearboxes are widely used to re-duce or increase the speed of prime movers to match these to the driven machinery. Especially in critical op-erations where redundant equipment is not installed, the gearbox is just as

important to reliability and safety as any other link in the power train.

Yet perhaps not surprisingly, many en-gineers are more interested in the driver or the driven equipment compres-sors, gas turbines, electric motors and pumps than in the gearbox, which is often treated as a commodity item.

The fact that this is possible is a tribute to the reliability of standard turbo gearboxes, which operate under punishing conditions of stress, impact and wear. Even gear experts can-not work miracles, however, and the turbo gearbox as we know it is rapidly reaching the limits of performance. It is time for something new.

Limits of conventionTraditional gear designs for tur-

bomachinery fall into two types: paral-lel shaft and epicyclic.

Parallel shaft gearboxes have two shafts, each carrying a single gear. They are available in power ratings

up to 188,000 hp (140 MW) for small gear ratios of less than six when in-stalled, for instance, between a gas turbine and a generator. As the name suggests, the input and output shafts do not share the same axis.

Epicyclic gearboxes split the power between several planet gears which move around a central sun gear while also meshing with a surrounding ring gear. Epicyclic gears are compact and provide coaxial input and output, but are limited to a power rating of 60,000 hp (45 MW) in the demand for a gear ratio of more than six.

To understand the limiting factors in gear design we need to translate exter-nal operating characteristics power ratings and speeds into gear-specific design parameters. The main factors controlling power and speed limits are:

Pitchline velocity (PLV) the lin-ear velocity of the gear teeth;

Elastic deflection produced by

The Next Generation Of Turbo Gearboxes > New designs offer potential to debottleneck entire drive trains

BY ToME STANIc

n A technician works on a Voith power distribution gear (PDG) assembly.


Tome Stanic is head of business devel-opment and aftermarket for Voith Turbo BHS Getriebe GmbH, Germany. He holds a mechanical engineering degree and an MBA in Change Management and International Consulting from the University of Applied Sciences, Kemp-ten, Germany. He can be reached at [email protected]. continued on page 18

cT177.indd 1 8/26/13 1:31 PM

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torques and bending moments on all parts of the gearbox, especial-ly as it applies to the pinion (the smaller of the two gears in a paral-lel shaft gearbox);

Desired input and output speeds; Operating limits of the bearings

(loads and journal velocities); Factor of safety chosen for the

application.The job of the gear designer is to

find the best balance between these limiting factors, which sometimes con-flict. For instance, taking advantage of the increased speed capacity of a high-performance bearing implies an increase in the PLV, which in turn raises both the circumferential forces within the gears and the tendency for oil flow to be interrupted. In a paral-lel shaft gearbox the solution is to in-crease the center line distance (and hence the overall gear size) to create a larger lever effect.

Currently the maximum achievable PLV is 650 fps (200 m/s) and the max-imum journal velocity is 330 fps (100 m/s). The maximum bearing load is 3.45 MPa according to API 613 (para-graph 2.7.2.4), the gear standard ap-plicable to high-speed gearboxes in the oil and gas industry.

These limits mean that in some cases the gear unit becomes the determining link in the drive train. Turbocompressors, for instance, are currently restricted to approximately 47,000 hp (35 MW) by their gearbox-es, depending to some extent on the input and output speeds required.

Outside the boxIncremental design improvements,

such as the use of high-grade steels to withstand high PLVs, or an im-proved bearing design for higher jour-nal velocities, boost the capabilities of conventional gear units.

The resulting improvements are small, however, and the tweaked gearbox is still operating at its limits. Also, of course, it is a bad idea to be using what are essentially prototype gear units running in unproven areas of the speed-power chart.

An alternative to waiting for incre-mental improvements in materials science is to use an alternative gear design with a split power path. Such an approach overcomes the limiting parameters controlling the teeth and bearings of conventional gear types.

Most importantly from the point of view of the plant designer, it removes the bottleneck imposed by current gear designs on the power limits of entire turbomachinery chains.

Splitting the power path to create a power distribution gearbox (PDG) al-lows the speed limit for a given trans-mission power to be increased and con-siderably eases the bearing problem.

The limiting factor in the design of a PDG becomes the toothing: the speeds at which the teeth mesh and the heat generated there, mainly through com-pression of a mixture of oil and air. PDGs can currently be designed for power ratings up to 228,000 hp (170 MW), output speeds up to 100,000 RPM, and gear ratios up to 10.

PDG design and functionThe PDG combines the simple and ro-

bust construction of parallel shaft gears with the load-splitting ability of epicyclic gears (Figure 1). The result is a gear unit which offers high power ratings, speeds and speed ratios while remaining well within critical technical limits and so pro-viding excellent safety margins.

The PDG contains three or more planet gears arrayed around a central sun pinion. Each planet gear is actual-ly a compound design whose second set of teeth meshes with a second sun pinion on a separate shaft (Figure 2). The whole arrangement acts like a two-stage parallel shaft gear, but with several advantages:

Distributing the power between several planet gears reduces tooth loads;

As with epicyclic gears, each sun pinion is supported by its planets, so no bearings are required on either the low-speed or the high-speed side;

The three planet gears are sup-ported by six hydrodynamic bear-ings instead of the four used in parallel shaft gear units;

The input and output shafts are coaxial;

Since there is no outer ring gear, as an epicyclic gearbox would re-quire, the PDG is compact.


n Figure 1. The PDG uses a planetary arrangement that can transmit more power at higher speeds than is possible with a conventional parallel shaft or epicyclic gearbox.

n Figure 2. Because the two sun gears are supported by the planets, the main input and output shafts of the PDG need no bearings.

a: Sun Pinion Slow-Speed Sideb + c: Compound Gear Planetd: Sun Pinion High-Speed Side

continued on page 20

CT177.indd 2 8/22/13 4:18 PM

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Integral double diaphragm couplings on the input and output shafts of the PDG accommodate axial, radial and angular offsets to ensure optimal power transmission and rotordynamic perfor-mance. The short axial length of these couplings reduces the overall distance between shaft ends (DBSE) between the driver and the driven machine.

Performance in critical applications

An example of a typical gas turbine- driven compressor shows how the PDG outperforms a parallel shaft gear unit in applications requiring high power density. The gas turbine speed is assumed to be 5000 rpm and the compressor speed 12,500 rpm.

Pitchline velocity: Figure 3 shows how the maximum PLV of the gear teeth varies as a function of transmit-ted power for the given input and out-put speeds.

A parallel shaft unit reaches in this case its maximum safe PLV of 620 fps (190 m/s) at a power rating of 34,900 hp (26 MW). For the PDG, the PLV curve rises more slowly, and at 34,900 hp (26 MW) its PLV is 30% lower (58 m/s lower in absolute terms) com-pared to that of the parallel shaft unit. Even at power ratings up to 87,000 hp (65 MW) and beyond, the PDG still has a PLV below 590 fps (180 m/s).

The reason for this improved perfor-mance is the smaller diameter of the planet gears in the PDG compared to the pinion gear in the parallel shaft unit. This increases the safety margin for centrifugal forces that is propor-tional to the square of the velocity di-vided by the diameter.

Journal velocity: The curves relat-ing bearing journal velocity to power transmitted (Figure 4) are quite similar to those for PLV against power. The paral-lel shaft gear cannot handle more than 34,900 hp (26 MW) before the journal velocity reaches its safe limit of around 328 fps (100 m/s). At this power rating, the PDG bearings are running at only 164 fps (50 m/s) a 100% safety mar-gin and even at 87,000 hp (65 MW) the journal velocity is no more than 213 fps (65 m/s), still well below the safe limit.

The lower journal velocities arise

because the pins (like stub axles) of the planet gears in the PDG are small-er in diameter than the radial bearings which support the pinion in the paral-lel shaft gear unit.

Bearing load: Along with pitchline and journal velocities, bearing load is the third main factor limiting gearbox performance. Figure 5 shows nearly identical bearing loads for both gear designs in our compressor example.

Even at high powers, increasing the diameter of the planet pins keeps the

PDG bearing loads below the maxi-mum of 3.45 N/mm2

set by API 613. These pins function as fixed profile sleeve bearings, and are proven in the more than 8000 epicyclic gear units supplied by Voith. Bearing loads are also reduced because the PDG has six bearings (two for each planet gear shaft) compared to the four supporting the gear set of the parallel shaft gear.

Efficiency: Especially in the oil and gas industry, reliability, safety and


n Figure 3. The PLV in a PDG remains below the 656 fps (200 m/s) safe limit for power ratings up to 87,000 hp (65 MW) and more. The traditional parallel shaft gear, on the other hand, tops out at a power rating of 34,900 hp (26 MW).

n Figure 4. Bearing journal velocities tell a similar story: where parallel shaft gears are limited to 34,900 hp (26 MW) in this application, the PDG maintains acceptable journal velocities up to 87,000 hp (65 MW) and more.


CT177.indd 3 8/22/13 4:18 PM

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reason for its lower efficiency is the higher temperatures in the high-speed bearings of the pinion shaft, which in turn require more oil for cooling.

When to use a PDGAs we have seen, splitting the pow-

er path gives the PDG more head-room in all three of the main param-eters PLVs, journal velocities and bearing loads which limit power transmission in conventional parallel shaft gears. Lower stresses and tem-peratures make the PDG more reli-able, and its efficiency remains high.

However, the higher complexity of

Close to its maximum power, the parallel shaft gear shows reduced ef-ficiency. The efficiency of the PDG re-mains higher even at power ratings up to 87,000 hp (65 MW).

Oil consumption: Also interesting to compare is the oil consumption of both gear units, since this affects the capital cost of the lubrication system.

At its power limit of 34,900 hp (26 MW) the parallel shaft gear uses more oil than the PDG (Figure 7) because of its high PLV and especially because of the higher bearing journal velocity.

Although the parallel shaft gear has fewer bearings than the PDG, one

availability of machinery are rightly the most important operating charac-teristics. But as operators also come to focus on the cost of energy and cutting CO2 emissions, efficiency also plays a role.

As with the other criteria, in terms of efficiency the PDG rivals the parallel shaft design (Figure 6). As the paral-lel shaft gear approaches its limit of 34,900 hp (26 MW), losses increase significantly, and at 34,900 hp (26 MW) the efficiency of the PDG is 0.7% high-er. Even more importantly, the PDG re-tains its efficiency of nearly 99% even when transmitting 87,000 hp (65 MW).

n Figure 5. With the right choice of pin diameter for the planet gears, bearing loads in the PDG remain below the API limit even at high powers.

n Figure 6. Close to its maximum power, the parallel shaft gear shows reduced efficiency. The efficiency of the PDG remains higher even at power ratings up to 87,000 hp (65 MW).

CT177.indd 4 8/22/13 4:18 PM

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rupt external lubrication and prevent the sun gears from getting enough oil. Special oil baffles are needed to tackle this problem, and there is room for further improvement.

As a result, the PDG is best suited to applications requiring high power density, where traditional gear de-signs are approaching the limits of feasibility. In such cases it offers some compelling advantages.

In particular, this new gear design brings opportunities to debottleneck drive trains in which the gearbox has previously been the limiting fac-tor. Gas turbine-driven compressor trains, for instance, can now use larger compressors, and gas turbine models that up to now have been used mainly for power generation can find new applications as com-pressor drivers. ct2

a PDG compared to a parallel shaft gear unit means that some design as-pects have to be considered carefully.

To ensure sufficient tooth lubrica-tion, for instance, the planet gears require internal oilways as well as ex-ternal flush lubrication. The relatively high ventilation within the gearbox cre-ated by the rotating suns and planets, which is at least proportional to the square of the velocity, also can dis-

n Figure 7. The PDG requires somewhat less oil than the parallel shaft gear, and oil consump-tion increases linearly with power rating.


CT177.indd 5 8/23/13 8:40 AM


The United States has made headlines in recent years for the abundance of shale gas beneath its soil. As oil and gas com-panies continue to tap into those re-sources, some gas compressor pack-agers also are paying more attention to Latin America.

My focus this year is to expand our business opportunities and our name recognition in South America, said Tom Sawyer, the director of International Business Development for SEC En-ergy Products and Services. I probably communicate with my South American contacts several times a week.

Sawyer and SEC are not alone. Sev-eral packagers already have a pres-ence in the continent, viewing it as the next frontier in the shale gas revolution.

South America: The Next Frontier Gas compression packagers set sights on market potential

By DJ SLATEr

Valerus shipped these 6X 7044GSI Waukesha Cooper MH64 packages, rated at 10,080 hp (7517 kW) to Congonhas, Brazil, in 2009.

But even with the glut of shale gas and oil resources in South America, those same packagers are proceeding with caution as the political and economic landscapes develop.

Things down there are driven much more dramatically by politics, Sawyer said. Argentina, for example, has tre-mendous oil and gas shale reserves. The problem is that the economy and the current political situation make it very difficult to do business there.

For example, last year Argen-tina President Cristina Fernndez de Kirchner announced that Argentina would nationalize yPF, the nations major oil company. The government said yPF, owned by repsol of Spain, had not invested enough to develop Argentinian oil and gas resources.

The action created a backlash from Spain and the European Union, and left packagers uneasy about doing business in the area, Sawyer said.

When that (nationalization) hap-pens, it throws up a huge red flag, Saw-yer said. Theres no lack of opportunity. Theres a lack of a favorable business climate there. Theyve got lots of poten-tial, but also a lot of issues.

Even when business conditions arent favorable, Sawyer said SEC, as well as other packagers, shouldnt cease their operations. you have to be there, because it will turn around, he said. The main thing is to have a presence and keep a finger on the pulse of the opportunity in Argentina.

The governments yPF strategy

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has shown some signs of success. In July, Chevron Corp agreed to in-vest US$1.24 billion to help YPF de-velop oil and gas reserves in the Vaca Muerta shale.

To pave the way for the deal, the government decreed that companies could export, tax free, up to 20% of their oil and gas production.

In addition to Argentina, other areas in South America have potential for a shale gas revolution. Patricia Martinez, the vice president of Latin America for Valerus Compression Services, said theres a wave of development in Bra-zil and Mexico, particularly with natural gas pipeline and infrastructure projects, as well as initiatives to reduce flaring.

In the last 10 years, weve seen a great deal of industry deregulation in Latin American countries, Martinez said. The energy space was previ-ously dominated by the national oil and gas companies, but now were seeing independent oil and gas com-panies flourishing.

This shift has been very positive for our business, creating an environ-ment that we havent seen before. The market is much more competitive. You dont have to be a multibillion dollar company to compete.

Still, this activity is not without its

share of challenges. Martinez said the economic growth in the region is frag-ile, making the business environment unpredictable. Another challenge has been the concerns about the environ-mental effects of shale gas recovery.

The common production practice of hydraulic fracturing has received nega-tive coverage from the media and some nations, such as France, have banned it. The fracking procedure uses water, sand and chemicals at high pressures to fracture shale and release the gas.

South American governments are in the early stages of studying the environmental impact of fracking, Martinez said.

At the end of the day, each country makes its own decisions and regula-tions, she said. Martinez added that the Latin American shale gas industry is still at a very early stage and is at least 10 years behind the U.S.

The concern over environmental im-pacts has worked out favorably for Fore-most Brahma Ltd. (Brahma Compres-sion), a Calgary-based gas compressor

packager specializing in the sub-400 hp (300 kW) segment. The company has found a niche in South America with its vapor recovery units (VRUs).

Thats our biggest product in South America, General Manager Don Schafer said.

Flaring gas has been huge in South America forever, he said. Now, more and more countries are starting to disal-low flaring. That gas is going to be cap-tured and brought into the gas lines.

Schafer added that the continents collective environmental conscious-ness works out well for packagers be-cause many of the concerns can be solved with compression technology.

Brahmas South American presence extends to several nations, including Colombia, Argentina, Ecuador, Mexico and Brazil. Its customers are mainly government-owned and operated oil companies such as Ecopetrol in Colom-bia and Pemex in Mexico.

Not everything runs smoothly for Brahma in South America. The con-tinents technology is behind the advancements made in the United States and Canada, Schafer said, and projects dont progress at a swift pace.

Any and everything that happens is slow moving, he said.

Geographical challenges also play

Brahma Compression uses 20-ft. (6 m) long shipping containers as the base floor and enclosure for its vapor recovery units. The finished packages are shipped inside the containers.

Spotlight:

CT248.indd 2 8/27/13 9:50 AM


a role. While Brahma has representa-tives in each of the countries where it conducts business, the company cant avoid the costs of transporting equip-ment to its customers.

There are not a lot of local compres-sion fabrication companies in South America, Schafer said. Thats why they come to us to do it. When our custom-ers have to pay to have our compres-sor packages shipped from Canada to South America, its an added cost.

He also noted a lack of diversity among Brahmas competitors in South

America. Schafer said hes seen the same U.S. and Canadian companies opeating in South America over the years without much change.

Positive change, though, is what many gas compressor packagers pre-dict for the continent in the decade to come. Martinez, like Sawyer and Scha-fer, is encouraged by the areas poten-

Brahmas containerized vapor recovery units have gained popularity in the South American marketplace as environmental concerns have grown.

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tial. Valerus Compression Services already has its resources in multiple projects in Latin America. The projects are in their infancy, but Martinez said theres plenty of room for growth.

There is a huge promise (for busi-ness) for the decade to come, she said. In my view, the industry has yet to see the promise of the shale re-sources tied up in Latin America.

Prior to 2013, Sawyer wasnt able to think about being entrenched in South America because SEC, an OEM packager for Caterpillar, GE Wauke-sha and Ariel Corp., was in the midst of an expansion to triple the size of its Houston facilities.

With that expansion near completion, Sawyer said he can now monitor South America and tap into the potential hes seen evolve over the past 20 years.

Were in a position to more readily produce equipment for areas outside the U.S., he said. We are going to start being more active in the South American marketplace.

Sawyer added that SEC is working on establishing relationships and proj-ects in Peru, Argentina and Venezuela.

I see tremendous opportunities for us down there, he said. Its just not something thats going to happen overnight. CT2

CT248.indd 3 8/22/13 4:48 PM


Sulzer is putting more of its API 610 pumps into the offshore seascape. The company re-ceived two orders for its pumps that will be used in floating production stor-age and offloading (FPSO) vessels on opposite sides of the world.

The first order calls for Sulzer Pumps to supply 69 pumps to Daewoo Ship-building and Marine Engineering. The pumps will be installed on a FPSO for the Inpex-operated Ichthys LNG proj-ect in the Browse Basin offshore West-ern Australia. The order is scheduled for delivery in several phases, span-ning from this year until mid-2014.

Sulzer Pumps South Korea will un-dertake the full project management and complete unit testing, while Sul-zer Pumps Customer Support Ser-vices, based in Western Australia, will handle offshore commissioning and eventual servicing of the equipment.

Various API 610 pumps, including OH3, BB2 and BB5 types, will be sup-plied for topside and hullside process and utility applications aboard the 1100 ft. (335 m) vessel. The pumps

will be made at various locations in the Sulzer Pumps global manufactur-ing network, with 40% of the pumps packaged at the companys Busan, South Korea, facility. Established in 2011, the packaging facility performs engineering, packaging and testing for bare shaft pumps and compo-nents, Sulzer said.

The second order has Sulzer sup-plying 42 pumps for two FPSO vessels,

P-66 and P-69, under a contract from Keppel FELS Brazils affiliate Lindel. The FPSOs operate in the pre-salt Iracema cluster areas in the Santos Basin, off the coast of Rio de Janeiro, Brazil.

Petrobras-led consortium Tupi chose Keppel FELS Brasil for the fabrication and integration of the vessels. With the contract, which includes pump pack-ages for sea water lift, water injection and auxiliary services, Sulzer will sup-ply pumps to eight FPSOs currently un-der construction for Petrobras and more than 1300 pumps in service for the companys offshore operations in Brazil.

Sulzer said the water injection pump packages contain API 610 BB5 pump models driven by 5.5 MW electric motors, while the sea water lift pump packages have vertical pumps run by 960 kW submersible electric motors. Other pumps are used for various auxiliary services, such as cooling water circulation, hot water circulation and water injection pump boosting.

Scheduled for delivery in 2014, the pump packages will be built at Sulzers manufacturing and distribution center in Jundia, So Paulo, Brazil. CT2

Pumping Up The Offshore Market > Sulzer supplying more than 100 pumps

through two orders

PumP tech

n The FPSO vessels P-66 and P-69 will receive 42 pumps from Sulzer. The FPSOs operate in the pre-salt Iracema cluster areas in the Santos basin, off the coast of Rio de Janeiro, Brazil.

Photo courtesy of INPEX

n Sulzer Pumps API 610 OH3, BB2 and BB5 type pumps will be installed on a 1100 ft. (335 m) FPSO vessel for the Inpex-operated Ichthys LNG Project in the Browse Basin offshore Western Australia.

CT256.indd 1 8/26/13 1:34 PM

Insight onsite.

Harsco.indd 1 7/19/13 8:33 AM

Universal Acoustic & Emission Technologies has purchased Ojibway Enclosure Systems, a manufacturer of enclosures and pack-ager of generator sets.

Universal provides engineered acoustic, emissions and filtration solutions for the oil and gas, power generation and other industrial mar-kets. The move brings enclosure and light-gauge fabrication capabili-ties to Universal, creating a single-source provider of air inlet and ex-haust systems, ducting, diffusers, enclosures and other components used on a turbine system.

In addition to its enclosure expertise, Ojibway allows Universal deeper pen-etration into the oil and gas market.

A good portion of our business is serving customers who utilize turbine systems that are used on compres-sor stations, said Ron Jake, marketing manager at Universal. A turbine sys-tem has a number of inlet and exhaust air-handling components, which we de-sign and manufacture. But we did not have the enclosure piece of it. A lot of

our turbine customers were asking us to quote an enclosure with their package.

Enclosures are an Ojibway skill set. Its a different, lighter-material gauge than what we are used to work-ing with the thicker, heavier-gauge metals for silencers.

The acquisition gives Ojibway im-mediate access to Universals exper-tise for designing noise control, emis-sions and air filtration products.

We have been a customer of Uni-versal for many years, said Debbie Schilling, senior business develop-ment manager at Ojibway. As part of our gen-set enclosure packaging, we install the engine silencers inside the enclosure packages.

Jake said, Ojibway allows us the opportunity to provide a much more complete package for recip engines and turbine customers. We can be a one-stop shop. Customers dont have to look for multiple suppliers. We can provide a complete solution from the turbine inlet to the exhaust, or a com-plete standby generator set package.

As of July 1, Ojibways products are

branded Ojibway Enclosures by Uni-versal. According to Universal, all em-ployees will be retained and will con-tinue to work at their current locations. The combined companies will have a workforce of 350.

Universal and Ojibway share com-mon customers including Caterpillar, Cummins, MTU and other prominent engine distributors.

Universal AET and Ojibway are now in a better position to serve their cus-tomers: engine distributors who source silencers, emissions treatment products or complete power generation packag-es for data centers, hospitals and other large-scale facilities that require standby power generators, Universal AET Exec-utive Vice President Dick Strojinc said.

Engine distributors will seek either a complete enclosed genset package, which is Ojibways core competency, or components of a system, which are Universals products. Now that Ojibway will be part of Universal, our staffs can work together seamlessly, and our customers projects will be managed by just one contact. CT2

Universal AET Acquires Ojibway Enclosure Systems > Creates complete inlet to

exhaust capabilitiesBy BRENT HAIgHT


n A Universal Puck Silencer is shown in an Ojibway enclosure.

CT244.indd 1 8/22/13 4:54 PM

KB_Delta_June.indd 1 5/23/13 8:10 AM

MAN Diesel & Turbo (MDT) offers the industrial mar-ketplace a line of industrial steam turbines tailored to meet spe-cific applications, with a particular em-phasis on compressor drive.

These steam turbines are designed and manufactured in Oberhausen, Ger-many, with capability up to 161,000 hp (120 MW) and in Hamburg, for up to

53,640 hp (40 MW). They are assem-bled in Changzhou for the Chinese mar-ket, one of the fastest developing busi-ness areas for the German company.

The increasing size and power re-quirements of the compressors made at Oberhausen and Zurich has im-posed a parallel development of their steam turbine drivers.

The steam turbine has to meet the

power and speed required by the compressor, but above all, it has to make an efficient use of the steam produced by the exothermic process in which the compressor is operating.

In many cases the process steam is not the ideal for a steam turbine, explained Klaus Behnke, vice presi-dent and head of engineering steam

MAN Expands Industrial Steam Turbine Line > Units are tailored to match increasingly large and powerful compressors

By ROBeRTO CHellINI

n Man Diesel & Turbo makes two different steam turbines, one rated at 161,000 hp (120 MW) and the other rated 6300 hp (4.7 MW), with the same modular turbine setup.



CT232.indd 1 8/22/13 4:57 PM

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MDT said the selection of a steam turbine to serve as centrifugal com-pressor driver can be achieved ac-cording to two different criteria.

One is to reduce to a minimum the number of casings of the compressor train by eliminating the gearbox. In this case the steam turbine speed has to match the compressor speed.

The other is to reduce costs by using smaller compressors as well as steam turbines that directly coupled and rotat-ing at the same high speeds.

This solution also allows savings in weight and footprint and is mainly re-quired for offshore platform applications.

In refinery applications, the steam turbine is often operated with ag-gressive steam. In these cases the steam has to be carefully analyzed and the materials used in the ma-chine, especially rotor blades, have to be selected accordingly. When the steam is moderately aggressive, it may be convenient to use special

turbines for the process industry at MDT Oberhausen.

Behnke said in gas-to-liquids and coal-to-liquids plants, the steam is available at about 290 psi (20 bar) and 428F (220C). At purified terephthalic acid (PTA) plants it has lower values: 43.5 psi (3 bar) with side steams just below 14.5 psi (1 bar). The increase in power outputs requires the turbine to handle enormous flows of steam.

MDT steam turbines are available in modular construction. A line of standard inlet and exhaust casings are selected to match the steam inlet and exhaust conditions and matched with intermedi-ate casings developed for the specific job, together with the necessary admis-sion and/or extraction nozzles.

The intermediate casing allows the combination of the high-pressure tur-bine with the medium-pressure one, in practice eliminating one turbine body. A row of variable guide vanes (VGV) can be placed in the intermediate pressure admission to increase the operating range of the machine.

Behnke said the MDT line of indus-trial steam turbines includes units that have special characteristics that are not commonly available.

They can handle high-pressure, high-temperature steam, 2030 psi (140 bar) and 1000F (220C) in small applications. These often are at refin-eries running compressors at 14,000 rpm to handle heavy gases.

Their wide load management al-lows the machine to operate when the process requires the sudden shut off of steam valves to comply with process parameters.

materials to prolong the service life of the machine.

If the steam is strongly aggressive (containing sulfur components) experi-ence has shown that the use of expen-sive materials will not avoid corrosion. In such cases it is economically more attractive to use standard materials and plan to replace the entire rotor ev-ery two to three years of operation.

MDT said the efficiency of a con-densing steam turbine is strictly re-lated to the vacuum achieved by the condenser. When water is available on site, a water-cooled condenser is the choice. In dry areas, an air cooled condenser can be the option.

When an air-cooled steam con-denser is selected, to maximize plant efficiency year-round and minimize steam consumption, it is essential to conduct a detailed analysis of the en-vironment with the customer.

It is necessary to know the av-erage seasonal temperatures, es-pecially in the winter and summer. Also, information on the hours of daylight and darkness are important to build the data needed to select the best solution.

Applying such knowledge, a small change in design parameters can make a great difference in the plants efficiency.

MDT constantly upgrades and ex-tends its industrial steam turbine line. A major project is underway to rede-sign of steam turbines for the direct drive of-high speed centrifugal com-pressors rated at 1340 to 13,400 hp (1 to 10 MW). CT2


n This direct-driven, compact, high-speed steam trurbine is made for refinery gas compres-sor applications.

n Variable guide vanes can increase performance significantly for extraction steam turbines.

Bearing Bush

Adjusting Lever

Adjusting Ring

Guide Rollers For Adjusting Ring

Guide Vane

Guide Vane Carrier

CT232.indd 2 8/22/13 4:58 PM

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Prognost.indd 1 6/7/13 11:25 AM


Recent OrdersDresser-Rand

Dresser-Rand has received a US$200 million contract from Apex Compressed Air Energy Storage for equipment for a 425,100 hp (317 MW) compressed-air energy stor-age (CAES) facility planned near Tennes-see Colony, Texas.

The Apex Bethel Energy Cen-ter would be the first CAES facility in the United States since the Power South facility in McIntosh, Alabama, which was built in 1991. It also contains Dresser-Rand turbo machinery.

A CAES system provides two different services either sequentially or concur-rently high-pressure air compression and electric power generation derived from expanding the compressed air. More than 40 such projects being considered across the U.S., many of them linked with wind and solar power farms.

SiemensSiemens Energy will supply Hangzhou

Zhongtai Cryogenic Technology Corp.

the compressor trains for three lique-fied natural gas (LNG) plants, the fifth follow-up order for Siemens from the Chinese company.

The trains, which compress the mixed refrigerant that cools the natural gas, each consist of a six-stage, verti-cally split, barrel-type compressor and a Siemens constant-speed electric motor. Siemens said this type of drive and control using inlet guide vane as-semblies provides more efficient and reliable operation than conventional compressor solutions with throttle valve or speed control.

The equipment will be entirely fabricated, assembled and packaged with the drives in Huludao, China. Sie-mens said it has developed and uses a pre-engineered compression concept for medium sized LNG plants.

The synthetic LNG plants each will have a capacity of 500 MMcfd (14.1 x 106 m3/d). Delivery of the equipment is due in June 2014. CT2

REEal improvement of your compressors

Ever worried about the reliability, energy efficiency and environmental soundness of your compressors? REE R

elia

ble Eff cient

Environmentally s

ound

10

9

8

7

6

5

4

3

2

1

0

For more information:

[email protected]

The continuous improvement of compressors is fundamental if plants are to meet

modern demands in terms of run cycle, energy effciency and enivronmental compliance.

In order to do this, clear data on the real performance of your compressor is required.

The REE Assessment carried out on-site by HOERBIGER senior compressor experts

ranks your equipment using the REE index. It allows you to see where there is potential

for improvement and savings, helping you to choose the right technology and make the

right business decisions. www.hoerbiger.com

Visit us at the

42nd Turboma

chinery

Symposium in

Houston, booth 15

01

Hoerbiger.indd 1 8/15/13 10:05 AM

Rotary Lobe Pumps

A brochure from Netzsch provides information on its Tornado rotary lobe pumps including photos and char-acteristics. The pumps have flow rates up to 35,315 cu.ft./hr (1000 m3/h) and pressures up to 145 psi (10 bar). A section on pump accessories is also featured.

www.netzsch.com

LiteRatuRe

CT253.indd 1 8/26/13 2:33 PM


REEal improvement of your compressors

Ever worried about the reliability, energy efficiency and environmental soundness of your compressors? REE R

elia

ble Eff cient

Environmentally s

ound

10

9

8

7

6

5

4

3

2

1

0

For more information:

[email protected]

The continuous improvement of compressors is fundamental if plants are to meet

modern demands in terms of run cycle, energy effciency and enivronmental compliance.

In order to do this, clear data on the real performance of your compressor is required.

The REE Assessment carried out on-site by HOERBIGER senior compressor experts

ranks your equipment using the REE index. It allows you to see where there is potential

for improvement and savings, helping you to choose the right technology and make the

right business decisions. www.hoerbiger.com

Visit us at the

42nd Turboma

chinery

Symposium in

Houston, booth 15

01

Hoerbiger.indd 2 8/15/13 10:05 AM

Gas Supply System

EagleBurgmann offers lit-erature on its RoTechBooster gas supply system. The sys-tem is designed to provide clean gas flow. Recommend-ed applications include cen-trifugal compressors, as well as equipment in the oil and gas, refining, petrochemical and hydrocarbon industries.www.eagleburgmann.com

HGM Pump Protection

KSB has released a bro-chure on its PumpExpert, a diagnostic system for HGM pumps. The system com-bines three functions: moni-toring, diagnostics and rec-ommendations for action. It features a user display showing measured vari-ables, offers infrared data transfer to a PDA.

www.ksb.com

Dri-Prime Pump

Flygt has published a specification sheet on its FCD100M dri-prime pump. The pump offers flow rates up to 1013 gpm (3835 L/min) and discharge heads to 124.7 ft. (38 m), with the capability of handling sol-ids up to 1.8 in. (45 mm) in diameter.

www.flygt.comcontinued on page 75

Ignition Products

The 2014 edition of BG Corp.s ignition products catalog is available. Prod-ucts covered include adapt-ers, gaskets, spark plugs, and turbine components. The company caters to in-dustrial gas reciprocating and turbine engine users through a worldwide distri-bution network.

www.bgservice.com

CT253.indd 2 8/26/13 2:34 PM

Spotlight:


The tropicalization of compres-sors, modifications to make them more resistant to extreme heat, is a common practice for Brazil-ian packagers.

Much of the nations production is near the Tropic of Capricorn, where temperatures average 78F (26C) year round. Summer temperatures can be as high as 104F (40C).

Marcelo Pereira Moura is manager of oil and gas business development for Atlas Copco, which has a facility in Barueri, on the western edge of So Paulo. He said the oil circuit thermo-static valve on compressors is rou-tinely changed to adjust for the high temperatures. Its necessary to define different set points and occasionally modify the suppliers.

Tropicalization Is Common For Brazilian Packagers Siemens adapts compressors, equipment for heat

By MAuro Belo SCHneIder

Siemens held a party when it manufactured its 1000th SST 300 steam turbine in Brazil.

The technicians follow the specifica-tions of our headquarters in Belgium, but we need to change some items, Moura said. Among the changes is the fan of the cooler, increasing the airflow to generate bigger capacity.

The electrical motors are WeG, de-veloped exclusively to be used for Atlas Copco compressors, and are not sold in the market, rated at 9 to 845 hp (7 to 630 kW). Moura said they have been adequate for the operating environ-ment and are used in the oil and gas chain from upstream to downstream.

Siemens also practices tropicaliza-tion when it assembles compressor packages. The process includes several steps: installation of all the base com-ponents, from the instrumental panel wiring up to junction box; installation of

all piping, painting, testing without load; supervision of the installation and com-missioning; quality control and prepara-tion of the Manufacturing data Book; preparation for dispatch and transport; purchase activities and training.

Almost everything is changed in Brazil in our packages, except the com-pressor and coupling, said Jader Cal-das, sales manager at Siemens. When the packages are used with the steam turbine, they are totally manufactured in our Jundia plant, in So Paulo.

As with other foreign-based com-panies, it also has to meet Brazils re-quirements for indigenous content in equipment. The amount depends on the project.

Siemens supplied compression trains for four floating production,

CT250.indd 1 8/22/13 5:14 PM


Spotlight:storage and offloading vessels (FPSOs) for the Cesso Onerosa petroleum exploration area, where the percent-age of local content for motor driven compressors varied from 38% for the first one to 49% for the fourth. For the turbocompressors, it varied from 22 to 32%. Caldas ex-plained that the percentages are negotiable.

There was a situation once when we needed to buy lo-cally the electric motors, base, tubing and valves because it was specified in the business, Caldas said. For other proj-ects, its normally not mandatory.

Siemens compressor packages are mostly used in refiner-ies and offshore facilities in Brazil. The compressors are im-ported from the companys Duisburg, Germany, manufactur-ing plant and are packaged at its Jundia plant in So Paulo state. If the company wants to maximize the local content, just the compressor, coupling and some other minor compo-nents must be imported.

Caldas said Siemens makes steam turbines in Brazil and packages them at the Jundia plant. Used to generate en-ergy, the equipment is also in demand by industries such as oil and gas, chemicals, mining and metallurgy, cellulose, food and others.

For powers above 134,100 hp (100 MW), they are made in Germany. The gas turbine drivers are manufactured in Lincoln, England, and Finspng, Sweden. Alternative com-pressors are packaged at Siemens plant at Elblag, Poland. Siemens also uses Ariel compressors.

The compressors in Siemens packages are centrifugal and axial, following API 617 and API 672 requirements. Discharg-es are up to 1450 psi (100 bar), volume and flow up to 46 MMcf/h (1.3 x 106 m3). Lubrication can be forced or none, such as with model STC-ECO, which has magnetic bearings.

Siemens uses steam turbine, gas turbine, electric motor and turboexpansion drivers. Depending on the demand, the company can apply emission controls and sound attenuation.

Siemens will invest US$600 million in Brazil through 2016, said Welter Benicio, oil and gas division director at Siemens, when the company announced the acquisition of Expro Holdings UK.

The news impacts directly the companys businesses in Brazil, which is considered the largest center of subsea oil and gas applications in the world a market that might reach 2 billion globally through 2020. One of Siemens main focuses will be to increase the Brazilian content of the products it offers.

The company said its Jundia plant has the only Schenck DH7/DH50 high-speed balancing machine in South America. The service for balancing turbine rotors and compressors in high speed was previously only done in Europe and would take 90 days. Since the machine was brought to Brazil three years ago, this time was reduced to one month. It is available to all operators of rotating equipment. CT2

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CT250.indd 2 8/22/13 5:15 PM

Dresser-Rand said it will em-bed its proprietary anti-surge control and load-sharing pro-grams into the Honeywell Experion C300-20 controller and will manufac-ture turbomachinery systems using the Honeywell device.

The companies said the cooperation combines Dresser-Rands centrifugal compressor knowledge and experi-ence with Honeywells Experion Pro-cess Knowledge System. The single integrated platform will give plant man-agers control of not only turbomachin-ery but also all other plant equipment.

The companies said the unified platform would deliver turbine control, compressor automation, compressor anti-surge protection, and plant and

safety controls. The open platform can be easily maintained and upgraded if necessary, improving process visibil-ity and safety.

The Dresser-Rand/Honeywell so-lution provides common spare parts and maintenance, eliminates the need for hardware-specific technician train-ing, improves productivity and allows for easy expansion.

The firms noted that one of the most effective ways to improve the perfor-mance of turbomachinery, which is es-sential to refining and petrochemical op-erations, is through control algorithms.

Dresser-Rand said its anti-surge control and load-sharing programs have been shown to improve produc-tion, simplify maintenance and reduce

energy consumption. It has made and installed more than 3000 turboma-chinery control systems since 1958.

The company said its anti-surge control inherently compensates for variable gas conditions and prop-erties, eliminating unnecessary re-cycle flow and associated losses. Its compre