FLEXIBLE SPEED CONTROL TRUMP GATHERS TEAM REVERSE ROTATION

ALTRONIC GOVERNOR CONSERVATIVE, PRO-GAS CENTRIF SHUTDOWN

JANUARY-FEBRUARY 2017

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January-February 2017

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

Featured Articles
12 Pruftechnik Developing New Condition Monitoring Option
16 AXH Air-Coolers Completes Major Expansion
20 Caterpillar Derives Power From The Cold
22 New Technology For Turbo Gears
26 Exhaustive Engineering
Cover Designed By 44 One-Stop Box
Alyssa Loope
46 Altronic Finds Speed Control Flexibility
COMPRESSORtech2 (ISSN 1085-2468)
Volume 22, No. 1 Published 10 issues/year
48 Voltage Problem Protection
(January-February, March, April, May, June,
July, August-September, October, November,
50 Extensive History Glowing Future
December) by Diesel & Gas Turbine Publications,
20855 Watertown Road, Waukesha, WI 53186-
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year/$10.00 per copy worldwide. Periodicals
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postage paid at Waukesha, WI 53186 and at addi-
34 Reverse Rotation Crops Up During Quest Project Testing
tional mailing offices. Copyright 2017 Diesel &
Gas Turbine Publications. All Rights Reserved.
54 Electromagnetic Effects On The TNFs Of A Reciprocating Compressor
Materials protected by U.S. and international
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Printed in the USA.

Canadian Publication Mail Agreement # 40035419. Departments

Return Undeliverable Canadian Addresses to:
P.O. Box 456, Niagara Falls, ON L2E 6V2, Canada. 4 Page 4 Keep It Cool
Email: ssmith@dieselpub.com. POSTMASTER:
Send address changes to: Circulation Manager, 5 Prime Movers
COMPRESSORtech2, 20855 Watertown Road, Suite
220, Waukesha, WI 53186-1873 USA. 6 About The Business Compression Market Sitting Near The Bottom
www.compressortech2.com
8 Monitoring Government Trump Gathers Conservative,
Follow @COMPRESSORtech2 on: Pro-Business Team
10 Events & Meetings
31 Literature
45 Featured Products
60 Scheduled Downtime
MEMBER OF
61 Marketplace
62 Advertisers Index
64 Cornerstones Of Compression Allis-Chalmers Horizontal Gas Engines
OPERATE AT THE NEXT LEVEL

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10
YEAR
 Page
COMPRESSOR
A Member of the Diesel & Gas Turbine Publications Group

PUBLICATION STAFF
Associate Publisher ................... Mark Thayer
Senior Editor ................................... DJ Slater
Senior Editor ................. Michael J. Brezonick
Associate Editor ........................... Klinton Silvey
4
Associate Editor ............................... Jack Burke
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Keep It Cool
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PUBLICATION HEADQUARTERS
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Telephone: (262) 754-4100 Fax: (262) 754-4175
CONTRIBUTING EDITORS
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DIESEL & GAS TURBINE PUBLICATIONS
President & CEO .................... Michael J. Osenga
Executive Vice President ....Michael J. Brezonick
I
f youre reading this from a place
where its bitter cold outside,
and you can hardly wait for the
first signs of spring, then you may
not agree with our cover headline,
Colder = Better.
Shoveling snow, scraping car win-
dows, travel delays and that bone-
deep chill that you can never quite
shake winter can really wear on
you by the time February rolls around.
We dont get much snow here in
the southern U.S. But as a long-time
Houstonian who spent his childhood
in the Midwest, I say that any day you
can see your breath is a good day! If
Jack Frost kills a few mosquitos, so
much the better.
Personal discomfort aside, the nat-
ural gas industry cheers for colder
weather. Around half the homes in
the U.S. are heated using natural gas,
and many more by electricity gener-
ated at gas-fired power plants, so a
series of strong winter storms will help
draw down the gas reserves that we
stashed away all summer.
Working natural gas in storage
reached an all-time high of 4047 Bcf
(1.1 x 1011 m3) in November, accord-
ing to the U.S. Energy Information
Administration (EIA). The record was
set largely because of a warm 2015-
2016 winter where the average tem-
perature was the highest on record
for the lower 48 states, according
to the U.S. National Oceanic and
Atmospheric Administration.
This season, the first three weeks
of December saw much colder tem-
peratures. Natural gas consumption
exceeded the previous years level
by 21% and topped the previous
five-year (2011-2015) average by
17%, according to the EIA and data
from PointLogic.
As of January 6, working natural
gas in storage was down sharply to
3160 Bcf (8.9 x 1010 m3), 10.3% lower
than the same period in 2016, but
only slightly lower (0.1%) than the
five-year average.
Natural gas prices have been vola-
tile, but averaging upward over the
last several months. For the first half
of 2016, the Henry Hub spot price
stayed below US$2.50, dipping as low
as US$1.49 in March.
Between June and October, the price
climbed from US$2.30 to US$3.25.
November was a wild ride as the price
fell to just over US$2.00 and then shot
up to just under US$4.00. Since then,
it has remained relatively high, varying
with the projected and actual changes
in temperature and accompanying
changes in supply and demand.
As I write this, there is still a lot of
winter left, and the northern part of
the country has continued to see cold
temperatures. But it has been quite
warm here in Houston.
When I get home from the office
today, Ill change into a pair of shorts.
Though, honestly, Id prefer to need a
coat. It is winter, after all. My opinion
may not be popular among folks who
live here to escape the cold and dont
pay attention to the natural gas mar-
ket, but from my perspective, colder
really is better. CT2
Mark Thayer, associate publisher
mthayer@dieselpub.com
 Prime Movers
Gas Compression Association
John Dutton (JW Power Co.) was
elected chairman of the Gas Compres-
sor Association (GCA) for 2017 at the
organizations annual fall meeting and
awards banquet in San Antonio, Texas.
Joe Avila (JW Power Co.) received
the GCAs Special Recognition Award,
honoring his work with the Health &
Safety Committee. As GCAs newest J. Dutton
committee, it collects and reports safety data from member
companies to GCA members.
Viega
Viega LLC has appointed Sean Deb-
nath as vice president of sales and
marketing. Debnath is responsible for
overseeing and managing the com-
panys sales, marketing, inside sales,
customer services and customer rela-
tions departments.
Debnath has more than 20 years of
industry experience. Prior to joining S. Debnath
Viega, he held vice president and director level positions in
sales and marketing at Kaydon Corp., Rexnord and Thermo
Fisher Scientific.
Rolls-Royce Power Systems
Andreas Schell has been appointed
CEO of Rolls-Royce Power Systems
(RRPS). He began in January, succeed-
ing Dr. Ulrich Dohle, who retired.
Schell will be leaving his current roll as
vice president, digital strategy, for UTC
Aerospace Systems. He joined UTC in
2009 as vice president, engineering, for
Aerospace Power Systems. A. Schell
Atlas Copco
Stockholm, Sweden-based Atlas Copco announced the
acquisition of the business of hb Kompressoren Druck-
luft- und Industrietechnik GmbH, a German company that
distributes and services industrial air compressors and
related systems for manufacturing and general industry.
hb Kompressoren is headquartered near Stuttgart, Ger-
many, and operates primarily in southwest Germany. About
10 employees will be joining Atlas Copco.
GE Oil & Gas
Visal Leng has been appointed president and chief execu-
tive officer (CEO), Asia Pacific, GE Oil & Gas. Leng has more
than 20 years of experience at GE, primarily in sales finance
and quality across multiple businesses in Europe and Asia.
continued on page 42

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About The Business
Compression Market
Sitting Near The Bottom
Packagers and rental fleets encouraged
by better signs entering 2017
BY NORM SHADE
A
s prices and demand for oil and natural gas re-
bounded somewhat during 2016, the outlook for
2017 is cautiously optimistic. While the flurry of new
obstacles promulgated by the Obama administration before
leaving office will not help, the Trump administration prom-
ises to encourage domestic oil and gas production and scale
back regulatory burdens. The challenge of reducing federal
regulations will be difficult.
Low oil and natural gas prices in 2015 and through most
of 2016 made business challenging for the compression
industry, but there are signs that the worst has passed.
Double-digit percentage business declines were prevalent
over the past year, but by the end of September, the rate of
decline slowed to single digits for the most companies, and
many remain tentative but hopeful for 2017.
Third quarter financial reports from a number of publicly
traded companies compared the quarter ending Sept. 30,
2016, with the same period for 2015 (year-year comparison)
and/or with the quarter ending June 30, 2016 (quarter-
quarter comparison).
CSI Compressco quarterly revenues were down 45% year-
year, but only 7% quarter-quarter. Results from other com-
panies include: Enerflex down 38% year-year; Total Energy
Services process and compression division (TES), which
includes Bidell, down 29% year-year; Natural Gas Services
Group (NGSG) down 23% year-year and 6% quarter-quarter;
Archrock down 21% year-year and 4% quarter-quarter; and
USA Compression down 13% year-year. As of December,
Exterran had not reported any financial results for 2016,
pending a restatement of past reports.
Comparing rental fleet utilization rates also reflects the
market trend. At the end of September 2016, it is estimated
that the industrys aggregate rental fleet stabilized close to
75% utilization, down from about 81% a year earlier. Fleet
utilization of smaller size wellhead compressors is gener-
ally less than larger units.
Norm Shade is senior consultant and president emeritus of ACI
Services Inc. of Cambridge, Ohio. A 47-year veteran of the gas
compression industry, he has written numerous papers and is
active in the major industry associations.
6 JANUARY-FEBRUARY 2017
Archrock reported 79% utilization for its 3,984,000 hp
(2,970,917 kW) fleet at the end of September 2016, con-
stant quarter-quarter, but down from 85% year-year. It
forecast a more stable market in 2017, benefitting from
increased demand for natural gas from LNG and pipeline
exports, petrochemical feedstock and power generation.
USA Compression reported 88% utilization for its
1,716,296 hp (1,279,862 kW) fleet, up from 86% quarter-
quarter, but still down from 90% year-year. It said that cus-
tomers are continuing to pursue projects that will require
meaningful compression.
CSI Compressco reported 75% utilization for its
1,128,329 hp (841,409 kW) fleet, down from 76% quarter-
quarter. It said that the decline in its compression fleet utili-
zation was the smallest experienced in the past four quar-
ters, which when considered in the context of improved
oil and gas prices as well as third-quarter drilling activity
seems to indicate the bottom for demand in the compres-
sion services business. It reported a modest improvement
in new compressor package orders in the quarter.
Exterran and Enerflex reported fleets of 1,181,000 hp
(880,686 kW) and 499,300 hp (372,334 kW), respec-
tively, but did not disclose utilization rates. NGSG re-
ported 196,721 hp (146,697 kW) operating, down 26%
year-year. TES reported 30% utilization for its 39,200 hp
(29,232 kW) fleet, constant quarter-quarter, but down
from 76% year-year.
Reports of new package orders have reflected a posi-
tive trend for about two quarters. Enerflex reported that its
fabrication bookings and backlog increased 57 and 34%,
respectively, year-year. It said that customers remain cau-
tious with their capital expenditures due to low commodity
prices, particularly in Canada. But it expressed cautious op-
timism as recent increases in commodity prices have led to
an increased level of inquiries and a rebound in bookings.
TES reported bookings increases of 73% quarter-quarter
and 21% year-year. NGSG commented that the rate of de-
cline in rental utilization has slowed and compressor sales
grew. It said that if present trends continue, this may be the
bottoming of the cycle, but it will be into 2017 before any
definitive recovery will be seen. CT2
COMPRESSORtech2
 Gas processing
expansion Project,
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Our customers dream was
to double production through
a major expansion project and
to do so on-time to maintain
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The motors were delivered on

schedule and were up
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Rigorous full-load testing
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Nidec ASI, turning dreams into results.

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Monitoring Government
Trump Gathers Conservative,
Pro-Business Team
Climate change, clean coal, trade issues could affect
compression firms
BY PATRICK CROW
D
espite the vagaries of the incoming Trump admin-
istration, the gas compression sector can expect a
more pro-business climate in Washington, D.C.
President Donald Trumps team will chart a more conserva-
tive course for the federal government. It will reconsider some
pending regulations and revoke some of Barack Obamas
many executive orders. More substantive changes, such as
the repeal of current laws and regulations, are less likely.
Trump will need solid help from Congress. Republicans
hold a comfortable 241-194 majority in the House of
Representatives. But their bare 52-48 edge in the Senate
may not hold together for every piece of legislation.
And Democrats will be able to filibuster some bills since
Republicans lack the 60 votes needed for cloture.
Several of Trumps cabinet appointees, like the appren-
tice master himself, are dubious about the science behind
climate change.
ExxonMobil CEO Rex Tillerson was nominated to be
secretary of state. No stranger to geopolitics, he would be
a key player in international climate change negotiations.
ExxonMobil has disputed global warming, but earlier this
year Tillerson said that the risks of climate change are real
and warrant serious action.
Former Texas Gov. Rick Perry was picked to head the
Dept. of Energy (DOE). Despite its name, it has less influ-
ence on energy production than either the Dept. of Interior
(DOI) or the Environmental Protection Agency (EPA).
Most of the DOEs funds and efforts go to managing
atomic warheads and nuclear waste sites. It also oversees
the national energy labs, sets appliance standards and is-
sues grants and loan guarantees to advance clean coal,
wind, solar and renewable fuels technologies.
The DOE has been the lead federal agency for programs
to combat global warming. Perry, though, is a climate change
nonbeliever who has advocated abolishing the department.
To many citizens of western states, the interior secretary
will be the most important figure in the government. The
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.
8 JANUARY-FEBRUARY 2017
DOI manages more than 500 million acres of federal lands.
It overseas energy leases, production and pipelines on all
public and Native American tracts.
Rep. Ryan Zinke (R-Mont.) was selected to lead the DOI.
Educated as a geologist, he advocated North American en-
ergy independence while campaigning for his House seat.
Zinke recently criticized a DOI rulemaking to reduce meth-
ane leaks from oil and gas operations on federal lands as du-
plicative and unnecessary. Regarding climate change, in 2014
he said, Its not a hoax, but its not proven science either. But
you dont dismantle Americas power and energy on a maybe.
Trumps nominee for the EPA may prove to be the most
controversial. As Oklahomas attorney general, Scott Pruitt
has been an EPA detractor, a fossil fuels advocate and a
climate change skeptic.
He joined with other state attorneys general in a lawsuit
challenging the EPAs Clean Power Plan (CPP) to cut emis-
sions further from coal-fueled power plants. Trump also
opposes the rule, which was the keystone of President
Obamas climate policy.
Trump said, For too long, the EPA has spent taxpayer
dollars on an out-of-control, anti-energy agenda that has
destroyed millions of jobs, while also undermining our in-
credible farmers and many other businesses and industries
at every turn.
He said that Pruitt will reverse this trend and restore the
EPAs essential mission of keeping our air and our water
clean and safe.
A yet-to-be-named Supreme Court nominee ultimately
may cast a swing vote that determines the CPPs fate. The
U.S. Court of Appeals for the D.C. Circuit is mulling lawsuits
challenging the program. Whatever its opinion, an appeal
to the Supreme Court is all but certain.
If the highest court overturns CPP, coal could be some-
what more competitive as a fuel for power plants, affect-
ing natural gas demand and prices. Long term, though, the
market has chosen gas over coal for electrical generation.
Trumps strong disdain for the 1994 North American Free
Trade Agreement (NAFTA) should be another concern for
producers and pipeliners. U.S. gas exports to Mexico have
quadrupled in recent years but that trend could reverse if
NAFTA is disavowed. CT2
COMPRESSORtech2
 FOCUSED ON YOUR NEEDS

Oil & Gas Natural Gas

Production Compression
With the sale of Enovation Controls, FW Murphy Production Controls
is continuing the legacy started by Frank W. Pat Murphy more than 75 years ago.
Our same traditions of customer focus, innovative ideas and reliable products carry on as we
continue to serve the Oil & Gas Production and Natural Gas Compression Markets.
ssist you.
Experienced, trusted FW Murphy personnel are on hand ready to assist
FW Murphy Production Controls remains dedicated to designing and delivering
reliable products that meet your specific needs. New Addres
s
NEW NAME
1612021 rev.1-17

SAME FOLKS
5417 S. 122nd E. Ave., Tulsa, OK 74146

www.fwmurphy.com
 Events & Meetings
Altronic_HHsprd_AS15_CT2.indd 1-2

Boldface indicates shows and conferences in which COMPRESSORtech2 is participating

FEBRUARY Norman, Oklahoma +86 10 5823 6555

Feb. 6-8 +1 (405) 325-3891 www.ciooe.com.cn/2017/en/
Iraq Oil & Gas Show www.ou.edu/outreach/engr/lrgcc_home.html
Basra, Iraq March 26-30
+ 90 21 23 56 0056 Feb. 27-March 2 SOGAT
www.basraoilgas.com Nigeria Oil & Gas Conference Abu Dhabi, United Arab Emirates
Abuja, Nigeria, Africa +971 2 674 4040
Feb. 8-9 +234 706 911 7347 www.sogat.org
Gas Electric Partnership www.cwcnog.com
Houston, Texas March 29-31
+1 (713) 529-3216 MARCH OMC 2017
www.gaselectricpartnership.com March 6-8 Ravenna, Italy
PVPC Expo 2017 +39 0544 219418
Feb. 14-16
Abu Dhabi, United Arab Emirates www.omc.it
Egypt Petroleum Show
+86 10 5165 4222
Cairo, Egypt
www.pvpcexpo.ae APRIL
+971 4 445 3781
April 4-7
www.egyptpetroleumshow.com
March 15-16 Gastech
Feb. 22-24 Global Oil & Gas Turkey Tokyo, Japan
Australasian Oil and Gas Conference Istanbul, Turkey +44 203 772 6091
Perth, Australia +44 207 596 5193 www.gastechevent.com
+61 3 9261 4500 www.global-oilgas.com/turkey
www.aogexpo.com.au April 9-12
March 20-22 GPA Midstream Convention
Feb. 26-March 1 China International Offshore San Antonio, Texas
Laurance Reid Gas Oil & Gas Exhibit +1 (918) 493-3872
Conditioning Conference Beijing, China https://gpaconvention.org

10 JANUARY-FEBRUARY 2017 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 Altronics vast experience in control system development
and production with Enbase Technologys advanced telematics and
software engineering has produced a breakthrough automation plat-
form that integrates local and remote engine and compressor control,
mobile field operations, and control room analytics.
Together, Altronics DE-3000/3000+ System plus the add-on/plug-in
TE-1000 Telematics Module comprise an innovative gas compres-
sor package platform that provides local, area, and
simultaneous long-distance monitoring and control
access to the skid.
The DE-3000 platform is known for its quality and
stability. The seamless integration of the TE-1000
Telematics Module extends that wireless functionality
and control to any enabled PC, tablet, or smartphone
via an on-board Wi-Fi server. A cellular or satellite modem connec-
tion offers the same access and control of the DE-3000 system from
virtually anywhere in the world. This includes full system configura-
tion, setpoint adjustment, and remote monitoring via
sophisticated telematics and predictive analytics.
The value of this new approach to gas compressor
monitoring and controlone that combines a stable
and proven local control with a robust, seamless
communication systemis limitless.
Contact your local Altronic Distributor for further
information on how the DE-TE package can deliver
a whole new level of value to you
and to your gas compressor
operations.

HOERBIGER Engine Solutions

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

8/20/15 1:43 PM

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

April 23-26 May 9-11 JUNE

GCA Expo & Conference Oil, Gas & Mines Africa Exhibition & June 6-8
Galveston, Texas Conference 2017 Offshore West Africa
+1 (972) 518-0019 Nairobi, Kenya Lagos, Nigeria
www.gascompressor.org +968 24660124 +1 (713) 963 6283
www.ogmaexpo.com www.offshorewestafrica.com
April 24-26
Gulf South Rotating May 17-19
Machinery Symposium June 6-9
OGU 2016
Baton Rouge, Louisiana Caspian Oil & Gas
Tashkent, Uzbekistan
+1 (225) 578-4853 Baku, Azerbaijan
+998 71 205 1818
w6ww.gsrms.org +44 207 596 5147
www.oguzbekistan.com
www.caspianoil-gas.com
April 24-27
May 23-25
Southwest Energy Institute June 13-15
Liberal, Kansas
Eastern Gas
Compression Roundtable Global Petroleum Show
+1 (620) 417-1170 Calgary, Alberta, Canada
http://swenergyinstitute.org Pittsburgh, Pennsylvania
+1 (412) 372-4301 +1 (403) 209-3555
www.egcr.org www.globalpetroleumshow.com
MAY
May 1-4
Offshore Technology May 30-June 1 June 20-22
Conference (OTC) Sensor+Test 2017 Power-Gen Europe
Houston, Texas Nuremberg, Germany Cologne, Germany
+1 (972) 952-9494 +49 5033 9639 0 +44 1992 656 637
http://2017.otcnet.org www.sensor-test.de www.powergeneurope.com

COMPRESSORtech2 JANUARY-FEBRUARY 2017 11

Pruftechnik Developing New
Condition Monitoring Option
US operations of the Germany-based company field-tested
a new online monitoring system for screw compressors

n At left, a results sample from Pruftechniks tests on screw compressors at AstraZeneca. At right, this zoom view shows the time signal
of acceleration with 130 kHz sampling rate at measurement point Bull Gear. According to Pruftechnik, this measurement demonstrates
the gear mesh frequency of the bull gear. A modulation with the speed frequency is apparently caused by misalignment or eccentricity of
the bull gear.

BY ROBERTA PRANDI

V
ibguard compact, a new vibration monitoring product
for drivetrains and rotating machinery, is Pruftechniks
latest addition to its online condition monitoring port-
folio. The new, compact version of Vibguard offers the same
performance as its existing big brother.
While the original Vibguard features 20 measuring chan-
nels, Vibguard compact offers six measuring channels for con-
tinuous monitoring of fast and highly dynamic processes. The
system can be easily integrated into the applications process
control environment using the bidirectional Modbus interface.
Vibguard compact is able to deliver continuous and de-
tailed condition overviews of all relevant machine compo-
nents, nearly in real time, Pruftechnik said.
The six analog channels of Vibguard compact were spe-
cifically developed for single aggregate monitoring and to
measure data in parallel and synchronously for continuous
acquisition. All six measuring channels are designed as high-
ly dynamic analog input channels and can be configured with
either integrated circuit piezoelectric (ICP) vibration sensors
or voltage input signals for process parameters.
In combination with speed and additional asset informa-
tion from the programmable logic controller (PLC), Vibguard
compact ensures reliable monitoring, even with frequently
changing operating conditions, Pruftechnik said.
The intelligent event recorder of Vibguard compact,
which captures, saves, and interprets large amounts of
data, makes the advantages of Industry 4.0 available to
customers in online condition monitoring and single aggre-
gate diagnostics, said Michael Stolze, product manage-
ment manager at Pruftechnik.
Vibguard compact can be utilized in combination with
Pruftechnik Condition Monitoring to develop a new condi-
tion monitoring system for simultaneous and continuous
data collection.
continued on page 14

12 JANUARY-FEBRUARY 2017 COMPRESSORtech2

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n The dominant peak in the cascade diagram assumes the pocket passing frequency (PPF) of Stage 2 at 1078 Hz, said Pruftechnik.
Pruftechniks subsidiary, the Pruftechnik, based in
Philadelphia, Pennsylvania, carried out a field test with
Vibguard compact, performing extensive function tests
in collaboration with AstraZeneca, a biopharmaceutical
specialist based in Frederick, Maryland.
AstraZeneca made available a two-stage, oil-free,
rotary-screw air compressor, which its reliability engi-
neers were already monitoring with Pruftechnik FFT-
nalyzer Vibxpert II.
Screw air compressors are an important part in the
production chain of AstraZenecas pharmaceutical prod-
ucts. Two of these compressors are available at once
and work in alternating operation. This gave us a good
opportunity to compare the vibration data and to check it
for plausibility, said Christian Kaps, senior project man-
ager at Pruftechnik Inc.
The data was transmitted via wireless modem to the
Pruftechnik Cloud Server, and data access was set up for
AstraZeneca and the Pruftechnik Cloud server, Kaps said.
The compressors run in two operating states: unloaded
and loaded with constant speed. The Vibguard compact
received a hardwired trigger signal to classify the data into
these two different states.
This was very critical because the vibration behavior
is different between the loaded and unloaded states, and
only the unloaded data were periodic enough for reliable
data analysis.
14 JANUARY-FEBRUARY 2017
Vibguard compact and Pruftechniks analysis software,
Omnitrend Center, allow for selecting up to seven operating
conditions that can be triggered by Dig Input as they were
in the test with AstraZeneca, or by parameter levels such as
speed or via Modbus.
The test period was six weeks, and we tested differ-
ent measurement configurations, Kaps said. Because
of the high gear-mesh frequencies and their harmonics of
approximately 10 to 40 kHz, we used the maximum FFT
bandwidth of 50 kHz and configured time signals with a
sufficient high sample rate to be able to recognize the
individual gear meshes.
With Vibguard compact Pruftechnik has developed a
new, very convincing online monitoring system for complex
applications, said Thomas Harris, an AstraZeneca reliabil-
ity engineer. We are planning to use this handy system for
temporary monitoring tasks and trouble shooting.
Pruftechnik Inc. recently opened a new office in San Diego,
California, just months after starting the North American op-
erations in Philadelphia.
This further expansion to California is a symbolic step in
the global growth of Pruftechnik, said Florian Buder, CEO
North America at Pruftechnik Inc. Being present at the
West Coast and East Coast of our most important market
will allow us to better support industrial operations in their
reliability efforts while keeping and building strong relation-
ships with our clients. CT2
COMPRESSORtech2
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AXH Air-Coolers Completes
Major Expansion
Company investments in facilities and development
drive significant growth

BY NORM SHADE

D
uring the gas compression industry downturn of the
past two years, AXH Air-Coolers has been busy po-
sitioning itself for an anticipated recovery in 2017
and beyond.
AXH Air-Coolers represents more than 50 years of ex-
perience and leadership in the air-cooled heat exchanger
industry, said Ken Jones, president. We encompass the
entire spectrum of air-coolers from initial sales, thermal
design and application through mechanical engineering,
design drafting, project management and manufacturing to
aftermarket support.
Jones and his partners started the company in 2001 as
Air-X-Hemphill, changing the name to AXH Air-Coolers at the
beginning of 2005 and moving operations to a 139,000 sq.ft.
(12,914 m2) facility in Claremore, Oklahoma, adjacent to
the famous Route 66. A growth average of 22% per year
over its first 15 years has resulted in numerous facility ex-
pansions. The company now features what it describes as
the largest facility complex in the air-cooler industry, with a
combined total of 556,500 sq.ft. (51,702 m2) in six plants,
located on 67 acres (27 ha).
AXH has designed and manufactured tens of thousands
of air-coolers for the natural gas compression and process
industries, Jones said. We have an extensive list of cus- n A galvanized cooler nears completion in one bay of AXHs new-
tomers including packagers, OEMs, engineering firms and est large cooler assembly building.
end users worldwide. The size and value of the average
cooler has steadily increased since 2009. We expanded During 2015 and 2016, AXH facilities grew by 177,000 sq.ft.
into air-coolers for the process and power generation indus- (16,444 m2) with the addition of Plants 4, 5 and 6.
tries over the past decade, which are somewhat counter- The large, original Plant 1, which has been expanded five
cyclic to gas compression. times since 2005, houses the offices and manufacturing of
AXHs most recent expansion, its largest ever, was set to cooler headers. A 105 ft. (32 m) HD plasma table with three
begin in late 2014 when the gas compression industry went independent CNC bridges, two 22 ft. (6.7 m) press brakes
into a major downturn. and a bead blast line are used to process steel plates into
We made a conscious decision to finish the expansion components to be welded into cooler structural frames and
started in 2014, despite the downturn, so wed be ready for headers. All weld preparations for headers are machined,
the next upturn, said Jim Lynch, vice president and gen- rather than flame cut, using five CNC bridge mills and a
eral manager. Its one of the advantages of being private five-axis CNC pipe beveller that can handle up to 20 in.
we added equipment and personnel, plus plant and of- (508 mm) diameter pipe. There are 89 individual ASME
fice space. We retained key personnel and added several code welding stations with MIG, TIG and flux core process-
strategic skill sets. We did the same thing during the less- es for carbon steel and 304/316 stainless-steel materials. In
er downturn in 2009 and were able to gain market share addition, there are seven dual and quad header submerged
quickly when the market recovered in 2010. arc machines, plus two robotic pipe-to-flange welding cells.

16 JANUARY-FEBRUARY 2017 COMPRESSORtech2

n Following major expansions completed in 2016, AXH Air-Coolers 67 acre (27 ha) Claremore, Oklahoma, complex has a combined total
of 556,500 sq.ft. (51,702 m2) of manufacturing capacity in six plants.

We are constantly looking at and trying new technology
and methods, Lynch said.
After welding, headers are moved into a 20 ft. x 70 ft.
(6 m x 21 m) vault area for radiographic testing. Next, sec-
tions are assembled and hydrostatically tested. AXH pres-
sure vessel certifications include ASME U and R, National
Board R, and Peoples Republic of China. Structural fab-
rication of cooler frames also occurs in Plant 1, which has
multiple cranes with capacities up to 30 tons (27.2 tonnes).
All material is tracked with bar codes throughout the
plants. Operators log on and off of work orders as they start
and complete operations. Visual order screens in each de-
partment allow real time visibility and tracking of component
and assembly shop orders.
continued on page 18

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n Long finned tubes are being assembled into headers in one of AXHs Air-Coolers assembly plants to make two large cooler sections.
Cooler tube lengths range from 2 to 66 ft. (0.6 to 20.0 m).
Plant 2 houses the finning operation with 10 machines
having capabilities for tubes up to 66 ft. (20 m) long. AXH
produced over 10 million linear ft. (3.05 x 106 m) of finned
tubing in 2014, its peak year of production to date. Plant 2
also features a 5 acre (2 ha) area with three 100 kW variable
frequency drives that is used for acoustic testing of coolers.
Additional overflow and growth capacity exists in Plant 3.
Plants 3 and 4 are dedicated to final assembly, run test-
ing and inspection. Plant 4, with multiple 10, 20 and 30 ton
(10.2, 20.3 and 30.5 tonne) cranes, has three parallel drive-
through bays with a 36 ft. (11 m) crane hook height that can
handle the largest coolers.
Plant 5 includes a louver manufacturing operation and
a fully automated 1000 gpm (265 L/min) stainless steel oil
flushing system that is capable of flushing three coolers si-
multaneously to meet API 614 and modified API, ultraclean
turbine OEM specs. Plants 1, 3 and 4 have a total of five
paint booths. The two newest in Plant 4, are 30 ft. x 75 ft.
(9 m x 23 m) and 34 ft. x 75 ft. (10 m x 23 m) paint rooms
with down-draft booths and open tops that are accessible
to overhead cranes. Plant 6 serves as a centrally located
warehouse for purchased components and spare parts.
We needed to add louver manufacturing to increase
capacity beyond what our traditional supplier could pro-
vide, Jones said. In the process, we decided to take the
best features of various designs and improve on them.
We validated the resulting product improvements in our
testing facility for up to 70,000 cycles, and our new louver
18 JANUARY-FEBRUARY 2017
designs have been in field service for well over a year.
AXH Air-Coolers has 18 outside sales engineer repre-
sentatives. The representatives include Air-X-limited in
Calgary, Alberta, Canada; EADS-Pendleton in Tulsa, Okla-
homa; and Westland Engineering in Buffalo, New York, and
the Long Beach, California, area. AXH cooler orders are en-
gineered and processed by a staff of six project engineers
and 12 design drafters. Thermal design rating is unique to
the application, flexible and adaptable to the customers
requirements. AXHs software includes thermal-structural
analysis, Inventor 3-D modeling, AutoCAD and HTRI/ACX.
The company offers an extensive line of air-cooled heat
exchangers that are available in a wide range of sizes,
types and models to fit many application requirements in
the natural gas compression, process and power genera-
tion industries. AXH models ZF, HF and HI are horizontal
air-coolers available in both forced and induced draft types.
Models EF, ES, FF, VI, VVF and VVI are vertical air-coolers
available with forced or induced draft. Fan sizes range from
1.5 to 18 ft. (0.5 to 5.5 m) in diameter and tube lengths
range from 2 to 66 ft. (0.6 to 20.0 m).
Standard coolers are designed to withstand 120 mph
(193 kph) winds and seismic zone 1. AXH air-coolers
include ASME code slab and box headers and AXH pat-
ented obround headers. All sections include a floating
header design, which allows at least one header to move
independently with expansion and contraction of the tubes
while maintaining proper alignment. Double-grooved tube
COMPRESSORtech2
 Recognized
Leader

n AXH Air-Coolers uses this test stand to evaluate improvements

in its louver designs. Some arrangements have been tested for up Innovator in State-of-the-Art
to 70,000 cycles. Pipe Supports & Clamps
Inventor of Flywheel Lock
sheets are standard and used on all process applications Leaders in Field Machine Work
and ASME code headers for a superior tube joint seal.
Pioneers in Casting Rapair
Single-grooved tube sheets are used on noncode head-
ers. Formed aluminum, interlocking channel-tube sup-
ports support each tube directly on the tube, rather than PRODUCTS: SERVICES:
on the fins, maintaining positive tube spacing and align- n Pipe Supports & Clamps n Field Machining

ment to prevent sag. n Epoxy Grout n Casting Repair

High-grade, split-housing, dual-taper roller bearings n Anchor Bolts n Crankshaft Machining

are standard on fan shafts and idlers, offering much lon- n Flywheel Locks n Machine Shop

ger life expectancy than the spherical or ball bearings that n Temperature & Vibration n Broken Bolt Removal

are commonly used in the industry. AXHs own aluminum Sensors n Frame Reinforcement

louvers incorporate a number of subtle improvements over n Spark Plugs n Alignment Services

typical industry louvers, the company said. All fan guards

are galvanized. Woven, vinyl-coated, polyester, bug screen
panels, which provide more than twice the fan inlet area,
are attached with either magnets or Velcro with positive
studs at the corner of each panel. As standard procedure,
all electric motor drive coolers are tested to confirm both fan
load and vibration.
Every cooler is either galvanized or receives both prime
and finish coats of high-abrasion-resistant machinery
enamel. A variety of optional primers, finishes and paint 918-252-7545
systems, as well as galvanizing, are available to withstand www.r-f.com
extreme operating conditions ranging from desert and tropi- info@r-f.com
cal to offshore and arctic environments. CT2 Tulsa, OK

COMPRESSORtech2 JANUARY-FEBRUARY 2017 19

ReynoldsFrench.indd 1 7/8/13 2:07 PM

Caterpillar Derives Power From The Cold
ABR feature provides G3600 series engines
with up to 7% boost in low temperatures

n Caterpillars G3600 A4 engines have an optional feature that allows its sensors to detect temperature fluctuations and automatically
adjust to take advantage of cooler, denser air. Pictured is the Caterpillar G3616 A4 engine.

BY DJ SLATER

T
o an engine, cold weather can be a best friend.
Cold air offers more power if the proper ad-
justments are made to maintain performance
while boosting the engines power capability. Thats why
Caterpillar developed an optional feature to instinctively
take advantage of cold-weather situations ambient
based rating (ABR).
ABR, available on G3600 A4 engines, allows the engines
sensors to detect the temperature change and automatical-
ly adjust to benefit from cooler, denser air. This process oc-
curs without the need for stopping or resetting the engine,
said Ed Porras, marketing, Caterpillar Oil & Gas.
With previous engines, you shut down the engine and
retune it when its cold to get more horsepower, Porras
said. (ABR) allows the engine to adjust up and down to
provide more power when its cooler. The engine signals
compressor controls, letting the system load the com-
pressor package to the engines full power for the actual
temperature in real time.
ABR operates by tracking charge air temperature and

20 JANUARY-FEBRUARY 2017 COMPRESSORtech2

 detecting when ambient temperatures drop. Lower charge
air temperatures mean wider detonation margin and denser
air. With more air density, there is more oxygen available
for combustion. More detonation margin and more oxygen
means more power is available to move gas.
ABR is capable of giving a G3600 A4 engine up to a 7%
power boost. While 7% doesnt appear to be a substantial
increase, Porras said that amount has significant quantifi-
able value in a gas compression package.
In a gas compression package, an engine accounts for
33% of the package cost, Porras said, adding that installed
horsepower has double the value of the entire package.
Once delivered and installed at the station, the system is
valued at more than six times the cost of the engine, he
said. Making a change even 7% can bring about rec-
ognized perks in operational effectiveness.
For example, the G3606 A4 engine is rated at 1875 hp
(1398 kW). Adding 7% boosts that amount by 135 hp
(101 kW), Porras said. If the value of horsepower is equal
to US$2000/hp, then the ABR provides US$270,000 in
capital value, he said. Extrapolating that number across a
six-engine operation brings the benefit to US$1.6 million.
This is a dynamic control system that can send a signal
to the compressor system to say it can handle more load,
Porras said. (ABR) really does present more value in the
capital sense and in ongoing production revenues.
The Cat G3600 first came about in 1990 for natural gas
applications. More than two decades later, the engine series
includes the G3606, G3608, G3612 and G3616. The en-
gines have power ratings ranging from 1875 bhp (1398 bkW)
at 1000 rpm to 5350 bhp (3990 bkW) at 1000 rpm.
The updated version of the 3600 series debuted in 2015,
offering expanded fuel flexibility and temperature capabili-
ties, as well as 5.6% power increase (see January-February
2015 COMPRESSORtech2, p. 28).
Even without the ABR, Porras said the engines are de-
signed to deliver a consistently high bhp rating in hot con-
ditions and high altitudes. With ABR, however, the engine
can do even more to move gas whenever temperatures fall
below summer highs, day or night.
I dont know what we could have done to make this a
better engine, technically speaking, he said. Weve ex-
ceeded our targets in every critical metric.
While some locations, such as Houston, Texas, dont see
the same cold temperatures as frigid locations, Porras said
the ABR still has merit, providing substantial value as com-
pared to associated costs. Caterpillar is able to evaluate
the estimated ABR value for any location, estimating annual
average horsepower gains on a site-by-site basis.
Its very satisfying that we created something thats go-
ing to contribute this dramatically to the industry, Porras
said. Its more than we hoped for. CT2

WED LIKE TO TELL YOU HOW OUR UNIQUE

OVEN PROCESS
MAXIMISES THE DURABILITY OF
DCL CATALYTIC CONVERTERS.

BUT WERE NOT ALLOWED TO.

DCL International didnt get to be a global leader without developing a secret or two.
For instance, our oven process, which, by makes a catalytic
converter element extremely durable. And we do this because longer durability means lower
cost of ownership for you. But its top secret, so our lips are sealed.
However, we can tell you that our vertical integration means expertise in every aspect of advanced emissions control technology,
which means products that work superbly well in the real, industrial world your world. So, while there are some things we have
to hide, you can learn more about DCL International products on our web site or give us a call.

1-877-965-8989 www.dcl-inc.com
U N I T E D S T A T E S C A N A D A E U R O P E
New Technology For Turbo Gears
Voiths new BHS AeroMaXX inner housing concept reduces
losses and oil consumption
BY ROBERTA PRANDI
V
oiths BHS AeroMaXX solution for turbo parallel-
shaft gears is reported to increase the efficiency of
the gear by up to 0.5 percentage points and reduce
oil consumption in the gear unit by more than 30%.
The new technology is based on a special inner housing
and optimized sleeve bearings.
A special inner housing is added in the direct vicinity of
the gear set, thanks to which cooling oil flows separately
from the lube oil, said Yvonne von Struensee-Binzer, glob-
al key account manager at Voith, in Sonthofen, Germany.
22 JANUARY-FEBRUARY 2017
n In the new BHS AeroMaXX solution
for turbo parallel-shaft gears by Voith,
the cooling oil flows separately from the
lube oil in a special inner casing.
The cooling oil absorbs heat from the external surface on
the inner housing and dissipates it into the bottom area.
The high pitch line velocities in high-speed turbo gear
units up to 656 fps (200 m/s) cause oil swirling and
oil squeezing in the gear mesh, which account for a sub-
stantial part of the power loss in these units. With the BHS
AeroMaXX technology, lubrication and cooling oil are
separated and thus losses are reduced, together with the
overall oil consumption. With this solution, a much smaller
volume of oil is required for the actual lubrication of the
continued on page 24
COMPRESSORtech2
When Minutes turn into Money
Wireless Vibration Monitoring System

Detect small problems before

they turn into BIG ones,
ANYTIME, ANYWHERE.

By monitoring equipment during transportation, the

OpsWatch system by ShockWatch provides warning
of potential damage to equipment before its installed.
OpsWatch measures both impact and low frequency
vibration to identify machine deterioration during
operation and detect potential shipping damage to
protect equipment, prevent unplanned downtime,
maximize utilization, and reduce the cost.

www.shockwatch.com 800.393.7920
 teeth contact surfaces, and the swirling of the oil and air n BHS AeroMaXX is designed for high
mixture is minimized. pitch line velocities in connection with
A test carried out by Voith on an 80,500 hp (60 MW) tur- medium- to high-powered drivelines.
bo gear between a gas turbine and generator in a power
generation application showed a power loss with the BHS
AeroMaXX of 630 hp (470 kW), against a standard power
loss of 940 hp (700 kW). In terms of oil consumption, the
test showed a consumption of 123 gpm (560 L/min) with
BHS AeroMaXX, in comparison with a standard 189 gpm
(860 L/min). In terms of oil flow, a reduction of 30% was
reported, while the power saving indicated an increase in
efficiency of 30%.
Von Struensee-Binzer said that the BHS AeroMaXX
solution has a passive-mechanical character and does
not require any additional accessories. The design
standards of the turbo unit remain the same, as well as
the overall operating behavior and the units reliability,
she said. For these reasons, the BHS AeroMaXX so-
lution is also recommended for retrofit projects. Voith
offers a warranty period of 36 months for both new
systems and retrofits, even when integrated into turbo
gears of other manufacturers.
The possibility of retrofitting an existing turbo gear is
independent of its original manufacturer, von Struensee-
Binzer said. With Voith gears as well as pre-designed
further types, retrofits can be carried out during standard
maintenance of the driveline.

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 n The passive mechanics of the system makes
the BHS AeroMaXX a good option for retrofits.

BHS AeroMaXX is designed for high pitch line velocities in connection with
medium to high powers that occur, for example, in the driveline of power plants
with compressors and generators.
In addition to the inner housing, the BHS AeroMaXX technology includes the
new BHS EcoMax sleeve bearings on the pinion shaft. These hydrodynamic
bearings are optimized specifically for the application and guarantee high-energy
efficiency with significant oil savings, said Voith.
As far as maintenance and service of the gears with BHS AeroMaXX, von
Struensee-Binzer said that an inspection window in the inner housing allows op-
erators to continue checking the condition of the tooth set without opening the top
portion of the gear housing. CT2

continued on page xx
Exhaustive Engineering
Product development and addition of heat recovery line positions
Miratech for its 25th year in engine exhaust treatment
n Miratech exhaust silencers will be installed on engines on the Rover Pipeline, an Energy Transfer interstate natural gas project to be
completed in 2017. Rover will gather gas from processing plants in the Utica and Marcellus Shales and transport 3.25 Bcfd (9.2x107 m3/d)
of gas to markets throughout the U.S. and Canada.
BY NORM SHADE
M
iratech, established in 1992 in Tulsa, Oklahoma,
has grown to be an industry provider of mission
critical emissions and acoustical solutions for
stationary natural gas and diesel reciprocating engines.
Despite the downturn in the oil and gas industry over the
last two years, the company has positioned itself to remain
in a strong position within the markets it serves.
End-user budgets have been very tight in the gas com-
pression market over the past two years, but our diversified
markets have helped us through the downturn, said David
Zenthoefer, executive vice president. We have been able
to retain our key knowledge-based people, and 2017 marks
our 25th year in business.
According to Zenthoefer, Miratech has changed from dis-
tribution to direct sales to better meet customers needs. The
companys reputation is associated with a customer centric
consulting approach, advanced engineering expertise, exten-
sive industry knowledge, project management, responsive-
ness, and quality products. Miratech is able to accommodate
both small under 300 hp (224 kW) and large up to
14,000 hp (10,440 kW) stationary engine applications.
26 JANUARY-FEBRUARY 2017
In November 2016, Miratech acquired the intellectual
property of Vaporphase, a leading supplier of heat recovery
systems for reciprocating engines in North America. The
addition of Vaporphase heat recovery capabilities will ef-
fectively round out our exhaust system product offering,
said Dean Glover, CEO. This will improve our position in
the growing market segment of combined heat and power
(CHP) plants, which act to reduce the carbon footprint over
traditional engine installations. More than 3000 Vaporphase
units have been produced over their 75-year history. This
deep installed base and focus on high quality makes them
a perfect addition to the Miratech family of products.
Although oil and gas especially gas compression
is Miratechs largest market, it also serves the power
generation, industrial (OEM and off-highway equipment),
rail and marine markets with emissions control, silencers
and accessories. In addition to the new heat recovery
line, the company has a comprehensive offering that in-
cludes all kinds of catalysts, catalyst housings, silencers,
monitoring systems and related services that address
and reduce engine exhaust pollutants such as NOx, CO,
continued on page 28
COMPRESSORtech2
PRECISION
CRAFTSMANSHIP
FOLLOW THE VALUE ADDED CHAIN BLUESTROKE
COMPRESSOR
OF AN API 618 PACKAGE @NEA TECHNOLOGY

3D CAD MODELLING: STARTING POINT FOR

A NEW 6-CRANK RECIP COMPRESSOR
Data files are exported from NEA's proprietary design
program KO3 to the CAD system to automatically gener-
ate 3D geometries and machine drawings. These CAD
files and all related information are securely stored in
the ERP system, which becomes the
knowledge hub for each manufactured
compressor part. Providing data tracking
and forecasts per click for real-time
process transparency.

NEUMAN & ESSER GROUP

www.neuman-esser.com
Manufacturing in Germany

VOC, diesel particulates, HAPs and noise. Along with its
products, Miratechs engineering team provides each cus-
tomer with customized technical solutions to their emissions
control requirements and installation configuration challenges.
Miratech catalysts provide affordable, effective, no-
hassle options for natural gas, diesel and dual-fuel engines,
Zenthoefer said. Our family of catalyst elements and con-
figurations ranges from metal foil with open metal channels
to substrates with extra turbulent zones in our exclusive
Next and Vortex element configurations. Both are better-
performing, longer-lasting catalysts and offer free washes
for life and a two-year warranty.
The washing service, provided at the Tulsa facility, in-
volves first washing the catalyst in a caustic solution that
removes inorganic masking, fouling and poisoning agents.
Another wash in an acidic solution removes organic resins,
residues and deposits from lube oil contamination. After
each of these washes, additional deionized water washes
remove the washing agents and other contaminants. After
drying and any necessary repair, the catalyst is ready for
return to service.
As Miratechs product mix has changed over the past five
to 10 years, company officials said that it has become the
largest engine silencer group in North America, providing
a comprehensive range of silencers for marine, fracking
pump and gas compression engines as well as process
plant exhaust streams. Many silencers incorporate cata-
lysts for integrated exhaust emissions and sound control. In
2014, Miratech acquired Phillips and Temro silencing divi-
sions, which broadened the company as an engine compa-
ny OEM supplier for standard box units. Exhaust acces-
sories, such as flanges, fittings, clamps, mounting bands,
piping, rain caps and guards and thimbles, are also offered.
Weve always been on the cutting edge of commercializ-
ing technologies for new regulations, said Mark McKenney,
gas compression division manager. We now look at noise
control the same as NOx, methane, hydrocarbon and other
pollutants control.
Miratechs new 60 dB(A) Quad-Tuned Silencers were
developed through two years of work with a Fayetteville
Shale customer to solve a site problem. A staff of PhD
engineers developed an advanced acoustic modelling
program along with building, testing, and then redesign-
ing, rebuilding, and retesting, prototype designs to validate
the new patent-pending technology. The chamber design
28 JANUARY-FEBRUARY 2017
n This large silencer with a tight
sound specification, being completed
at Miratechs Tulsa, Oklahoma, facil-
ity, is a Quad-Tuned solution for a
Caterpillar G3616 gas engine applica-
tion in the northeast U.S.
employs quadruple-tuned reactive components that effec-
tively control sound, allowing for higher sound attenuation
than multiple silencers in series and reducing the risk of
exhaust leaks. Field testing confirmed sound attenuation
of up to 60 dB(A). To put that sound level in perspective,
the noise measured 9.8 ft. (3 m) from the exhaust pipe of
a fully loaded natural gas or diesel industrial engine is ap-
proximately 110 dB(A). A reduction to 60 dB(A) is equiva-
lent to the noise of people talking.
Each silencer design is customized to meet the spe-
cific customer needs. A design algorithm allows tuning of
the muffler to match a specific engines environment and
application for optimal performance. These software
tools, together with bench-testing data collection, allow
Miratechs engineering team to effectively shape the ex-
haust stream inside the housing to achieve the required
sound attenuation level at an optimum pressure drop,
McKenney said.
In addition to catalysts and housings, Miratech offers
various emissions control and monitoring systems. The
systems incorporate electronic controls with human-ma-
chine interface (HMI) scenario-based design graphics to
help maintain accurate compliance. Some of the compo-
nents within the systems include SCR controllers, differ-
ential pressure monitors, air-fuel ratio controls and data
logging kits. For rich-burn engines, Miratech offers three
levels of rich-burn controllers based on the site and regu-
lation needs. Because engine loads change during the
operation of natural gas engines, the MEC-R system is
designed with a Miratech three-way catalyst to maintain
the proper air/fuel ratio over varying speeds, fuel quality,
ambient conditions, and barometric pressures. For lean-
burn engines, the Miratech MEC-L control assists with
emissions and combustion efficiency with the operation
of oxidation catalysts.
Miratechs Mira-Monitor is a continuous parametric moni-
toring system (CPMS) that helps gas and diesel engine us-
ers comply with reciprocating internal combustion engine
(RICE) national emissions standards for hazardous air pol-
lutants (NESHAP) regulations. It includes the technology
and equipment needed to monitor and record catalyst inlet
temperature and differential pressure at one-minute intervals
to comply with NESHAP CPMS requirements. It uses differ-
ential pressure as an indication of when the engine is running
and therefore when data needs to be logged. It also alarms
COMPRESSORtech2
n This Waukesha 8L-AT25GL natural gas, lean-burn gen-set with an MEC-L controller (left) is the largest test engine in the Miratech
innovation center. The SCR testing housing is shown alongside the engine. Miratech also has a 95 hp (71 kW) Caterpillar G3304 natural
gas rich-burn engine with an MEC-R controller (right). Both test arrangements have heat exchangers for controlling exhaust temperature.

when there is high exhaust temperature or differential pres-
sure. Users can configure and extract logged data reports,
which provide credible evidence of continuous compliance.
Miratechs analysis controlled injection system (ACIS)
continuously measures the NO concentration in the ex-
haust gas after a selective catalytic reduction (SCR) cata-
lyst. Based on this measurement the amount of reactant
to be injected into the exhaust stream is calculated. The
measuring system and dosing unit are part of the same in-
tegrated control system, making it possible to reach very
low exhaust pollution standards from engine idle to 100%
rated load.
With a growing installed base in the gas compression
market, Miratech has emerged as a leader in providing
SCR systems that continually meet ongoing compliance
needs, McKenney said.
With the recent addition of heat recovery systems to its
product portfolio, Miratech is now positioned to provide
continued on page 30

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even more comprehensive total exhaust solutions. A typi-
cal reciprocating engine is roughly 30% efficient, meaning
70% the fuel energy input does not generate shaft horse-
power. That 70% is given up as heat, with typically 30% lost
to the exhaust, 30% to jacket water cooling of the engine,
and 10% to radiation and other losses. Todays cogenera-
tion or combined heat and power (CHP) systems recover
much of the energy in the exhaust and jacket water to use
for heating, cooling, domestic hot water, or other process
uses. As a result the overall efficiency of the system can be
increased to more than 80%. Miratechs new Vaporphase
product line, which includes both hot water and steam pro-
duction systems in both horizontal and vertical applications,
has applications on numerous brands of engines fueled by
diesel, gas and synthetic fuels. The heat recovery silencers
are constructed to the applicable ASME code (Section 1, 4,
or 8) for the application.
Miratechs innovation center focuses on research and
development. The Tulsa complex includes four test engines
with testing facilities equipped for real-world validation.
Testing capabilities include sound, flow modeling, structural
integrity, pressures, temperature and emissions measure-
ment for catalyst formulation, silencer and other develop-
ment for the companys new products and technologies.
Cradle-to-grave project support is provided for large- and
small-scale projects, including support for site layout, pre-
construction, installation, wiring interconnects and layout
and site commissioning services. Miratechs North Ameri-
can team is capable of worldwide service deployment. De-
sign engineering capability includes product design and
modeling, Solidworks CAD, finite element analysis (FEA),
computational fluid dynamics (CFD) and acoustic model-
ing software. Application engineering includes application
guidelines, aftertreatment and silencer selection software
and engineered solutions.
A recent example of Miratechs capability is a Denbury
Resources installation that had one Caterpillar G3606 and
four Caterpillar G3608 gas engines and needed to replace
existing systems that were underperforming for both emis-
30 JANUARY-FEBRUARY 2017
n The test facility at the Miratech
innovation center includes a 250 hp
(186 kW) John Deere 6068HF275 die-
sel gen-set with a heat exchanger. The
engine has a natural gas bi-fuel kit, as
well as a bypass branch for testing
smaller exhaust flows. Miratech used
this facility to validate its integrated
LTR system for the California Air
Resources Board (CARB).
sions and acoustics. The system replacement had to be
implemented with minimum engine downtime, and the site
required strict Class 1, Div. 2 electrical compliance for the
replacement system. Five SCR/oxidation systems were re-
quired, using urea as the reactant.
Miratech developed an innovative and adaptable solution
that included factory-built skidded systems that were pre-
loaded with catalysts, said Tim Martin of Miratechs inside
sales and project management team. We also supplied a
duplex pump system, with redundant pumps, and enclosures
for each of the controllers. Each of the engines was sched-
uled for a one-week installation and startup in the spring of
2016, which included the demolition of the existing systems
and erection of new support structures by Denburys contrac-
tor. We sent a technician for the installation and startup of the
first unit and each subsequent unit, he said.
Martin went on to explain that the system has reduced
NOx, CO and CH2O (formaldehyde) by 90% and NMNEHC
by 80%, while achieving 30 dB(A) of sound attenuation. The
project included a two-year maintenance agreement, which
includes quarterly visits by a technician.
Miratechs Tulsa operation includes the company
headquarters, engineering, sales, the innovation center,
catalyst washing facility and manufacturing for emissions
control and silencer products. Its facility in Prior Lake,
Minnesota, manufactures silencers and accessories, and
a facility in Winnipeg, Manitoba, Canada, manufactures
spiral silencers. According to Jeff Brown, director of stra-
tegic accounts, Miratech has more than 20,000 oxidation
and three-way catalyst systems installed on engines in
oil and gas applications, either stand-alone units or inte-
grated with silencing.
In power generation, we have more than 500 SCR sys-
tems installed, with many incorporating DPF and oxida-
tion catalysts for CO, VOC and methane control, Brown
said. In the high-volume industrial engine silencer market,
we have many custom designs for customers that include
engine OEMs, engine dealers, packagers and processing
equipment systems integrators. CT2
COMPRESSORtech2
 Literature
CO2 Compressor Unloaders Single Sealing Ring Asynchronous Motors

Atlas Copco Gas and
Process Division released a
brochure on its eight-stage,
200-bar GT-Series CO2
compressor, specifically
developed for applications
requiring high compression.
The compressor has an
integral gear design to
optimize the individual
impellers and respective
stages, while reducing the
size of the compressor.
www.atlascopco-gap.com
Dresser-Rand published Stasskol has released a Schorch, part of ATB Group,
a leaflet on its unloaders brochure about its patented has published a brochure
for reciprocating compres- single sealing ring for with its asynchronous
sors. These devices are compressor piston rods. machines portfolio, including
used during compressor According to the company, low-voltage units up to
start-up and for capacity the sealing ring allows 4800 kW, that can be used
control during compressor pressure load to be spread as motors or generators
operation. These unload- homogeneously over the and high-voltage units up
ers feature an aluminum entire piston rod packing, to 25,000 kW. Schorch also
piston and stainless steel to preserve materials and offers explosion-protected
housing, and standard- maximize operational motors for severe opera-
ized components to reduce service life. tional conditions.
parts inventory and cost. www.stasskol.de www.schorch.de
www.dresser-rand.com

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 techc
Reverse Rotation Crops Up

orner
During Quest Project Testing
MDT makes modifications to thwart compressor concerns

BY PETER BEAUSOLEIL, JON ISLEY, BERND HEINL AND KYLE KUECKER

T
he Shell Scotford Upgrader is located about 22 mi. a triethylene glycol (TEG) dehydration absorber, locat-
(35 km) northeast of Edmonton, Alberta, Canada. It ed between the sixth and seventh compression stages.
was originally commissioned in 2002 and is designed Dried CO2 returns to the seventh and eighth stages for
to process 255,000 barrels of oil equivalent per day of dilut- final compression up to the critical fluid state and pipeline
ed bitumen from Shells Muskeg River Mine and Jackpine pressure. The EPC contractor, Fluor, purchased the MAN
Mine. Synthetic crude resulting from this process is shipped Diesel & Turbo (MDT) compressor, which was driven by
to refineries, of which a significant portion is sold to the a 22,118 hp (16,500 kW) synchronous GE motor at 1200
Shell Scotford Refinery. RPM. Summaries of the overall system and compressor
The Quest Carbon Capture and Sequestration project will are given in Tables 1 and 2.
capture and store up to 1,322,774 tons (1.2 million tonnes)
Manufacturer: GE Energy Rated Power:
of carbon dioxide (CO2) per year from the Upgraders Hy- Synchronous
16,500 kW (22,118 HP), Rated Speed:
drogen Manufacturing Units (HMU). This represents 35% Motor
1200 RPM
of all Scotford Upgrader CO2 emissions. The compressed
Coupling Manufacturer: BHS Type: MKS800-AAT
CO2 is transported 40 mi. (65 km) north from the site in a
12 in. (30.5 cm) diameter pipeline, eventually being injected MAN DIESEL & TURBO SE / RG 90-8
into wells 1.4 mi. (2.3 km) underground in a saline aquifer Compressor
Eight Stages, CO2 gas
formation for storage.
n Table 1. System description.
Equipment selection
The CO2 compressor is designed to compress wet 99%
pure CO2 recovered from the CO2 Capture and Amine Re-
generation sections at 5.5 psig (38 kPa gage). The objec-
tive discharge pressure has an operating range of 1189 psig
(8198 kPa gage) to 1784 psig (12,300 kPa gage) at rated
capacity. At reduced rates, the compressor will produce dis-
charge pressures as high as 1885 psig (12,997 kPa gage).
This highest discharge pressure is set in accordance with the
well requirements at initial start-up and for future operation.
The selected compressor is an eight-stage, integrally
geared, centrifugal machine with an electric motor drive.
Throughout the first six stages, wet CO2 is compressed at
a 1.8 to 2.1 compression ratio where, at each stage, the
stream is cooled and water is condensed and removed Description Speed (RPM) Frequency (Hz)
by knockout separation. The minimum water saturation
pressure is reached on the sixth stage at about 943 psig Motor / Bull Gear 1200 20.0
(6500 kPa gage). Any residual water is then removed in Pinion - Stages 1/2 6806 113.4
Pinion - Stages 3/4 11,620 193.7
Peter Beausoleil is a rotating equipment engineer at Shell Scotford.
Pinion - Stages 5/6 15,880 264.7
Contact him at: peter.beausoleil@shell.com. Co-authors include
Pinion - Stages 7/8 22,686 378.1
Jon Isley, director of Process Engineering, Fluor; Bernd Heinl, head
of Systems Engineering, MAN Diesel & Turbo; and Kyle Kuecker,
project engineer, Engineering Dynamics. n Table 2. Operating speeds of compressor stages.
continued on page 36

34 JANUARY-FEBRUARY 2017 COMPRESSORtech2

 STASSFURT HOUSTON
GERMANY USA
SEALING EXPERTS SINCE 1920

BOSS
Balanced www.stasskol.de

Oil Sealing
Solution
n Figure 1. Compressor before installation on foundation.
n Figure 2. Installed compressor with piping.
Figure 1 shows the pre-installed compressor, and a birds-
eye view of the installed compressor is shown in Figure 2.
The compressor system is configured with inlet guide
vanes to the first stage, blow-off valves after the sixth and
eighth stages, and a recycle line from the eighth to first
stages. Process vessels in the system include knock-out
drums and water coolers between each of stages one to
six, aerial coolers after stages six and eight, and a dehydra-
tion unit between stages six and seven. The compressor
system flow diagram is shown in Figure 3.
n Figure 3. Compressor system flow diagram.
36 JANUARY-FEBRUARY 2017
n Figure 4. Strain gage telemetry system.
The compressor itself is housed in a building, but each of
the vessels is located in a separate skid outside the build-
ing. MDT had offered a packaged compact layout for the
compressor knockout drums and water cooled heat ex-
changers, similar to other packages they had already built
for similar applications, but the proposed cooler design did
not comply with Shells standards. As such, the selected
design had significant piping and vessel volumes between
each stage of compression.
Commissioning
Unlike most process units in a refinery or upgrader, the
compression of the CO2 for a carbon capture project occurs
at the end of the process, not at the beginning. As such, the
compressor train was the last of the equipment commis-
sioned on site before the pipeline.
Data collection
Engineering Dynamics Inc. (EDI) provided vibration and
torque monitoring in order to validate torsional natural fre-
quencies (TNFs) during the commissioning of the compres-
sor train. There was concern that the across-the-line synchro-
nous motor start up could cause significant pulsating torque
and excite TNFs below 120 Hz before the synchronization.
COMPRESSORtech2
 A battery-powered telemetry system was temporarily
installed on the motor shaft to measure transmitted and
vibratory torque. The strain signal was transmitted to a
fix-mounted receiver, similar to the one shown in Figure 4.
All of the radial proximity probes and key phasors on the
motor, bull gear, and pinion shafts of each compressor
stage were monitored. The individual probes are wired to
a Bently Nevada 3500 series machinery monitoring sys-
tem, which has buffered outputs.
In addition, a current probe was installed inside of the ex-
citer cabinet to measure motor amps
and estimate the electrical power.
The EDI data acquisition system con-
enth and eighth stages was spinning at 9710 rpm in reverse.
There was some concern regarding the health of the
compressor after it rotated in reverse, primarily with the
radial bearings. All of the radial bearings had center piv-
ots (no offset) and were symmetrical except for the first
pinion, which had a bearing pad offset of 10%. During
the reverse rotation, radial vibration of both stages on
the first pinion showed vibration amplitudes greater than
the trip amplitude for that stage, nearly to the expected
continued on page 38

Emissions
sisted of National Instruments 24-bit
A/D converters and proprietary soft- # 1 E n g ine
ware!
ware that was used to control the
T esting Soft
instrumentation, as well as digitally
record, analyze and plot all data.

Testing
The compressor was first started
on May 28, 2015, on full recycle, with
a minimum discharge pressure of
551 psig (3800 kPa gage). At this low
pressure, the eighth stage could not
generate head due to the geometry
of the stage, and so the anti-surge
valve was adjusted to 75% open to
raise the discharge pressure to 682
psig (4700 kPa gage). The compres-
sor appeared to be running well, and
condition monitoring showed low vi-
bration amplitudes and bearing tem-
peratures. Being short staffed, the

TEC soft
project underwent a three-hour me-
chanical test, resuming the following Testing & Emissions
day with anti-surge testing. Shell and Compliance Software
MDT shut down the compressor over- for the testo 350 Emissions Analyzer
night to ensure it would only be oper-
ated after being fully commissioned. New automated testing runs
Now g New standard calibration template
Reverse Rotation
cludin Improved calibration screens
The compressor was shut down In Improved reporting templates
in a controlled manner using the
normal stop command from the
distributed control system. Once Intuitive: Simple navigation and Site setup
the motor breaker had tripped, the
compressor physically came to a
Flexible: Calibrate, test, review, or print anywhere
stop in 30 seconds and then began Efficient: Save testing values into analyzer
to rotate in reverse, with the motor - download to PC anytime
shaft (bull gear) reaching a speed
of 514 rpm in the reverse direction
Contact Testo now for a free trial version
as shown in Figure 5. This means
info@testo.com 1-800-227-0729 www.testo350.com
that due to the high gear ratio, the
high-speed pinion driving the sev-

COMPRESSORtech2 JANUARY-FEBRUARY 2017 37

n Figure 5. Motor shaft torque and speed over time after initial shutdown.
bearing clearance. MDT confirmed that because the ro-
tation was not at high speed and with no high energies
involved, it was unlikely that the bearings were damaged
during this event.
The thrust bearing was also identified as a concern, as
it is not of a tilting pad design, but a tapered land bearing
design. Unfortunately, as with the radial bearings, this thrust
bearing is extremely difficult to visually inspect and would
require dismantling the top half of the compressor, including
the third and fourth pinions to access. Due to the difficulty of
performing a physical inspection, the team decided to only
open the inspection ports on the gearbox and examine the
gear teeth and bearing thrust collars. Vibration and tem-
perature readings on a subsequent compressor run would
help identify further bearing damage.
Other components considered were the lube oil system,
which was designed to operate in reverse, and the carbon
seals, which are bi-directional and therefore able to with-
stand reverse rotation.
Shell and MDT discussed performing a second test run
under controlled conditions to obtain further data on the
dynamics of the compressor system. All parties felt that a
second test would be beneficial to see if the compressor or
motor had been damaged from the first run, and to evaluate
the impact of some minor deficiencies in the system from
the first run including:
The timed opening of the two blow-off valves did not
occur two seconds before the motor stopped, as per the
intended design of the shutdown logic.
38 JANUARY-FEBRUARY 2017
It was discovered that by bypassing the TEG unit during
the first run, the only interstage check valve in the com-
pressor system located just upstream of the TEG had
been inadvertently bypassed as well. As the decision to
bypass the TEG unit was for simplicity of commission-
ing the compressor and TEG separately, Shell decided
immediately to not allow this method of operation in the
future and had the bypass physically and procedurally
locked out from use.
Pressure measurements were added downstream of
the two blow-off valves in order to measure the pres-
sure drop across these valves and determine if they had
reached choked flow.
The team understood that these small changes would not
eliminate the reverse rotation, but would at least help with
the dynamics of the system and reduce the energy avail-
able to create a reverse rotation situation, and therefore
expected a lower reversal speed.
On June 2, 2015, the compressor ran for a second time
for 30 minutes at a discharge pressure of 537 psig (3700 kPa).
On shutdown, the result was a reverse rotation of 371 rpm
at the bull gear.
The risks of having a multistage compressor run in re-
verse are not simply limited to bearing or seal damage. The
potential consequence is that running at full operational
discharge pressure, there could be enough potential en-
ergy in the system to over-speed the electric motor in the
reverse direction, causing catastrophic failure of the motor
and potential fatalities.
continued on page 40
COMPRESSORtech2
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Additional Design Efforts: System Modeling
Following the two reverse rotation events, it was clear to
Shell engineers that the problem was complex and could
not be solved in isolation. Therefore, a dynamic model of
the system was built to replicate the empirical data and
test potential solutions. To this end, in order to mitigate the
impact to the project schedule as much as possible, three
parties were approached to perform a dynamic simulation
of the system: MDT, Shells Process Optimization and Mod-
eling team in Houston running UniSim, and an internal con-
tractor sourced out of the Shell Technology Center Calgary
(STCC) using the VMGSim process simulation platform.
They were initially tasked to build the model of the system
and demonstrate that it could match the empirical data col-
lected for the two reverse rotation events. This first step
was required in order to validate and tune the model.
One of the most difficult, yet important, aspects of build-
ing the model was determining how the impellers behaved
in multiple quadrants of operation that is, not only when
flow proceeds forwards through the impeller with a positive
pressure differential, but also when gas flow is proceeding
backwards through the impeller as it spins in either the for-
ward (design) direction or in reverse. While the compressor
is rotating in reverse, the stages in which the flow is also
40 JANUARY-FEBRUARY 2017
reversing are actually acting as turboexpanders. Naturally,
this distinction has a large effect on the dynamics of the
system, as it is one of the determining factors in how fast
the compressor will spin in reverse.
It turned out that the STCC team was able to build a vi-
able simulation the fastest and match the empirical test
data, so the project team continued with them for our simu-
lation needs. We maintained a working relationship with
MDT, seeking their input and approval for potential design
changes. Several different modifications were proposed by
the team, and a concept evaluation session was held to
determine the advantages and disadvantages of each:
New blow-off valves to atmosphere at the fourth, fifth
and sixth stages.
New recycle line from sixth stage to suction.
New check valve at fourth stage suction.
Based on design, procurement, construction and oper-
ability factors, the first option was selected and the project
proceeded with detailed design of the modifications.
Physical cause analysis
In general, the compressor may be divided in two sections:
low-pressure stages one to six, and the high-pressure stag-
es seven and eight with the TEG unit.
Stages seven and eight, downstream of the dehydration
unit, have very small impellers and volutes compared to the
high gas masses that are stored in the dehydration unit.
During shutdown, the gas flows through these stages in the
forward direction, so that these stages have no impact on
the reverse rotation. The mass is prevented from flowing
backward by the check valve in front of the dehydration unit
and is vented by the blow-off valve and the anti-surge-valve
after stage eight. However, this takes a long time because of
the relatively small open areas in the impellers and volutes
and the high gas volume at a high density in the system.
Therefore, only the low-pressure section needs to be con-
sidered when determining the cause of the reverse rotation
of the compressor. The high gas mass stored in the cool-
ers, knockout drums and process piping, especially between
stages four to six, may only be vented by the blow-off valve
between stage six and the check valve or by backflow to
a lower pressure stage of the compressor. As the blow-off
valve at stage six was only dimensioned for start-up of the
machine, the blow-off capacity was limited. That is the reason
why most of the CO2 in stages four and five flows backwards.
The reverse flow through the machine creates a torque at
the impellers that slows them quickly and eventually forces
them to rotate in reverse, where they act as turboexpand-
ers. It was calculated that immediately before shutdown of
the machine after the second test run, there was 5670 lb.
(2572 kg) of CO2 in the low-pressure section of the com-
pressor, compared to the stage six blow-off valve capacity
to vent about 1874 lb. (850 kg) during the initial 30 seconds.
Note that check valves were not used between stages in
the original design to allow for a cascaded design pressure
COMPRESSORtech2
n Figure 6. Compressor system flow diagram with new blow-off valves.

profile, which provided overpressure protection by system
design rather than overpressure protection by PSV.
To eliminate the reverse rotation, the dynamic model
built by MDT showed that the maximum pressure that
may remain in the system after 20 seconds was 43.5 psia
(300 kPa abs).
System modifications
The recommendations of MDT were taken and used to
design the additional piping and blow-off valves required
to vent enough CO2 to prevent the reverse rotation. Using
the VMGSim software, the project team was able to vali-
date the recommendation while recognizing that this modi-
fication would not be sufficient to eliminate all reverse flow
through the compressor, just enough to prevent reverse
rotation up to the rated operational discharge pressure. The
final design was to add new 8 in. (203 mm) blow-off valves
to the knockout drums at the suction to the fifth and sixth
continued on page 42

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n Figure 7. Motor speed over time at gradually increasing compressor discharge pressures.
stages of the compressor, as well as beside the original
sixth stage blow-off valve upstream of the dehydration unit.
Figure 6 shows the compressor system flow diagram with
the new blow-off valves.
Final Acceptance Tests
While the new piping, valves and associated supports
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services to a wide range of clients across a host of industry
sectors, including oil and gas. The companys focus is on the
42 JANUARY-FEBRUARY 2017
and instrumentation were being constructed, the engineer-
ing team turned back to creating a test plan for accepting
the compressor system and continuing with the subsequent
commissioning activities. A test plan was developed to shut
down the compressor using undelayed or emergency
trips from steadily increasing discharge pressures. The in-
tent was to ensure that the compressor did not reverse on
identification, assessment and management of man-made
and natural hazards by the application of a blend of expertise
drawn from a range of scientific and engineering backgrounds.
Southern Star
Southern Star Central Gas Pipeline has appointed
Jimmy D. Staton as president and CEO. He replaces
Jerry L. Morris, who retired. Morris has spent 39 years
with the company.
Staton most recently served as executive vice president
and member of the Board of Directors of Venture Global
LNG. Prior to joining Venture Global, Staton served as CEO
of the Columbia Pipeline Group, Northern Indiana Public
Service Co. and the Columbia Distribution Companies.
COMPRESSORtech2
shutdown throughout the full operating range of immediate Technical recommendations that can be followed by fu-
depressurization scenarios. A planned shutdown could be ture projects to prevent reverse rotation include:
sufficiently controlled by opening the blow-off valves sev- Recognize the number of stages in a compression
eral seconds before the motor was stopped, but in an emer- system and the potential energy stored in inter-stage
gency trip the electric motor must be shut off without delay. volumes, particularly when sizing liquid knockout ves-
Figure 7 shows how quickly the compressor decelerat- sels and the impact on shutdown. Integrally geared
ed at each discharge pressure, until finally experiencing a compression systems may behave differently than
slight rollback when shut down from near the design operat- inline systems.
ing pressure of 1770 psi (12,200 kPa). Consider including dynamic modeling of compressor
The project team accepted that these test results showed systems in the design phase, or adding physical con-
that the modified system was only capable of preventing a trols such as check valves, blow-off valves, or recycle
reverse rotation for discharge pressures of up to 1770 psi lines between each stage. The interaction of the com-
(12,000 kPa). Though, per design, the compressor was ponents within the compression package needs to be
capable of higher discharge pressures, the short-to-medium considered by the system integrator, working with all
term operational requirements were satisfied by this pres- parties involved.
sure range. An automatic discharge pressure trip was Consider the specific behavior of CO2 at high pressures
therefore set at 1740 psi (12,000 kPa), with the controlled when designing a compressor system for carbon capture.
limit set to 1668 psi (11,500 kPa). The project was then able The use of bi-directional components in the compres-
to continue with surge testing of the compressor, and com- sor such as seals and bearings, along with sufficient
plete commissioning of the unit as a whole. lubricating oil supply, significantly reduces the risk
After commissioning was completed and the compressor of damage to the compressor from reverse rotation.
was considered safe for operation, the unit was transferred Note that there are no measures to stop reverse ro-
to the custody of the site on Aug. 18, 2015. Since then, the tation once it begins, as shutdown systems are no
compressor has been in nearly continuous operation. longer effective. CT2
See references at: ct2.co/references
Data analysis
Before initial startup testing, the pri-
marily concern was the torque in the
motor shaft during the synchronous
motor start. Measured dynamic torque
values and corresponding stresses in
the motor and gear shafts during start- MAKE THE CONNECTION
up were below those predicted by the
MDT torsional analysis and were con-
sidered acceptable. However, during
the first monitored shutdown, the phe-
nomenon of reverse rotation became
the main focus of investigation during
The global leader in flexible couplings for pump &
subsequent testing.
compressor applications. Trust the innovator-trust CENTA.
Conclusions and Over 20 unique designs | Torsional Vibration experts
recommendations
To review, the reverse rotation is-
sue occurred in September 2015 with
Shell, MDT and Fluor on hand to docu-
ment lessons and recommendations.
It was determined that while the com-
pressor hardware had been identified CENTAX-Series N/NL CENTAFLEX-Series A
For reciprocating compressors For compressors & pumps
as a novelty for Shell, the compressor
system as a whole was not identified
or appreciated as such. The project CENTA POWER TRANSMISSION
design team had simply attempted L E A D I N G B Y I N N O VAT I O N
to follow internal standards for liquid 2570 Beverly Dr. #128, Aurora, IL 60502 T 630.236.3500
knockout drum sizing in compressor Catalog downloads at www.centa.info | Email inquiries to ct@centacorp.com
systems.

COMPRESSORtech2 JANUARY-FEBRUARY 2017 43

One-Stop Box
Alta Solutions AS-7000 Offers Vibration Protection
And Analysis In One System
n The AS-7000 can capture up to 64 dynamic signals using two 24-bit analog-to-digital converters per channel.
BY KLINTON SILVEY
A
lta Solutions (Alta) has created a modular, one-box
system intended to provide critical machinery with
both vibration protection and analysis.
Vibration protection is a fairly old technology. Since first
edition API 670 was published in 1976, the accuracy, char-
acteristics, and functions of machinery protection systems
(MPS) have been well defined. In its basic form, if a ma-
chine experiences a predefined level of vibration, then the
protection system shuts the machine down. To analyze the
cause of the rumbles, usually a separate, portable analysis
tool is needed which often must be operated by a spe-
cialist who may or may not be on-site. The delay in analy-
sis capabilities can be costly in terms of downtime while
waiting on a specialist to fly in, or in machine failure, which
could have been detected and prevented.
The Alta AS-7000 MPS is designed to eliminate the need
for two separate systems and simplify the analysis pro-
cess while still providing vibration protection, which could
amount to big savings as companies update their monitor-
ing and protection systems.
Before, you would have a [US]$30,000 or $40,000
vibration protection system, and those portable (analy-
44 JANUARY-FEBRUARY 2017
sis) systems were [US]$60,000 or $70,000, so no one
was going to spend two-and-a-half times (the cost of the
vibration protection) to put that on every system, said
Robert Mihata, president of Alta Solutions. But now,
were able to take that extra (analysis) system and in-
corporate for the cost of what you would normally find on
just a standard (vibration protection) system.
Mihata is hoping companies will see the value of high-
end analysis software when applied to more pieces of
equipment and incorporate it when replacing older tradi-
tional MPS. Altas timing for the AS-7000 might be just right.
According to Mihata, a large number of gas turbine en-
gines with Alta condition monitoring and other companies
vibration protection systems equipped were commissioned
in the early 2000s. While the monitoring systems were fairly
new at commissioning, the vibration protection systems
were based on technology that was already 10+ years old
at the time. Although they have proven functional, electron-
ic systems degrade with time, and the 20- to 25-year-old
technologies are being scheduled for upgrades.
Moreover, the industry downturn has resulted in a lot of
knowledge consolidation. There are fewer people trained to
COMPRESSORtech2
do diagnostics using the older portable
Featured Products
systems, and those technicians are Compressor Sizing Tool
spread out. For many pieces of equip- GE Oil & Gas has launched new software from their Reciprocating Compression
ment, spending an extra US$60,000 division called PowerFlow Sizing Software. This software allows customers to size
for analysis tools when buying vibra- any of their compression products Ajax, Cooper-Bessemer and high speed
tion protection is already necessary, is reciprocating (HSR) compressors replacing three legacy sizing tools. AGA8 and
simply not worth the investment. VMG gas analysis and other customizable features are available. Downloads and
But safety standards will require training are available at:
updates, regardless. Alta hopes those www.engagerecip.com
in need of modernization will consid-
er the AS-7000 to cover both needs Proflo Monitoring Solution
in one box at a price point compa- The Proflo USB-IR Adaptor and Proflo Assist software are
nies can live with. Depending on the the latest Compressor Products International (CPI) solutions
needs of the specific machine, an AS- for monitoring compressor lubrication systems.
7000 could cost anywhere between The Proflo USB-IR Adaptor and Proflo Assist Software
US$15,000 and $65,000. read and transfer information from the Proflo PF1 monitoring device, which records
The system itself exceeds API 670 the average cycle time for each 30-minute block of lubrication system operation to
5th Edition guidelines and incorporates a Microsoft Windows-based laptop, tablet or other USB-equipped device through
a duplicate signal path that integrates the use of infrared technology. The accompanying Proflo Assist Software pres-
the signal analysis capabilities Alta ents the cycle time trend data to operations and maintenance personnel, delivering
prides itself on. It features an em- powerful, convenient condition-based maintenance capabilities.
bedded computer that allows remote The Proflo PF1 provides real-time access to technicians and alerts operators
analysis via any laptop with an Eth- or engages shutdown protection based on the cycle time of the system. CPI said
ernet port. There is no longer a need real-time access to this information can help technicians intervene and prevent a
to make sure the correct channel has range of problems, including the extrusion of packing and piston rings, locking of
been plugged in to. the packing case, valve stiction and more.
Every vibration input channel con- continued on page 61
tains two 24-bit analog-to-digital con-
verters, one for the protection function
and the second for analysis signal
acquisition. The AS-7000 can simul- Experience, Reliability, Integrity...
taneously capture as many as 64
dynamic signals.
The 7000 system is offered in ei-
ther a 9 in. wide or a 19 in. wide
chassis. Flexible hardware allows
outputs to Modbus, RTU, TCP, Alta
Solutions VibDash, OSI soft PI, as
well as other historian interfaces.
Standard industry contact screw
terminals simplify the retrofit task.
Sensor power, -24 Vdc for proximity
probes and 24 Vdc at constant cur-
rent for IEPE devices is provided by
the 7000 system. The 7000 sensor
inputs are compatible with sensors
from any manufacturer having an
output voltage range of -20 to 20 V
ac or dc.
The AS-7000 system supports cur-
rent interfaces for rotating equipment The AXH manufacturing complex consists of
monitoring, while Altas development six plants, totaling 559,100 SF on 67 acres.
design is supporting future protocols
by leveraging IOT technologies.
The system was to be available in
early 2017. CT2 (918) 283-9200 Fax (918) 283-9229 www.axh.com

COMPRESSORtech2 JANUARY-FEBRUARY 2017 45

 Altronic Finds Speed
Control Flexibility
New GOV+ governor works with PLC
panels and stand-alone operations

BY DJ SLATER

W
hen Altronic sat down 18 months ago to evaluate its elec-
tronic speed governor offerings, it had a line with a limited
range. The GOV line worked independently, but not on a
targeted basis with PLC panels.
The narrative has changed since that time, with Altronic releasing
its GOV+ electronic speed governor, a module that fits into its PLC+
product line and works as a stand-alone unit for natural gas engines.
The goal is to deliver new value and capability to our PLC control
panel business and customers and to offer a cost-effective, stand-
alone solution for natural gas engine speed control both carbu-
reted and fuel-admitted models both in and out of the PLC panel

n The GOV+ electronic speed governor provides closed-loop speed control of a natural gas-fired
engine by controlling an actuator.

Storm adds Hoerbiger products to portfolio

BY ROBERTA PRANDI

H
oerbiger, the Swiss specialist in compression tech-
nology, drive technology and hydraulic systems,
signed an agreement with Germany-based August
Storm GmbH & Co. KG (Storm), to add its ignition and control
systems to Storms portfolio of products for engine services.
The agreement, signed in October, follows a prior service
cooperation agreement between Hoerbiger and Storm es-
tablished in June. The cooperation covered spare parts
management, 24/7 field service and workshop services to
support customers with high equipment availability, engi-
neering services and equipment upgrade solutions for re-
ciprocating compressors and engines.
The new deal will strengthen Storms range of prod-
ucts for engine upgrades in the 130 to 9400 hp (100 kW
to 7 MW) range, the companies said. Storm now offers
Hoerbiger ignition systems and engine control units for all
common gas and diesel engines. These ignition systems
produce lower emissions and lower operating costs by uti-
lizing economical load capacity management in conjunc-
tion with efficient and reliable operation.
Storm is an original equipment manufacturer (OEM) in-
dependent service company that employs 300 specialists in
its headquarters in Spelle, Germany. It has two international
branches and 11 service branches.
In addition to the portfolio for mechanical machining, en-
gine spare parts and components, Storm is active in the
field of services for stationary and energy systems, mobile
and marine power systems and compressor systems.
For compressors, Storms services cover all aspects of
reciprocating piston compressor systems. These include
the maintenance (service, repair and overhaul) in accor-
dance with the companys Prodis service plan for profes-
sional mechanical machining of components with qualified
service technicians on-site or in the companys own shop.
Storm offers customized, manufacturer-independent main-
tenance for all conventional reciprocating piston compres-
sor models in the natural gas and petro-chemical industries.
In terms of retrofitting, Storm offers solutions that include
technical consulting with respect to the optimization of the
operating life and uptime. For example, Storm will optimize
the combination of material between cylinder liners and pis-
ton rings and rider rings, and the combination of material
between piston rods and compression packings.
Storm also performs the overhaul of components such
as compression packings, suction and discharge valves,
crossheads, cylinders, cylinder liners, and piston rods with
a new coating technology. Crankcases and cylinders can
be overhauled with line boring of main bearing pockets

46 JANUARY-FEBRUARY 2017 COMPRESSORtech2

environment, said David Bell, senior vice president of
Aftermarket Sales & Service, Altronic. The GOV+ brings
significant value in terms of performance, ease of setup
and cost.
The GOV+ governor, manufactured by Altronic in Girard,
Ohio, provides speed regulation of an engine by controlling
an actuator. It has the versatility to fit into virtually any gas
engine application when paired with the appropriate actua-
tion device, Bell said. This allows the governor to have a
reach that stretches across the global natural gas engine
market in new and retrofit applications. It also fits into the
Altronic AGV and ActuCOM product lines, as well as third-
party actuators and throttle bodies, Bell said.
Nearly two years ago, this type of flexibility wasnt avail-
able to PLC operators, who had to develop, implement
and validate their programs individually. Additionally, not
every operator takes the same approach to their program-
ming functions. The GOV+ governor simplifies the pro-
cess, Bell said.
For Altronic, the GOV+ provides a wholly standardized,
pre-manufactured solution that the customer can apply, ad-
just and troubleshoot across all of their applications, he
said. This is essentially a configurable solution that can be
applied across a fleet of compressor packages of varying
designs, fueling systems, horsepower ranges and control
panel technologies, PLC or not.
COMPRESSORtech2
The GOV+ governor features configurable startup logic
ready, purging, starting, warmup and running as well
as three adjustable warmup ramps with configurable ramp
speed in rpm/sec. with hold timers. Its speed input pulse
can come from magnetic, Hall-effect or other types of ac-
tive pickups. To control speed, a configurable 4 to 20 mA
or 0 to 10 V analog signal can be used to regulate an
actuator position.
The GOV+ governor uses an integrated Ethernet port
to communicate to a PLC, PC or other communication
device. User-selectable communication protocols in-
clude EtherNet/IP or Modbus/TCP. Monitored values are
displayed on an HMI display and can be compared to
user-adjustable set point levels for sequencing, alarm
and shutdown.
An extruded aluminum enclosure houses the governor,
which mounts to standard DIN rails. It includes up to five
connections, which are pluggable, push-in and spring-cage
I/O and power connections. The governor, which is CSA
certified for use in hazardous areas, has a power require-
ment between 10 and 32 Vdc and a temperature range of
-40 to 176F (-40 to 80C).
Standardized, yet configurable products for use in
PLC or stand-alone environments is something that we
believe will be revolutionary for new and retrofit markets,
Bell said. CT2
n Among the Hoerbiger products included in the agree-
ment with Storm is the configurable DE-3000 safety
shutdown and control system for compressors and other
rotating equipment.
and crosshead channels by Storm either at the cus-
tomers site or in the companys workshop.
Additional services by Storm include spare parts
supply, new production of piston rods, cylinder lin-
ers, crossheads and plain bearings, valve service,
reconstruction of base plates, measurement using
laser technology, and an in-house department for
measurement and control engineering.
Storms capabilities also include the reconditioning
and grinding of crankshafts up to a maximum length of
315 in. (8000 mm) and maximum weight of 22,000 lb.
(10,000 kg) in a process that goes through incoming
inspection, concentricity check, crack detection and
hardness test. The procedure is completed by docu-
mentation with a measurement data sheet before and
after grinding, and an acceptance test of crankshafts
by main classification companies. CT2
JANUARY-FEBRUARY 2017 47
Voltage Problem Protection
Model Predictive Torque Control saves compressor systems
during power disruptions
n ABBs MPTC software installed on a MEGADRIVE-LCI, such as this one, protects against gas supply interruptions during voltage disruptions.
BY IAN CAMERON
A
BB has released what it said is the first variable-
speed drive (VSD) control software that uses model
predictive control (MPC) to protect compressor op-
eration during power supply disruptions.
MPC predicts the future behavior of a system via a math-
ematical model and solves an optimization problem to com-
pute the best control action with respect to given criteria
and limits of operations, ABB said.
ABB is applying MPC, which is a well-known control meth-
od, to control torque by means of an LCI drive, and the final
product is called model predictive torque control (MTPC). The
MPTC software was initially developed to ensure the operation
of compressor stations during voltage disruptions caused by
lightning strikes, winter storms or ice buildup on power lines.
When power supply disruptions happen, protection systems
quickly shut down the compressors, halting the supply of gas.
Restarting compressors can last from a few hours to days.
Historically, gas turbines have powered compressors, but
today, large synchronous electric motors handle that task,
ABB said. The motors are controlled by VSDs, such as
ABBs largest drive, the MEGADRIVE-LCI.
Installed in the MEGADRIVE-LCI, the MPTC uses a con-
trol algorithm based on MPC that ensures the operation of
the drive during power and grid disturbances in order to
provide the compressor with partial torque, preventing the
compressor from going into surge.
According to ABB, the MEGADRIVE-LCI is the first appli-
cation in which MPTC is used to control a commercial multi-
48 JANUARY-FEBRUARY 2017
megawatt drive system with much faster dynamic behavior,
meaning the underlying optimization problems need to be
solved in less than a millisecond. ABB said it has installed
1000 MEGADRIVE-LCIs globally
Live testing of the software occurred over the winter at
two Statoil gas facilities in Norway. It was installed on ABB
MEGADRIVE-LCIs used to power two 42.2 MW compres-
sors at a gas processing plant in Kollsnes and three 7.5 MW
booster compressors in Krst, north of Stavanger, which
transports and treats gas and condensate from areas on
the Norwegian continental shelf.
The first gas arrived at the Krst plant in June 1985, and
dry gas was dispatched by pipeline to Emden in Germany the
same year. The Statpipe trunkline system carries gas from
the North Sea to Krst. The Krst facility also receives
gas from sgard and other fields in the Norwegian Sea
through the sgard Transport trunkline.
The processing plant at Kollsnes, west of Bergen, Norway,
treats gas from the Troll, Kvitebjrn and Visund fields in the
North Sea, and can handle up to 5 Bcfd (143 MMm3/d). In-
stallation of a sixth export compressor at the complex in 2005
expanded capacity from the original 4.2 Bcfd (120 MMm3/d)
in October 2006. Statoil is the technical service provider at
Kollsnes and Krst, and Gassco is the operator.
Gas is piped from Kollsnes to continental Europe through
four trunklines Statpipe, Zeepipe, Europipe I and Fran-
pipe. The gas is exported to France, Netherlands, Belgium,
Germany, Czech Republic, Austria and Spain. CT2
COMPRESSORtech2
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Extensive History Glowing Future
Continuous innovation builds on Reynolds Frenchs
70 years of engine and compressor repair experience

BY NORM SHADE

S
ince 1946, Reynolds French & Co. has challenged the
conventional by providing repair and machining ser-
vices on-site and in-shop for compressors, engines
and other types of large industrial machinery. The com-
panys evolution has continued by consistently pioneering
newer methods used in high-stress areas or on severely
damaged castings.
Our certifiably successful techniques have included:
larger locking devices, innovative bolting, fabricating sec-
tion replacements, the most modern crack repair tech-
niques and structural reinforcements all repair tech-
niques designed to do everything feasible to reclaim or
exceed the strength of the original casting, said Kirk
Chalmers, president.
Chalmers, the son-in-law of one of the company found-
ers, has been with the Tulsa, Oklahoma-based company
since 1978. His son, James A. (Sandy) Chalmers, vice-
president, represents the third generation involved in run-
ning the enterprise. Along the way, Reynolds French has
continued to develop its services and products to solve cus-
tomer needs in the compression industry.
In addition to field repair services using specially devel-
oped field machining and repair tooling, a small machine
shop was added for supporting field repairs. By 1970, the
shop had full machining capability, and crankshaft-machining
capability was added in 1978.
We have the same capabilities in the Tulsa shop facili-
ties that we have in the field, Kirk Chalmers said. Gen-
erally, the cost will be 20 to 50% less when done in the n Following a connecting rod bolting failure that caused a broken
shop, although that requires equipment removal and ship- web and side wall of one throw of a Cooper-Bessemer LM-8 recip-
ment from the customer. The Tulsa shop is equipped with rocating compressor frame, Reynolds French completed an engi-
heavy crane capacity, assembly and rebuild space, and a neered repair in the field using metal lock and steel reinforcement
number of machine tools including large capacity horizon- techniques. Since the compressor (which is actually constructed
tal boring mills, the largest of which has a 6 in. (152 mm) as two four-throw frames bolted together) needed a complete
diameter spindle, 6 ft. (1.83 m) effective vertical travel, 10 overhaul to repair other wear and tear, during the next turnaround
to 31 ft. (3.0 to 9.5 m) horizontal travel and up to 4 ft. (1.2 m) in 2015, the unit was sent to the Tulsa, Oklahoma, shop for a com-
stroke. Complete engine machining, as well as many other plete overhaul as shown here. Work included repairing cracks in
special machining jobs other than engines, can be done valve caps, machining the bottom of the frame and the doghouse
on these machines. (crosshead guide) flanges, verifying alignment and re-dowelling of
The companys casting repair capabilities are well known. the end cover.

50 JANUARY-FEBRUARY 2017 COMPRESSORtech2

 n The repair of this six-throw Worthington Super Cub separable reciprocating compressor (left) includes examples of steel reinforcement
of two broken main bearing supports at one end of the frame (center). On both throws, the mounting blocks (right) were restored to engage
with the frame spreader bars between throws. After Reynolds French completed these repairs and machining of mounting surfaces, the
frame was line bored before being returned to the field for service.

Beginning as one of several small companies that repaired
cracks in castings with a method of metal stitching that in-
cluded small locks and overlapping threaded dowels, called
lacing, it was successful in repairing relatively low-stress
areas on castings. During the 1950s through the 1970s,
Reynolds French explored new methods of repairing dam-
aged castings, which could not be held by the conventional
method of locking and lacing. Meanwhile, only a very small
percentage of the many companies that were limited to
locking and lacing were able to survive.
New repair techniques were pioneered for use in high-
stress areas or on very badly damaged castings. A number
of combinations and variations of several repair techniques
were pioneered by Reynolds French. Much larger locking de-
vices can be custom-made in size, shape and type of materi-
als for specific needs. Innovative high-strength bolting can be
installed in such a way that the bolt shank (between the bolt
head and the threads) spans a crack, pulling it together as the
bolt is heated and installed. This method transfers the load
from the cracked area to the bolt and the areas below the bolt.
continued on page 52

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 Entire casting sections are replaced where holes have
been knocked out or there are too many cracks to make lock-
ing practical or dependable. Steel is cut and hand-fitted to an
area of the casting, which has been cut out and removed. It
is then secured in place without welding. Walls of castings
can be further reinforced with a steel plate that is secured by
bolting. The steel is hand-fitted for maximum contact. Steel
pieces, often very many, are cut, fitted and installed in such a
way that the damaged area, which may have been previous-
ly overloaded with stress, is relieved because the steel trans-
fers the load to a different area. In extreme cases, it has been
necessary to totally remove part of a casting. A pattern maker
can be brought in and a new section cast, stress-relieved
and installed with one or a combination of several methods.
Because of the high costs of equipment downtime, dis-
assembly and reassembly for our customers, our repair
philosophy has always been to do everything feasible to
reclaim strength of the casting, usually resulting in some
combination of these repair techniques, Kirk Chalmers
said. For instance, most every job includes a certain
amount of locking and lacing. We feel that it is largely due
to this philosophy that our success rate on repairs, our
growth, and reputation have become what they are.
Reynolds French has repaired cylinder head, engine
base and mainframe, exhaust manifold, compressor cylin-
der, power cylinder, compressor frame, pump housing and
many other types of industrial castings.
The companys field machining group can travel with
portable boring bars, flange facers and portable milling ma-
chines to reclaim precision surfaces and alignment. It can
work on strictly machining-type (in-place machine work,
engine alignment, etc.) jobs or work hand-in-hand with re-
pair specialists when necessary. Machinists can bore and/or
face virtually any configuration from 2 in. (50 mm) to 96 in.
(50 to 1152 mm) diameter.
On these combination jobs, having one company do
n In response to requests from customers, Reynolds French
developed an engineered flywheel lock that is more reliable than
other designs being used and which can be set to any desired po-
sition of the flywheel or crankshaft in the complete 360 turning
radius. Hundreds have been retrofitted on both slow-speed and
high-speed engines and compressors.
52 JANUARY-FEBRUARY 2017
both portions has tremendous advantages over separate
companies, Kirk Chalmers said.
Reynolds French has refaced surfaces of compressor
crosshead guide and frame mounting flanges, frame bot-
toms, cylinder decks, frame split lines, bearing cap land-
ings, jaw fits, pedestals, as well as pipe flanges and many
other critical surfaces. Since the 1980s, Reynolds French
has provided the capability to turn crankshaft journals,
straighten crankshafts, and polish rod pins without crank-
shaft removal. This has been a mainstay of the companys
services, and in fact, in the 1990s, we pioneered the equip-
ment and technique to successfully machine and polish
main bearing journals in place, Kirk Chalmers said.
Field alignment is another company specialty. Services
include wire line inspection, optical alignment, manual
crankshaft deflection measurements, leveling and runout
corrections, line boring, crankshaft straightening, proper
grouting methods and application of several lines of foun-
dation products.
Since 1980, the company has distributed numerous foun-
dation products including ITW/Philadelphia Resins Chock-
fast grout, which it handles in 11 states in the central U.S.
The company plays host to semi-annual, two-day grouting
seminars that train customers in the application and installa-
tion of engineered epoxy grout and chocking systems. They
further increased their product base in the 1990s with the
addition of adjustable chocking system products, complete
anchor bolt systems, cementitious grouting products and
a complete line of epoxy coatings and repair compounds.
CWC epoxy grout was added to the stock product lineup in
1998 and Escoweld epoxy grout in 2005.
In 1997, Reynolds French developed a uniquely de-
signed and engineered line of pipe supports for compres-
sor and plant piping. Instead of earlier wedge-type de-
signs, it pioneered rounded supports that were stronger
and more dependable in service. This product, which is
called Tulsa Pipe Supports (TPS), quickly became pop-
ular with engineering companies and end users. TPS
overcomes the U.S. Department of Transportation (DOT)
requirement to avoid metal-to-metal pipe supports. They
support the pipe without causing corrosion, fretting or the
vibration associated with conventional metal supports.
Made to be easily removed for pipe inspection and easily
adjustable, they are constructed of high strength epoxy
material and corrosion-free zinc plated hardware, with no
painting required.
It was not long after this product proved to be what many
customers needed that Reynolds French also began man-
ufacturing TPS pipe clamps to meet customer demands.
Standard design drawings with a corresponding standard
dimension schedule were developed, along with the stock-
ing of Fabreeka liner material. TPS pipe clamps and base
plates can be supplied with galvanized, painted or black
iron surface conditions, depending on customer require-
ments. Three different standard sizes of TPS pipe supports,
each with two lengths, are offered for use with pipe and
COMPRESSORtech2
n The repair of this large Hazelton slurry pump provides an excellent example of Reynolds Frenchs repair expertise. A piece of flange
and nozzle was broken out of the pump housing (top left) when flange bolts were mistorqued. With the customers concurrence, Reynolds
French had to heat-treat the very hard white cast-iron (Rc 60) housing to soften the material enough to make it machinable (top right).
They then installed steel reinforcement (bottom left) and special fabrications (bottom center) to reclaim the flange. It was then machined
to original equipment manufacturer specs (bottom right) and the repair passed leak testing.

pulsation bottle diameters from 2 to 54 in. (51 to 1372 mm).
In 2006, again due to specific requests from customers,
Reynolds French developed a more reliable, engineered
flywheel lock that could be set to any desired position of
the flywheel or crankshaft in the complete 360 turning ra-
dius. It was engineered to ensure the safety of workers and
equipment that are working inside a crankcase while an en-
gine or compressor is being serviced or repaired.
In short, customers needed a variable position flywheel
lock (IPFL), which is the name we gave this patented in-
vention, Kirk Chalmers said. Safety had to be our top
priority, as men and equipment inside engines would com-
pletely depend on it. With continuous improvement and
development of a series of locking cogs and spacer beam
adapters, the Reynolds French flywheel lock is universally
adaptable to accommodate the flywheel cog indentation of
virtually any large engine, whether slow, medium or high
speed. Hundreds of the flywheel locks have been installed
for customers. Each one is designed, built, tested, and
installed to custom fit the flywheel of the customers en-
gine. The device is easily positioned using the supplied
turn handle, and it comes standard with a lockout/tagout
device for further safety.
Recent additions to the companys product lineup include
the BossPac Blue Box vibration sensor and the BossPac
Wasp early valve leak notification product. The 3-D vibra-
tion sensor was developed to give a true vibration feedback
in every plane of motion. Using its digital signal processor,
the sensor filters and conditions acceleration and velocity
signals for use with a separate remote readout unit. Data is
evaluated to alert with alarm or shutdown signals as speci-
fied by the user programmable settings controlled with a
user-friendly, four-button layout. The WASP (wireless ac-
celeration sensor puck) is a wireless velocity, acceleration
and temperature sensory device used in permanent and
mobile condition monitoring systems.
Reynolds French has successfully repaired high-speed
and high-horsepower compressors from South America
to Alaska, large damaged engines from Germany to the
Philippines, and marine equipment from the Gulf Coast to
the Great Lakes, Sandy Chalmers said. Weve repaired
and machined thousands of other pieces of equipment,
including rock crushers, pump housings, steam turbines,
cylinder and compressor heads, presses, and equipment
used in sugar and steel mills, both on location and in our
shop facility. CT2

COMPRESSORtech2 JANUARY-FEBRUARY 2017 53

 techc
Electromagnetic Effects On The

orner
TNFs Of A Reciprocating Compressor
With A Soft Coupling
First TNF shift occurred from torsional spring to ground
related to electromagnetic effect

Editors Note: This abridged paper was originally pre-

sented at the 2016 Turbomachinery and Pump Symposia
in Houston, Texas.

BY TROY FEESE AND ALEKSANDER KOKOT

T
his paper shows how the torsional stiffening effect
of the electromagnetic field can affect the torsional
natural frequencies (TNFs) of a compressor system
that utilizes a torsionally soft coupling. The torsional mea-
surements documented herein show that a shift in the first
TNF occurred due to the effective torsional spring to ground
related to electromagnetic (EM) effect. The torsional data con- n Figure 1. Diagram of VFD Motor-Driven Reciprocating Com-
firmed that this effect is significant for a motor-driven recip- pressor System
rocating compressor system with a torsionally soft coupling.
Induction Motor, Rated 1050 hp (783 kW)
Speed Controlled by Variable Frequency Drive
Case Study Introduction Motor
Original Design = 750 to 1200 RPM (62% - 100%)
Four identical compressor trains were installed at a gas Recommended = 780 to 1200 RPM (65% - 100%)
plant. Initial design analyses indicated that the units should Rubber-in Shear with Double Rubber Elements
not have any torsional issues; however, the operating com- Torsional Stiffness = 0.49 106 lb.in./rad,
pany requested that torsional testing be performed during Coupling Dynamic Magnifier = 6
commissioning. Some compressor manufacturers recom- Continuous Vibratory Torque = 27,700 lb.in. 0-p at 10 Hz
Continuous Vibratory Torque = 13,850 lb.in. 0-p at 40 Hz
mend field-testing as standard procedure to verify results
of the theoretical torsional analysis when a variable speed External Flywheel Mounted on Compressor Hub
Flywheel Added WR2 = 110,000 lb.in.2
motor drives a compressor, since it is more likely that a tor-
sional resonance could be encountered within a relatively Two-Throw Reciprocating Compressor
wide speed range. Compressor Two-Stage Residue Gas Service
Cylinders Normally Double-Acting (DA)
These compressor units shared a common variable fre-
quency drive (VFD). This VFD was used to soft start one n Table 1. Description of Compressor System

Troy Feese is a Senior Engineer at Engineering Dynamics
Incorporated (EDI) in San Antonio, Texas. He has 25 years of expe-
rience performing torsional vibration, lateral critical speed, and rotor-
dynamic stability analyses as well as evaluating structures using finite
element methods. Contact him at: tdf@engdyn.com. Aleksander
Kokot is an engineer at WEG Equipamentos Eltricos S.A. in
Brazil. He has five years of experience working in the Laboratory
of Vibration at Federal University of Technology Paran and
Faculty of Engineering of the University of Porto. Contact him at:
aleksander@weg.net
motor at a time and then transfer that motor to across-the-
line operation for constant speed (60 Hz electrical). Once
three motors are running across the line, the VFD can ac-
tively control the speed of the fourth unit to adjust for vary-
ing plant operating conditions. A general description of the
compressor package is provided in Figure 1 and Table 1.
Field Measurements
Measurements can be used to verify the torsional predic-
tions. When acquired in the field, tests can be conducted

54 JANUARY-FEBRUARY 2017 COMPRESSORtech2

under full load where the actual response can be deter-
mined. Measurements include dynamic torque, alternating
stresses, torsional oscillation, etc. These values can then
be compared to allowable limits.
Only a few points on the unit are available for measure-
ment. Therefore, a torsional analysis is still needed to infer
amplitudes at other locations that are inaccessible. By nor-
malizing the computer model to match the measured data,
conclusions and inferences can be drawn at the points of
the system that are not directly measured.

n Figure 3. Waterfall plot of dynamic torque vs speed during

cold start.

n Figure 2. Strain gauge telemetry system.

Strain gauges were installed on the motor shaft along with

a battery-powered transmitter on the coupling hub (Figure 2).
The four gauges were wired in a full Wheatstone bridge
arrangement to measure only shear strain while cancelling
out the effects of bending strain, axial strain, and varying
temperature. The output voltage signal from the receiver
was then converted to torque. The telemetry system was
calibrated to measure transmitted torque (average), as well
as dynamic torque with a frequency range up to 500 Hz.

Discussion Of Measured Data

Cold condition
The torque responses were measured in the motor shaft
during a cold start. From the waterfall plot shown in Figure 3,
a TNF was identified between 12 and 14 Hz.
The waterfall plot was created by vertically stacking mul-
tiple frequency spectra taken at intervals of operating speed.
Harmonics (multiples of running speed) appear as diagonal
lines in the waterfall plot. Any torque excitation at these fre-
quencies can excite a TNF. The slice plot shown at the bot-
tom of Figure 3 was created by tracing through the 1x and
2x harmonics. Response peaks shown in the slice plot indi-
cate the TNF. Note that some smearing of frequencies oc-
curred because the fast ramp rate of the VFD during startup.
The torque data were re-plotted to show the time waveform
during startup. By counting cycles within the small time period
at resonance, a TNF was identified at approximately 13.8 Hz.
A torque spike was observed when the motor was switched
from the VFD to across-the-line operation. As shown in Figure
4, during this transient event the highest torque spike was
n Figure 4. Torque measured during transfer from VFD to
across-the-line motor operation cold condition.
approximately 100,000 lb.in. (11,300 Nm) (twice the full load
torque), which is still lower than the allowable peak torque for
the rubber coupling. Using peak-hold averaging during the
electrical switching event, non-synchronous response peaks
were evident at 5 and 12 Hz. The 5 Hz frequency was not
observed during the initial startup.
Warm condition
A second start was recorded with the unit and rubber
coupling in a warm condition. The coupling was consid-
ered warm since the compressor unit had been operating
for some time. For reference, the estimated temperature of
the coupling was less than 120F (49C).
Although rubber-in-shear couplings are thought to have
relatively constant torsional stiffness, the TNF can vary with
the temperature of the rubber elements and with the mean
continued on page 56

COMPRESSORtech2 JANUARY-FEBRUARY 2017 55

and dynamic torque through the coupling. The TNF was
slightly lower in the warm condition (11-13 Hz) compared
with the cold condition (12-14 Hz).
A torque spike occurred when the motor switched from
VFD to across-the-line operation. This sudden change in
torque excited TNFs of the system. Response peaks were
noted at 5 and 11.75 Hz. These two frequencies will be dis-
cussed in more detail later in the paper.
The motor was operating across-the-line (no VFD) just
before a loaded shutdown. The unit was stopped by cutting
off electrical power to the motor, therefore any EM stiffening
effects should have quickly dissipated. Load torque from
the compressor caused the unit to stop rotating in just a few
seconds so a waterfall plot could not be made.
The maximum torque reached during the loaded shut-
down reached 100,000 lb.in. (11,300 Nm) but remained
below the allowable peak torque of the coupling for tran-
sient events, so no damage occurred to the rubber ele-
ments. The response frequencies ranged from 8-10 Hz
during the shutdown event.
Comparison Of Measured Data With Predictions
During shutdown when the motor was de-energized (no
EM stiffness), the TNF was measured between 9-10 Hz.
However, at load (with EM stiffness), the TNF ranged from
11-14 Hz and was found to be within the operating speed
range. This range in TNFs can be attributed to varying tor-
sional stiffness of the coupling (cold vs. warm) and of the
EM across the motor air gap (no-load vs. full-load). Table 2
summarizes the measured TNFs at these various condi-
tions. Note the significant increase in TNF with EM.
Conditioning No EM Load Load (With EM)
Cold 10Hz 12-14 Hz
Warm 9 Hz 11-13 Hz
n Table 2. Summary of measured TNFs.
In the design stage, an independent torsional vibration
analysis (TVA) was performed as recommended by API.
The TNF involving the coupling was calculated to be ap-
proximately 30% below the minimum running speed, which
should normally be a sufficient separation margin (SM).
However, the coupling and flywheel were selected using a
TVA that did not include the EM stiffening effect across the
motor air gap. Had the torsional stiffness due to EM been
considered, a softer coupling and/or larger flywheel would
likely have been specified for this compressor system to
achieve the full speed range. Recall that decreasing tor-
sional stiffness would lower the torsional natural frequen-
cy, and increasing the mass moment of inertia would also
lower the torsional natural frequency.
Normalized Torsional Model
The stiffening effect associated with the EM is equivalent
56 JANUARY-FEBRUARY 2017
to a torsional spring attached between the motor core
and ground. This additional stiffness explains why the
measured TNF was higher compared to the calculated
value that did not include the EM. The EM also creates a
frequency near 5 Hz, which was observed only after the
torque spike occurred transferring from VFD operation.
The TNF at 5 Hz was not evident during startup because
it is well below running speed (no low frequency excita-
tion from the VFD).
n Figure 5. Parametric study of TNFs sensitivity to EM stiffness.
Once the torsional computer model was normalized to
match the no-load case, a parametric study was performed
to evaluate the sensitivity of the TNFs to EM stiffness. As
shown in Figure 5, the EM torsional stiffness at the motor
air gap would need to be approximately 1.1 x 106 lb.in./rad
(120.6 kNm/rad) to correlate with the first two TNFs that
were measured in the field.
The estimated EM stiffness across the motor air gap
appears to be reasonable because Drive B in the
Hauptmann, et al., paper had a similarly rated motor with
a reported stiffness of 0.9 x 106 lb.in/rad (98.7 kNm/rad).
Holopainen [7] reported a torsional stiffness of 1.4 x 106
lb.in./rad (160 kNm/rad) for an induction motor rated for
1250 HP (932 kW). In comparison, the EM torsional stiff-
ness of 1.1 x 106 lb.in./rad (120.6 kNm/rad) is approximately
2.2 x the equivalent torsional stiffness of the rubber cou-
pling elements (i.e., 1.1 / 0.49 = 2.2).
Simplified Torsional Model
Although a detailed mass-elastic model is normally
required for an accurate torsional analysis, a simplified
two-inertia model is created here for illustration purposes.
Equivalent mass-elastic values are listed in Table 3. In ad-
dition to torsional stiffness, EM can also provide damping.
The dynamic magnifier given by the manufacturer for
the rubber element in the coupling is an indication of
damping. However, if the damping is neglected, then the
following equation can be used. For two unequal inertias,
COMPRESSORtech2
 Electromagnetic (EM)
K1 = 1.1 x 106 lb.in./rad (120.6 kNm/rad)
Estimated From
C1 = 780 lb.in.-s/rad (88.1 Nm-s/rad)
Measurements
J1 = 242 lb.in.-s2
Motor Rotor
(27.3 Nm-s2)
K2 = 0.49 x 106 lb.in/rad (53.7 kNm/rad)
Rubber Coupling
Dynamic Magnifier = 6
Flywheel (FW) J2 = 314 lb.in.-s2
+ Compressor (35.5 Nm-s2)

n Table 3. Equivalent mass-elastic values.

and two unequal springs, the undamped torsional natural n Figure 6. (top) Torsional modeshape involving rigid body
frequencies can be calculated using the following equa- motion. Figure 7. (bottom) Torsional modeshape involving
tion from Blevins [8]: the coupling.

1
As shown, the increase in TNFs due to EM is significant
1 2
and should not be ignored. Although this may seem like
1 k1 k2 k2 k1 k2 k2 2 4 k1 k2 2
fi = 3 + + + + - a surprisingly large increase, Knop [3] also noted that in
J1 J1 J2 J1 J1 J2 J1 J2
22 his experience the real natural frequency could easily be
higher by 50% or more. The EM effects make a pronounced
Equation 1 difference for this particular compressor system because
the torsional stiffness of the rubber coupling is less than
Without the EM effects, the results from the simple model half of the EM stiffness. Later in this paper, systems with a
are f1 = 0 Hz and f2 =19.5 Hz.1With EM TReffect, the results torsionally stiff coupling are shown to be less sensitive to
from the simple TLmodel
= are f1 = 5 Hz and f2 = 13.4 Hz, which the EM effect.
s
reasonably match the measured TB
2srresults.
The first two torsional modeshapes are plotted in Figures
6 and 7. Comparisons are made with and without the EM ef-
fects. Torsional modeshapes are a little difficult to represent
on paper. Torsional oscillation is normalized to maximum of
+1 or -1 (unitless). A point of maximum oscillation
2 is called
( T
an anti-node. Significant twisting throughL ) a shaft or cou-
Kemby
pling is indicated
=N1T
a line Bcrossing zero,2and this point is
(1+( TL ) )
referred to as a node (where no oscillation occurs).
For example, a zero mode would be predicted without
EM because the torsional system is not attached to ground
(free to rotate). Adding the EM stiffness between the motor
core and ground, as indicted by the dashed line, increases
the TNF from 0 to 5 Hz.
Kem 0.9 in-lb/rad
6
For the torsional mode10 involving significant twisting
through the coupling, the TNF is 9.5 Hz without EM and
increases to 13.4 Hz with EM. This represents an increase n Figure 8. Comparison of calculated normalized dynamic
in frequency of approximately 40%. torque in coupling with and without em.
continued on page 58

COMPRESSORtech2 TL JANUARY-FEBRUARY 2017 57

Cem =Kem 2
( T )
 Figure 8 shows the normalized dynamic torque in the
coupling based on a constant dynamic torque applied at the
compressor location so that the response would be scaled
to unity at zero frequency. This calculation was made using
a proprietary torsional vibration program developed by the
authors company.
First, the response was plotted without EM. As shown
in Figure 8, the predicted TNF at 9.5 Hz would be below
the speed range. Then with the EM stiffness included, the
TNF increases from 9.5 to 13.4 Hz and is actually within the
speed range. As was shown in Figure 7, the modeshape
for the TNF at 13.4 Hz involves maximum twisting through
the coupling with the motor and compressor having out-of-
phase torsional oscillation.
With EM included, another TNF appears at 5 Hz, which is
well below the minimum speed. As was previously shown in
Figure 8, the modeshape for the TNF at 5 Hz has the entire
motor-coupling-compressor system twisting across the EM
spring to ground. Without the EM stiffness to ground, this
would have been considered the zero mode for the system
and typically not plotted in the TVA.
The primary problem that was uncovered during the field
test was that there is a TNF at 13.4 Hz that falls within the
operating speed range and therefore does not have the API
recommended separation margin. Although the TNF at 5
Hz appears to have a higher peak response, it is well below
the minimum operating speed and not a concern. In fact,
the TNF at 5 Hz may not have even been noticed except for
the switching from VFD to across-the-line that momentarily
produced a small torque spike.
Discussion Of Predicted Vs. Measured Results
An evaluation was made to determine how the motor EM
stiffness would affect the system if a stiffer disc type cou-
pling were used instead of the torsionally soft rubber cou-
pling. This was accomplished by performing a parametric
analysis as shown in Figure 9 where the torsional stiffness
n Figure 9. Comparison of calculated normalized dynamic
torque in coupling with and without EM.
58 JANUARY-FEBRUARY 2017
ratio of the combined motor coupling compressor shaft stiff-
ness/EM stiffness was varied from 0.1 to 12.
For the example covered in this paper with the torsion-
ally soft coupling, the stiffness ratio was approximately 0.5
and the increase in TNF was 40% due to the EM effects.
The results show that if the equivalent torsional stiffness
between the motor and compressor were four times the EM
stiffness, then the increase in TNF would be approximately
5%. However, if the torsional stiffness between the motor
and compressor were approximately 10 times the EM stiff-
ness, then the increase would only be 2%. This indicates
that the EM effect would likely be minimal when using a
disc-type coupling.
Another discrepancy between the predicted and mea-
sured results can be due to the torsional stiffness variation
of the rubber coupling. Tolerances in rubber, which is a nat-
ural product, can mean that the dynamic torsional stiffness
will deviate by 15% from the values provided in the cata-
log. The dynamic torsional stiffness can also be influenced
by the temperature of the rubber elements, steady torque
transmitted through the coupling, and by the frequency and
amplitude of the vibratory torque. For example, some cou-
pling manufacturers determine the torsional stiffness on a
test rig at a frequency of 10 Hz and then recommend a cor-
rection factor for other frequencies.
Electromagnetic Model
Up to this point, the EM effect has been shown to exist,
and the EM stiffness value was inferred from the torsional
model and field test data. The estimated torsional stiffness
was also shown to fall within a range of stiffness values
previously published in other papers. The following sec-
tion discusses how the EM can be calculated in the design
stage based on supplied motor information and simplified
equations.
The electromagnetic field in the air gap of an electric
motor induces forces in the radial and tangential direction.
The steady-state torque and power output of an induction
motor are the result of electromagnetic fields, which act
across the air gap between stator and rotor. The motor rotor
has tangential forces applied to it, which are responsible for
the torque generation. No resultant radial load is expected
when the motor rotor is centered within the stator.
There are some types of machines that require more
detailed analysis of the electromagnetic interaction when
applied in a motor-driven system. Motors with sleeve bear-
ings present eccentricity due to the bearing requirements
for operation, and, according to the level of deviation, could
be relevant to the resultant load. High-speed motors or gen-
erators, operating near a rotor lateral critical speed, have
the eccentricity increased due to bending and whirling of
the rotor. The total resultant force in the air gap is called
Unbalanced Magnetic Pull (UMP) and different methodolo-
gies can be used to evaluate the influence of the electro-
magnetic parameters in the dynamics of the rotor.
COMPRESSORtech2
 The information listed in Table 4 can be used to com- Conclusions
pute the EM stiffness for the motor used in the example Torsional excitation from the VFD motor was insignificant
for this paper. compared to the reciprocating compressor. This is because
the VFD is a modern type pulse width modulation (PWM)
Description Variable Value
with relatively low torque ripple. However, authors have
Number Of Stator Poles N1 6 seen other cases where excessive torsional vibration oc-
Breakdown Motor Torque TB 146,232 lb.in.
1 curred when the VFD control was improperly tuned for the
Rated Full Load Motor Torque TR 1 2
55.147 lb.in. application [11,12].
1 k1 k2 k2 k1 k2 k2 2 4 k1 k2 2 1 The rubber coupling had a much lower allowable limit
fFrequency
i = 3 Of + + Torsional
Superimposed + + - 126 rad/sec
1 1 2
Vibration J1 J1 J2 J1 J1 J2 2 J1 J2 12 2 for dynamic torque than the steel motor shaft and com-
212 k1 k2 k2 k1 k2 k2 4 k1 k2
fElectrical
i = 31 Supply
kJ1 + Frequency kJ1x+
kJ2 + kJ2 (60 Hz kJ2 +kJs2 2 - 4J377
2)
2
k1Jkrad/sec
2 1
1
pressor crankshaft, and would therefore be the weak
fi = 232 1 + 1 + 2 1+ 1+ 2
2 - 4Jk Jk 2
1 2 2
link in the system. The rubber coupling would typically
1 Jk1 Jk1 Jk2 Jk1 Jk1 Jk 2 1 2
fSlip
i= 3 + 2+
2At2 Rated Load + 2 +Sr 1 2
- 0.0092 act as a fuse in the system and likely fail before the other
J1 J1 J2 J1 J1 J2 J1 J2
n Table
22 4. Data from Electric Motor Manufacturer. components. Cracks were not evident in the rubber el-
ements, which indicated that the newly-commissioned
1
The first step is to calculate 1 TR time constant: compressors had not been operating for long periods
TL = the electrical

1s 2s1r TRB
T with excessive torsional vibration.
TL = 1 1 TR
TL = 1s 2s 1 rr T
TB
TBR Recommendations
TL = s 2s To ensure a safe and reliable design of a VFD motor-
2sr 2 TB
sEquation driven compressor train, a complete simulation of the entire
TL=0.0544 sec. unit is necessary and field tests are also recommended.
2
( TL ) Separation margins should meet API or the unit should be
Kem
Then the EM =N1Twill
stiffness B be: 2 2 shown to have acceptable torsional response at all load
(1+( L )L2) )
( TT conditions and operating speeds.
Kem =N1TB ( TL ) 2 The EM effect should be included in future TVAs, espe-
Kem =N1TB (1+(
( TT )L )2 )
2
L
Kem =N1TB (1+( TL )2) cially when the coupling is torsionally soft (stiffness ratio
less than four). See Table 5 for error estimates when EM is
(1+( TL ) )
not considered.

Torsional Stiffness Ratio = Increase Of TNF With EM

Kem 0.9 10 in-lb/rad
6
Combined Motor-Coupling- Compared To Predicted First TNF
Kem 0.9 106 in-lb/rad
6 Compressor Shaft / EM Without EM
Kem 0.9 10 in-lb/rad 0.5 +40%
Equations6 3 and 4
Kem 0.9 10 in-lb/rad 1 +20%
And finally the EM damping is: 2 +10%
TL 4 +5%
Cem =Kem 2
( TTL ) 6 +3%
Cem =Kem TLL 2 10 +2%
Cem =Kem ( T
TL )2
L
Cem =Kem ( TL )2 n Table 5. Summary of Estimated Error If The EM Effect Is Omitted
( T5L )
Equation
Cem1000 in-lb-s/rad For the compressor unit in the example, it was rec-
ommended to limit the operating speed range. Based
As shown, the calculated EM stiffness of 0.9 x 106 on measured field data, the minimum operating speed
lb.in./rad (98.7 kNm/rad) compares favorably with the EM was increased from 750 to 780 rpm to prevent possible
stiffness of 1.1 x 106 lb.in./rad (120.6 kNm/rad) that was damage to the rubber elements in the coupling. This rec-
based upon the measured field data. This indicates that ommendation was accomplished by reprogramming the
these equations can be used to estimate the effective VFD in the field.
EM stiffness. It was also recommended that continuous operation of
Using the calculated EM stiffness with the simple two- the compressor with single-acting cylinders or failed valves
inertia model previously developed, the first two TNFs be avoided since such operation would significantly in-
were re-calculated to be 4.7 Hz and f2 = 12.6 Hz. These crease dynamic torque at 1x running speed, and could pre-
calculated TNFs closely compared with the measured maturely wear out the rubber coupling elements. CT2
frequencies. See references at: ct2.co/references

COMPRESSORtech2 JANUARY-FEBRUARY 2017 59

 2
3 Scheduled Downtime DJ SLATER, PUZZLEMASTER

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

7 5
6
Past Tense
Annoyed Listened
V L B S T O P P E D E S I A R U A W I I
Answered Loved
J S Q R E T I R E D E L I A S N X R Z T Appeared Missed
D U B R O K E N J O Y E D U N I T E D V Arrived Nudged
J R M E N T R A V E L E D O T K R E A A Broken Occurred
F V T P U A A Q L D N N Y W I H T K J J Classified Preferred
Closed Qualified
I I Q R E R A E D E R E W S N A G T E Q Completed Raised
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D E T I V N I P G E U E V I O P Q H A X Consolidated Retired
D D V M S P A R R R D S L H P U N Q N T Copied Returned
M E D O O H A R Y M Y O C E A K Y F Q O Defeated Sailed
Denied Stopped
D N S C L D E I F I S S A L C T S Q E G Determined Succeed
D E T A E F E D D N A R I I O U E T T R Enjoyed Summoned
E T R D E L D S O E E F G R M S K D V O Failed Survived
S S D R D L E C S D I U Q M P I E A J F Finished Taught
Forgot Traveled
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continued from page 45
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COMPRESSORtech2 JANUARY-FEBRUARY 2017 61

201701CTA2792_GCA_Connection2017_HH.indd 1 1/17/17 2:04 PM
Advertisers Index
*Further information on this companys products can be found in the 2016 Edition of the Diesel & Gas Turbine Sourcing Guide
(at www.Dieselandgasturbineguide.net) and/or 2016 Compression Technology Sourcing Supplement (at www.CTSSnet.net).

ACI Services Inc. ......................................................... 29 GE Oil & Gas -

Reciprocating Compression ......... Fourth Cover
Air-Cooled Heat Exchangers ...................................... 45

Altronic LLC ........................................................... 10, 11 Gulf South Rotating Machinery Symposium ............ 24

*Ariel Corporation ........................................................... 1 *KB Delta Compressor Valve Parts, Mfg. ..............32-33

ARMCO Compressor Products Corp. ........Third Cover Modulift ........................................................................ 17

*Burckhardt Compression AG ..................................... 15 Motortech GmbH ......................................................... 41

Centa ............................................................................ 43 Neuman & Esser Group .............................................. 27
Compressor Products International ............................ 5
Nidec ASI S.p.A. ............................................................ 7
DCL International Inc. ................................................. 21
Philadelphia Gear ........................................................ 39
*Dresser-Rand ............................................................... 13
Reynolds French ......................................................... 19
E Instruments International ........................................ 40
Shockwatch ................................................................. 23
*Elliott Group ............................................Second Cover
SOGAT 2017 ................................................................. 51
Exline Inc. ..................................................................... 25

FW Murphy Production Controls ................................. 9 Stasskol GmbH ............................................................ 35

Gas / Electric Partnership ........................................... 31 *Testo Inc. ..................................................................... 37

Gas Compressor Association .................................... 61 Zahroof Valves Inc. ....................................................... 3

Cornerstones Of Compression story continued from page 64
German company, Nuremberg Machine Co., becoming its
sole licensee for gas engines in North America. At a time
when production of giant steam engines was diminishing,
the new West Allis Works was ideally suited to the produc-
tion of gas engines. Allis-Chalmers engineers and work-
men swiftly redesigned the European engines. By 1904,
Allis-Chalmers was producing horizontal, tandem, double-
acting, four-cycle gas engines from 250 to 3000 hp (186 to
2237 kW) and twin-tandem units from 520 to 6000 hp
(388 to 4474 kW). The average Allis-Chalmers gas en-
gine frame weighed more than 90 tons (82 tonnes), and
the giant crankshaft more than 100 tons (91 tonnes). The
first engine produced was a 1000 hp (746 kW) unit for
the Milwaukee works of the Illinois Steel Co. Details of
Allis-Chalmers engine designs are discussed in Guldners
Internal Combustion Engines, 1910.
The new engines were so promising that, in 1904, Allis-
Chalmers introduced a new trademark: Ours the Four
Powers: Steam, Gas, Water, Electricity. Although the mar-
ket for these engines was largely limited to industries using
waste gas from blast furnaces, they constituted 21% of the
companys unfilled orders in June 1906. One order for the
Indiana Steel Co.s immense Gary, Indiana, plant was for
17 gas engines, each rated at 4000 hp (2983 kW). They
were installed in a single 966 x 105 ft. (294 x 78 m) power-
house, said to be twice the size of any previous gas engine
installation anywhere. From 1905 to 1912, 51 large engines
were produced.
Allis-Chalmerss intensive expansion and diversified prod-
uct development, coupled with labor problems, resulted in
financial difficulties in 1912. The company was reorganized
and production of many diversified products continued, but
rather than improving, the U.S. economy declined into a
depression by 1914. Sweeping recovery came in 1915 due
COMPRESSORtech2
n These Allis-Chalmers gas en-
gines were installed in the Illinois
Steel Co. plant in South Chicago.
They used blast furnace gas to
produce power to run the plant.
The largest units, in the fore-
ground, are rated at 10,000 hp
(7457 kW) with cylinders having
a 60 in. (1524 mm) bore x 66 in.
(1676 mm) stroke.
to production for World War I. Diverse products steam
turbines, hydraulic turbines, large centrifugal pumps, elec-
trical equipment, large motors and generators, automotive
starters and lighting components, and machinery for rock
crushing, cement production, mining, flour milling, and saw-
milling brought the company back into prosperity.
Although few new steel mills were being built, produc-
tion of gas engines held up fairly well from 1912 through
1920. Although only 24 engines were produced during this
period, all were 4000 hp (2983 kW) or larger, including an-
other 17 for the Indiana Steel Co. These engines, equipped
with Allis-Chalmers generators, used waste gas to generate
all the electrical power for the plant. In fact, during World
War II, they also furnished power for the city of Gary. A few
Allis-Chalmers engines were applied in gas compression
applications, including two 24 in. (610 mm) bore x 36 in.
(914 mm) stroke, 1200 hp (895 kW) twin-tandem gas en-
gines sold to Northwestern Natural Gas Co. (later Ohio Fuel
Gas) in 1917.
After 1920, only four more Allis-Chalmers gas engines
were built. The last and largest was rated at 10,000 hp
(7457 kW), produced in 1930 for the Illinois Steel Co.
plant in South Chicago, Illinois. The engines cylinders were
60 in. (1524 mm) bore x 66 in. (1676 mm) stroke. Total Allis-
Chalmers gas engine production was only 81 units, but the
average rating was more than 3400 hp (2535 kW), making
Allis-Chalmers the largest manufacturer of gas engine horse-
power in the early years of the 20th century.
Although its gas engine business faded after 1920, Allis-
Chalmers enjoyed many more decades of success with
many other diverse products, including farm tractors and
machinery, which had been first introduced in 1914. In the
1980s and 1990s, after a series of divestitures transformed
the company, Allis-Chalmers was eventually dissolved. CT2
JANUARY-FEBRUARY 2017 63
 Cornerstones Of Compression
Allis-Chalmers Horizontal Gas Engines
Diversified industrial company manufactured heavy machinery for steam,
gas, water and electricity power
BY NORM SHADE
I
n 1848, the U.S. had approximately 10,000 manufactur-
ing firms. Less than 1% were still in existence a cen-
tury later. One of these was the Allis-Chalmers Co., a
diversified machinery company that by 1953 was one of
the big three with General Electric and Westinghouse
in the electrical field and the third largest tractor and
farm equipment producer. Often overlooked was the fact
that Allis-Chalmers was also an early manufacturer of large
horizontal gas engines.
Founded in 1847 in Milwaukee, Wisconsin, as The
Reliance Works, the company built products that in-
cluded French burr millstones, portable mills, shafting
and water wheels. In 1861, Edward P. Allis took over the
company to get it out of financial difficulties from the pre-
Civil War depression. Changing the name to Edward P.
Allis & Co., he quickly grew it and by 1869 produced the
first Allis steam engine.
Hiring Edwin Reynolds, one of the great engineers of the
19th century, Allis soon was producing Reynolds-Corliss
steam engines, which became known throughout the
world. In 1884, Allis built the largest centrifugal pump in the
U.S., and two years later, Reynolds designed the first triple-
expansion, steam-powered pumping engine. In 1888, he
designed and built the first screw pump.
64 JANUARY-FEBRUARY 2017
n The large volume of gas pro-
duced by blast furnaces in steel
mills was transformed from a
waste product into fuel to power
gas engines. These Allis-Chalmers
twin-tandem horizontal gas en-
gines were used to drive blow-
ers which supply air to the blast
furnaces at the Illinois Steel Co.
As the age of electricity emerged in the late years of the
19th century, Reynolds developed and built two horizontal
cross-compound steam engines with the generator spiders
mounted directly on the engine shafts. These units were so
successful that belt driving of generators was soon aban-
doned throughout the country. By the time that Edward P.
Allis died in 1889, his industrial company had 1100 employ-
ees and was designing and building hoisting engines for the
Lake Superior copper mines, rolling mill engines for steel
companies, blowing engines and compressors for blast fur-
naces, and many other products. After Allis death, control
was turned over to Reynolds.
At the turn of the century, the company was a world
leader in the production of steam engines and flour and
saw milling machinery. But Reynolds foresaw even larger
engines and machines being built. In 1901, Allis-Chalmers
was formed by merging the Edward P. Allis Co., Fraser and
Chalmers Co. and Gates Iron Works. Soon, Allis-Chalmers
was building compressors, engines, tanks, locomotives
and many other industrial machines. One of Reynolds first
steps was to begin building the giant West Allis Works, a
plant that would employ 10,000 men and produce $20 to
$30 million worth of machinery a year.
In early 1903, Allis-Chalmers bought the patents of the
continued on page 63
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