Larry Zgrabik - ABB
ABB Products & Technology -
Subjects: Uncategorized
ABCs of Hiring & Retaining Generation X&Y Employees
William A. Couch, PE - El Paso Pipeline Group
When it comes to hiring and retaining Generation X and & employees, it is no longer your Dad’s Oldsmobile…wake up folks, they
don’t make Oldsmobiles anymore…think iPods! That’s the problem! Baby boomer managers are finding it more and more challenging
to find, hire and, most importantly, retain Gen X and Y employees. There must be a paradigm shift in the way we approach the
employment of Gen X and Y employees. This presentation will be a (fun filled) experience with definite learning “takeaways” for the
attendees.
Subjects: Uncategorized
Charles Ely, PE - ACTT, div. of CECO
ACTT/GMRCSoftware Update
Subjects: Uncategorized
James McCarthy - Innovative Environmental Solutions
The federal Clean Air Act and State regulations continue to pursue emission reductions from natural gas industry sources. In addition, federal greenhouse gas (GHG) requirements are being developed. This annual session on air regulatory issues will cover the status, content, and potential impact of recently proposed and final U.S. EPA air pollutant and GHG regulations affecting gas industry sources. Key state actions will also be discussed. The air quality issues will be summarized and implementation issues will be discussed. Highlights will include key regulatory developments from the last year, including the requirements and status of the March 2009 EPA proposal to revise the National Emission Standards for Hazardous Air Pollutants (NESHAP) for gas-fired reciprocating internal combustion (IC) engines. The proposed rule is scheduled to be finalized in early 2010 and would require emission controls for many existing engines, with NSCR required for rich burn engines and an oxidation catalyst required for lean burn engines. Implementation issues associated with the 2008 federal New Source Performance Standard (NSPS), which established federal standards for NOx, CO and VOC emissions for new gas-fired IC engines, will also be discussed. In addition, the National Ambient Air Quality Standard (NAAQS) for ozone was lowered in March 2008 and EPA is reconsidering the fine particulate (PM2.5) NAAQS based on recent challenges. NOx emissions are regulated as a precursor to both ozone and PM2.5, and potential implications will be discussed, including the status of regional programs that may require geographically broader NOx controls for existing IC engines or turbines. The session will also provide an update on GHG emission issues and regulations. A federal GHG reporting rule has been proposed and additional GHG legislation is under consideration. Federal activity will be reviewed and the relationship of federal actions to state and regional GHG programs will be discussed.
Subjects: Uncategorized
Art & Science of Reciprocating Machinery Analysis
Bob Webber - Dynalco, Division of Crane Corp.
Reciprocating compressors and engines have many predictable failure modes that can be detected and corrected before they significantly affect the machine’s performance or availability. This short course introduces data collection and analysis techniques that can be used to detect compressor rod failures, valve leaks, rink leaks, and valve dynamics problems; compressor horsepower and capacity inefficiencies from valve leaks, rink leaks and pulsation; engine mechanical failures like liner scoring, valve train condition, wrist pin knocks and piston slap; engine combustion inefficiencies from ignition timing and firing problems, power cylinder unbalance, and port and valve dynamics. The course focuses on the scientific and physical principles at play rather than on a specific tool. Using the problem-solving techniques outlined in this course, participants will be able to determine what measurements to take, where and how to take them and how to covert the data into intelligence about their machine’s condition and performance.
Subjects: Uncategorized
Assessment of Dynamic Pressure Losses in Reciprocating Compression Plants
Klaus Brun, PhD, Dennis Tweten & Marybeth Nored - Southwest Research Institute/Rainer Kurz, PhD - Solar Turbines Inc.
The term dynamic pressure loss is used somewhat freely in the reciprocating compression industry to describe pressure losses thatare associated with the dynamic component (rather than steady-state) of the flow through the piping system in a compressor station. Conventionally, dynamic pressure losses are determined by assuming a periodically pulsating 1-D flow profile and calculating the transient pipe friction losses by multiplying a friction factor from the Moody diagram with the flow dynamic pressure component (1/2pv2) for each time step for a single time-discretized pulsation period. In reality, the dynamic pressure loss is more complex and is not a single component but rather consists of three different physical effects. These three effects are not necessarily interrelated and have to be individually assessed to determine a true pressure drop of unsteady and periodically pulsating flow. These three pressure loss components are: (1) unsteady flow profile viscous losses, (2) transient inertial losses, (3) fluid to piping driven dynamic structurallosses. The first and second are well understood (although usually ignored or incorrectly calculated) while the third requires an improved physical understanding of the piping system as it involves fluid and structural energy interaction. Specifically, the dynamic structural component of dynamic pressure losses which area due to flow pulsation driven piping vibrations are not well understoodand have not been previously quantified, particularly for resonant piping flow. A number of experiments were performed by SwRI in a reciprocating compressor closed loop facility to determine these loss components using dynamic pressure and vibration measurements for a number of resonant, non-resonant, and resonant-clamped pipe operating conditions. Results show that the dynamic structural loss component can be significant and cannot be ignored when predicting dynamic pressure losses. This paper describes findings from these experiments and aims to quantitatively assess the above described components individually for a typical reciprocating compression system. Analytical, CFD and experimental data are presented.
Subjects: Uncategorized
Basic Thermodynamics of Reciprocating Compression
Greg Phillippi, Ariel Corporation
This short course will cover the fundamental principles of reciprocating compressors and engines. For the compressor, this will include discussions of PV diagrams, capacity, volumetric efficiency, and horsepower. In addition, it will cover the effects of changing conditions, gas analysis, temperature, and pulsation on compressors. For the engine, discussions of the sequence of events for twostroke and four-stroke engines that include pressure and vibration patterns with respect to volume and time will be presented. Finally, it will briefly cover engine combustion characteristics for a few common cases.
Subjects: Uncategorized
Brian Kromer – Infleksion
A growing global politic of environmental stewardship and acknowledgement of industrialization’s impact and contribution to pollution can be termed as “carbon consciousness”. Despite the acceptance or agreement of such sentiment, such public persuasion has a definite impact on current and future environmental regulation. In addition to compliance and permitting activity, discussions of a proportional tax related to carbon or a system of “cap and trade” are being considered. Now more than ever, an accurate portrayal of industry’s contribution to the carbon footprint is vital to the process. The need for “environmental intelligence” and a benchmarking process is evident and is vital to the mutual interest of all of industry and the very public, political process. The entire AIRS/AFS record set of the EPA has been cataloged and collected into a database. The database has further been supplemented by four-digit SIC code in order to determine industry participation by individual record. Additional data available from state agencies increases the resolution of process, along with other federal data from agencies other than the EPA such as the DOE. This independent, credible, third party data then becomes the basis for the presentation of “environmental intelligence”. The resulting facilities can be organized by Air Major, Air Synthetic Minor, Air Minor and their relationship to hazardous air pollutants. Furthermore, the relationship to criteria pollutant non-attainment is also represented.
Subjects: Uncategorized
Case Studies Highlighting the Importance of the Design Phase in Compressor Packaging
Christine Scrivner & Angel Rivera - Southwest Research Institute/ Marlan J. Jarzombek, PE &Zora Raoufpour, PE - Atmos Energy Corporation
In recent years, operating companies have increased efforts to lower the installation costs of reciprocating compressor packages without necessarily considering the effects on operation and maintenance. In many cases, major modifications have been necessary to achieve satisfactory operation. This paper will discuss case studies where the high costs of post-installation modifications far exceeded the costs of having the appropriate design analyses completed at the design stage. These modifications and their benefits will be discussed in detail. This paper will also discuss the types of analyses that should be performed prior to installation.
Subjects: Uncategorized
Comparative Study of Air Flow Measurement Techniques & How They Compare to Lab Tested Results
Patrick Jacob - Williams Gas Pipeline/Eric R. Dufur & Eric R. Figge - ScavengeTech, LLC
While testing a Williams Gas Pipeline Clark HBA8 turbocharger at the Kansas State National Gas Machinery Lab, several different methods were used to determine the turbocharger air flow rate. During the test, emissions data was recorded and the results were used to calculate the air flow rate using a carbon balance method as well as EPA Method 19. Also during the test, the air flow rate was directly measured using a Kurz anemometer installed in the turbocharger turbine exhaust. A turbocharger monitoring system was installed during the test and the pitot tube differential pressure data collected by the turbocharger monitoring system was to determine the air flow rate through the turbocharger compressor. All of the flow rate methods were compared to the actual measured flow rate collected by the NGML test cell ASME venture nozzle to determine viable flow testing methods that could then be used in the field. All methods were then used in the field to compare to the turbocharger monitoring system standard.
Subjects: Uncategorized
Matthias Huschenbett - Hoerbiger Services America, Inc./Greg Beshouri - Advanced Engine Technologies Corp.
This paper reports on the continued application of advanced balance strategies developed as part of the PRCI ERLE 1c and 1e programs. This work was first published in the very well received 2008 GMC papers “Analysis & Application of Advanced Balancing
Techniques to PCC Fitted Pipeline Engines” and “Combustion Sensing in Pre-Combustion Chambers Using Ion Sense”. This 2009 paper reports on the automation of those advanced balancing strategies and their application to various pipeline engine makes and models and various PCC configurations.
Subjects: Uncategorized
Development of an Autobalance System for Legacy Slow-Speed Integral Engines
Noah Dixon, Jr., Bruce Howerton & David Williams – Williams Gas Pipeline; Ed Flanagan – Windrock, Inc.
This paper will describe the development of an automatic, continuous engine pressure balancing system that has been installed on a Cooper-Bessemer 10V250 on the Williams Gas Pipeline system. The autobalance system uses permanently installed pressure monitoring that provides pressure information to a continuous feedback control system. This system uses an electronic fuel valve to adjust fuel delivery for each cylinder to achieve near perfect balance for all unit operating conditions. Topics to be covered will include system design features, fuel valve development, total system cost, combustion diagnostics, and the effects of autobalancing on combustion statistics, fuel consumption, exhaust emissions, and mechanical condition.
Subjects: Uncategorized
Diagnostic Monitoring & On Board Diagnostics for Engine-Compressors: Needs & Opportunities
Gregg Arney & Jeff Chini - Southern California Gas Co./Greg Beshouri - Advanced Engine Technologies Corp.
Unprecedented numbers of staff with compressor-engine specific expertise are retiring from the pipeline. Their fewer and younger replacements will be tasked with more responsibilities precluding development of compress-engine specific expertise. To maintain and improve reliability and reduce maintenance costs, better Diagnostic Monitoring (DM) tools are needed to fill the experience and expertise gap and assist the new workforce with troubleshooting and diagnosis. Concurrently, regulatory expectations are shifting from quantification, requiring CEMS or PEMS, to Green-light/Red-light automotive like On Board Diagnostics (OBD). These OBD approaches utilize already installed sensors and actuators to monitor and maintain emissions compliance and have supplanted costly extractive testing for automotive engines in many states. OBD could potentially offer similar benefits in the pipeline. Recognizing these challenges and opportunities, SCGC sponsored the PRCI funded ERLE 1d program to evaluate diagnostic approaches using current and emerging technologies to fill these gaps and exploit the regulatory opportunity. Under ERLE 1d, AETC investigated diagnostic approaches used in the automotive, flight engine and other industries. AETC also met with stakeholders, defined the most common modes of compressor engine failure and methods of detecting those failures. Based on these findings, the ERLE 1d team defined infrastructure requirements, system approaches and potential benefits for various monitoring strategies. This paper summarizes the findings and offers suggestions on moving forward with OBD and DM in the pipeline industry.
Subjects: Uncategorized
Dresser-Rand Mini-SIP, Low-Volume Screw-In Precombustion Chamber
Jon Tice - Dresser-Rand
Dresser-Rand Mini-SIP, Low-Volume Screw-In Precombustion Chamber
Subjects: Uncategorized
Rainer Kurz - Solar Turbines Incorporated
Dry Gas Seal Retrofits
Subjects: Uncategorized
Efficient Bottle-Less Compressor Pulsation Control: Experimental Test Results
W. Norman Shade, PE & John J. Bazaar - ACI Services, Inc./Glen F. Chatfield, John G. Crandall & Dale K. Wells - Optimum Power Technology
Traditional compressor pulsation attenuation systems are carefully designed combinations of primary and/or secondary volume bottles, often with complex internal choke tubes, baffles, and chambers, as well as various orifice plates installed at specific locations in the system piping. These devices accomplish pulsation control by adding resistance, or damping, to the system; they result in additional system pressure losses upstream and downstream of the compressor cylinders. These pressure losses reduce the overall system efficiency, but the trade-offs are tolerable for most compressor applications. However, for common pipeline transmission applications having low pressure ratios (in the range of about 1.1 to 1.6), system pressure losses can noticeably degrade the overall operating efficiency, especially with the use of higher speed (>600rpm) compressors. Previous GMC papers have reported the results of computer model simulation studies and lab testing of low-pressure reciprocating air compressors with tuned pulsation attenuation networks (PANs). Both the simulations and lab tests showed that properly configured multiple tuned pulsation attenuation networks are effective means of controlling compressor pulsations with little or no resultant system pressure losses. Continuing research has explored additional PAN geometries that completely eliminate the need for traditional pulsation bottles, choke tubes and orifices with the potential for reduced system cost as well as reduced system pressure losses. This paper reports the results of further laboratory testing as well as the first field testing of a discharge PAN system containing no pulsation bottles and no orifices applied to a 750 to 1000 rpm, 6-inch stroke reciprocating compressor. Field test results are compared with predictions for both the PAN system and the original two-bottle system showing the pulsation reduction and system pressure drop.
Subjects: Uncategorized
EFRC Guidelines for Vibrations in Reciprocating Compressor Systems
Andre Eijk - TNO Science & Industry
One of the disadvantages of a reciprocating compressor is that it generates pulsations and vibrations, which, without limitation and proper attention during design, manufacturing, installation and operation, can lead to fatigue failures, inefficiency, capacity limitations and unsafe situations. There is a strong interaction between the different elements in a compressor installation and the compressor and pipe system should be treated, therefore, as one integrated system. To judge the integrity of the compressor system, vibration levels are normally applied and for this purpose, several international standards (ISO and VDI) have been developed the last decade. Besides several international standards, there is a wide variety of internal guidelines, which have been developed and are being applied by compressor manufacturers, engineering offices and end users. Most of these internal guidelines have been derived from international standards. The lack in most of the international standards (and probably also the internal guidelines) is that they do not make a good distinction between recommended vibration levels for different parts of the compressor system, e.g. cylinder, crankcase, foundation and/or different types/configurations of compressor (horizontal/vertical, high/low speed, single/double distance piece, high/low power, etc.). Within the R&D group of the European Forum for Reciprocating Compressors (EFRC) a project was started to develop an EFRC guideline which takes into account recommended vibration levels for different parts of the reciprocating compressor system. One of the tasks of the EFRC project was an interview with several leading compressor manufacturers and operators to get insight into the applied recommended vibration levels within the company. This paper will discuss the different international standards, the results of the interviews, and the first results of the EFRC guideline.
Subjects: Uncategorized
Engine Modeling & Simulation to Correct Operational Issues with a Lean Burn Two-Stroke Engine
Dustin Malicke - Cameron Compression Systems/Randy Raymer - El Paso Pipeline Group
This paper is divided into two parts. The first part addresses why we have a need for advanced computer modeling, which will discussthe issues facing the large bore engine and why the solutions are neither simple nor straight forward and why additional science needs to be utilized. In the second part, the paper describes how computer modeling of the air induction and exhaust system can be used to determine issues with existing components that affect combustion stability and overall engine reliability. Areas that are investigated include the intake manifold, exhaust manifold, internal air chest, ports, port timing and turbocharger match. The software model can then be used to validate design changes or optimize specific design criteria to achieve the desired result.
Subjects: Uncategorized
EPC 50 Small Engine Air Fuel Ratio Controller
Dave Bell - Altronic, Inc.
EPC 50 Small Engine Air Fuel Ratio Controller
Subjects: Uncategorized
Equipment Analysis & Pattern Interpretation for Non-Equipment Analysts
Randy Anderson - ACTT, Division of CECO
This short course is intended to teach the basics of equipment analysis and pattern interpretation for engines and compressors. It is intended for supervisors, engineers, operators, mechanics, and other personnel responsible for operational and maintenance decisions. The course topics will include: pressure-timing curves (P-t), pressure-volume curves (P-V), vibration and ultrasonic analysis, infrared temperatures, primary and secondary ignition traces and basic calculations (horsepower, mean effective pressure [MEP], peak firing angle [PFA], flow balance, rod load, and first derivative).
Subjects: Uncategorized
Exhaust Gas Aftertreatment (Catalyst Systems)
Jon K. Tice - Dresser-Rand
This short course will be an interactive tutorial workshop on the theory, design and application of exhaust aftertreatment systems for gas engines and will include coverage of NSCR (Non-Selective Catalytic Reactors) or “Three-Way Catalysts”, Oxidation Catalysts, SCR (Selective Catalytic Reactors) and the Air-Fuel Ratio Controls (AFRC) necessary to make them function. Extensive “real world” experience and treatment of what can go right, what can go wrong, and what to do about it will be presented. Specific examples will be used to illustrate the key points in the application of aftertreatment systems. Finally, there will be an overview discussion of emerging technology which is likely to be applied to gas engine aftertreatment systems
Subjects: Uncategorized
Exhaust Manifold Design Optimization for Cylinder Scavenging & Turbocharger Performance
Diana K. Grauer & Kirby S. Chapman, PhD - Kansas State University NGML
This paper presents an investigation into the NOx reduction role and turbocharger optimization played by the exhaust manifold by exploring the impact of the exhaust manifold design on turbocharger and engine operation. Exhaust manifold performance is defined as the measure of the exhaust manifold to: (1) optimize cylinder scavenging efficiency and (2) minimize the pressure differential between the compressor discharge and the turbine inlet by exploiting the blow-down pressure pulses and minimizing the static pressure gradient along the exhaust manifold. Pressure pulses in the exhaust manifold have been identified as a plausible mechanism thathinders efficient cylinder scavenging and turbocharger operating range. While modifying the ports and manifold may not be cost effective, a complete understanding of and the ability to address the impact of these pressure waves on turbocharger performance and scavenging efficiency will lead to more reliable engine upgrade projects as the industry approaches the 0.5g/bhp-hr engine. Specifically, the research team used modeling techniques supported by a rich set of field test data to develop a set of guidelines for exhaust manifold designs that: (1) takes advantage of or minimizes the negative impact of blow-down pulses, (2) allows for optimal cylinder
scavenging, and (3) minimizes the overall pressure differential between the compressor discharge and turbine inlet to increase the turbocharger operating range. Ultimately, these guidelines will help lead to the concept of first-time/every-time upgrade success.
Subjects: Uncategorized
Exhaust NO2/NOx Ratio from Lean-Burn Natural Gas Engines
Daniel B. Olsen – Colorado State University Engines & Energy Conversion Laboratory Gregg Arney – Southern California Gas Company
Oxides of nitrogen (NOx) are composed primarily of nitric oxide (NO) and nitrogen dioxide (NO2). Exhaust from most combustion sources contains NOx composed primarily of NO. There are two important scenarios specific to lean burn natural gas engines where the NO2/NOx ratio can be significant: (1) when the engine is operated at ultra lean conditions and (2) when an oxidation catalyst is used. Large NO2/NOx ratios may result in additional uncertainty in NOx emissions measurements, since the most common technique (chemi-luminescence) was developed for low – ratios. In this work, the scenarios are explored where the NO2/NOx ratio can be large. Additionally, three NOx measurement approaches are compared for exhaust with various NO2/NOx ratios. The three measurement approaches are chemi-luminescence, chemical cell, and Fourier transform infrared spectroscopy. A portable analyzer with chemical technology was found to be the most accurate for measuring exhaust NOx with large NO2/NOx ratios.
Subjects: Uncategorized
Experimental Assessment of the G8.3E Engine & Catalyst Emissions Performance
Jisang Sun & Mark A. Rosswurm - Cummins, Inc./Arthur Reining – Johnson Matthey
As part of the G8.3E engine and catalyst development program, Cummins and Cummins Emissions Solutions performed an 8,000 hour field test on a gas compression application. Cummins worked with Johnson-Matthey, the catalyst manufacturer, to install a number of core segments in the new catalyst. These 25mm core segments were removed periodically and analyzed for NOx, CO and HC conversion efficiency at several space velocities and gas temperatures. Contaminant loading measurements were also taken, along with catalyst effective area. Engine oil consumption was mapped over the engine operating range to correlate with in-house test data. Reduction of data showed a significant change in catalyst conversion efficiency over time that correlated with the increase in oil-related deposits on the surface of the catalyst core. As expected, the spatial distribution of these deposits from the front to the rear of the catalyst showed significantly higher levels of deposits at the front of the catalyst core as compared to the rear. Flow distribution across the face of the catalyst, as measured by sampled deposit loading, was fairly uniform and correlated well with the computational fluid dynamics model.
Subjects: Uncategorized
Fluid Dynamic Analysis of Reciprocating Compressor Valves to Assess Its Aerodynamic Performance
Vishwas Iyengar, PhD & Klaus Brun, PhD - Southwest Research Institute
The flow inside a reciprocating compressor valve can be very complex. The slots on the valve, the limited flow area and the inherent aerodynamic losses complicate the problem. Most valves operate in high flow rate and high pressure environments. Poor flow aerodynamics in the valve can have a significant effect on its performance and hence on the overall system. Quite often the gas upstream of the valve can be discontinuous and non-uniform. This can, at times, create a distorted pressure profile on the valve which can have a severe effect on the valve life and hence its performance. Although all the factors affecting the performance of the valve are well known, there is still a need to fully understand the inner workings of the valve aerodynamics. In this study, a new simplified approach is presented to capture some of the factors contributing to the aerodynamic performance of a reciprocating valve. Three-dimensional computational fluid dynamics is used to facilitate this study. A two-fold methodology is used to analyze the transient nature of the flow approaching a valve. At first the compressor and discharge stroke inside the cylinder are modeled. This part of the problem is transient in nature; a moving computational mesh approach is used to accurately capture the sinusoidal motion of the stroke. From this part of the analysis the pressure and velocity profiles near the suction and discharge valves are obtained. The second part of the study analyzes both the suction and discharge valve in a quasi-transient nature. The pressure and velocity profiles obtained from the cylinder analysis are applied as boundary conditions to the valve only analysis. Here the valves are modeled as a steady state problem at various opening positions: 25% open, 50% open, and 100% open. The pressure loss across the valve at the various opening positions is assessed as a function of the velocity/pressure profiles obtained from the transient cylinder analysis. This provides a good insight into the aerodynamic performances of the suction and discharge valves. Results from the analysis confirm that the operating gas in the cylinder has a strong non-uniform velocity profile at the face of the valve. The pressure differential across the valve is used as an indicator to assess the performance. Comparisons are made to assess the differences in pressure differential for uniform and non-uniform upstream velocity profile. It is found that the pressure loss is higher when the velocity profile upstream of the valve is non-uniform. An assessment of the pressure loss due to non-uniform inflow at different valve opening positions shows that the pressure loss is higher as the valve opens more. Some of the other factors affecting the valve aerodynamic performance will also be presented. It is believed that the findings from this study provide new knowledge into some of the factors influencing the aerodynamic performance of a reciprocating valve that could be used by industry.
Subjects: Uncategorized
Full-Scale Benchmark Testing of Centrifugal Compressor Surge
Augusto Garcia-Hernandez, J. Jeffrey Moore, PhD, Matthew Blieske & Klaus Brun, PhD - Southwest Research Institute/ Rainer Kurz, PhD – Solar Turbines Incorporated
The transient behavior of compressor stations, particularly under rapidly changing conditions, is of vital interest to compressor station operators. Predicting transient behavior is an important factor in designing protection systems for events such as emergency shutdowns. A limited number of “accidental” data sets from compressor manufacturers and users are available in the public literature domain. A variety of simulations and modeling approaches has been presented over the last few years at industry conferences, typically without experimental data to support them. The available experimental data for transient shutdowns are not of sufficient quality and resolution to compare predictions properly with analytical results or simulations available from current software packages. Necessary information about the compressor, the driver, the valves, and the geometry of the system is often missing. Currently utilized software has not been adequately validated with full-scale realistic benchmark data, as this data is not available in the public domain. Modeling procedures and simulations seldom contain validation data as this type of transient test data is often difficult to obtain. The primary objective of this work is to present experimental transient compressor surge data, to facilitate the verification and comparison of existing and future transient surge models. Detailed test set-up methods, instrumentation selection, piping geometry and model results are to be discussed. Relevant, dimensionless parameters are presented and validated utilizing the test data. Conclusions from the testing and recommendations for the transient analysis software will be provided.
Subjects: Uncategorized
G3516B with Ultra Lean Burn Technology Contract Gas Compression Fleet Experience
John Bosholm - Regency Energy Partners/Victor L. Sheldon, Jr., PE - Caterpillar Inc.
This paper is a report to the North American Gas Compression Gas Gathering Market of one company’s experience with the G3516b LE Engine with Ultra Lean Burn Technology in rental fleet compression service. The report presents the various technologies employed in this gas compression driver to achieve low engine-out NOx to effectively comply with Ozone Nonattainment Area restrictions. A multi-disciplined approach presents from the perspective of both the end user and engine manufacturer on how the engine was applied, packaged, installed, commissioned and placed into continuous compression service in the Barnett Oil Shale of TCEQ Chapter 117 DFW 8 hour Ozone Nonattainment Area levels (0.5g NOx/bhp-hr emissions without NOx aftreatment). Ultra Lean Burn Technology is instrumental to compression in that it applies a variety of technologies in meeting the challenging, ever-evolving environmental rulings while bringing effective, reliable, emissions flexible products to the natural gas compression market. The North American Natural gas Industry has seen a wide variety of changes in the emissions constraints in recent years on federal, provincial, state and local levels. Requirements for low emissions of NOx, CO, VOCs (Volatile Organic Compounds) and HAPs (Hazardous Air Pollutants) while desiring improved fuel efficiency leads to challenging product requirements. In January 2008 the EPA Spark Ignited Stationary New Source Performance Standards set new federal standards and announced the more strict requirements of the next stage in 2010/2011. States have promulgated strict State Implementation Plans to develop a means to comply with the Federal Clean Air Act. The current economic climate presents additional challenges on how best to install the best value for assured Not To Exceed emissions. Expected rulings for reducing Carbon footprint for gas compression sites will drive greater awareness for improved fuel efficiencies while delivering lower engine-out NOx emissions. This paper examines the experiences of a compression rental fleet operator during field validation of new lean burn combustion technology applied to an open chamber engine with compliance to much lower NOx emissions requirements. It will present an overview of the new technologies capabilities seen at the site.
Subjects: Uncategorized
Gas Turbine Performance & Maintenance
Rainer Kurz, PhD - Solar Turbines Incorporated/Klaus Brun, PhD - Southwest Research Institute
Gas turbines are widely used to drive gas compressors and pumps in the oil and gas industry. This short course will address the general operating principles of gas turbines, and based on these principles, explain the performance and application characteristics of gas turbines. Differences between aeroderivative gas turbines and industrial gas turbines will be explained, together with the general requirements of the major codes and standards for these types of machines. The combustion process and the capability to use a variety of fuels are explained, together with gas turbine emissions and the impact of different fuels and different operating conditions. Special attention is on issues to maintain the performance of gas turbines and, in particular, the topic of inlet air filtration is addressed. The topic of inlet air filtration, the different options available, and environmental conditions that drive solutions will be discussed in some detail.
Subjects: Uncategorized
High Efficient Pipeline Compressor Packages
Christean Kapp - Siemens Industrial Turbomachinery Inc.
High Efficient Pipeline Compressor Packages
Subjects: Uncategorized
High Pressure Pipeline Applications
Rainer Kurz, PhD - Solar Turbines Incorporated/Klaus Brun, PhD - Southwest Research Institute
While typical gas transmission pipelines operate at pressures up to about 1500 psi, a number of applications in North America and Australia use or plan pipelines operating at significantly higher pressures. Often, these operations are referred to as “dense phase”. These are, in general, operating conditions above the critical pressure and temperature of the gas. Several existing installations are described and analyzed. We will explain the underlying reasons why higher pressure pipelines are considered as well as the tradeoffs compared to traditional, lower pressure pipelines. This involves, in particular, the impact of a larger effort to bring the gas to thehigher pressure. The impact on compressor and driver selections is also considered, in particular the impact of the higher power density of the centrifugal compressors at higher pressures.
Subjects: Uncategorized
Hoerbiger Electronic Fuel Control System (EFC)
Hans Mathews & Ronnie Walker - Hoerbiger Engineering Services
Hoerbiger Electronic Fuel Control System (EFC)
Subjects: Uncategorized
Improved Performance of an Existing Pipeline Compressor Station
Shelley D. Greenfield & Hemanth Satish - Beta Machinery Analysis/Dwayne A. Hickman - ACI Services, Inc. Adam Long - Piedmont Natural Gas Co.
Many pipeline owners have a keen interest in improving the efficiency of their existing compressor stations. Even small improvements in compressor efficiency can result in significant reductions in fuel costs and increases in throughput generating higher revenue. A business case for removing bottlenecks within the station piping system can be made. This paper identifies ways to evaluate a compressor station’s piping system and to quantify the financial returns for improving the system efficiency. The investigation includes evaluating the system over a wide range of operating conditions required at this facility and assessing the most beneficial technical and economic solutions. The analysis is conducted with a combination of field analysis and computer simulation for an existing Piedmont Natural Gas facility.
Subjects: Uncategorized
Increased Efficiency of a Poppet Style Valve for High Speed
Glenn Hatch - Dresser-Rand
Increased Efficiency of a Poppet Style Valve for High Speed
Subjects: Uncategorized
Investigation of High Efficiency Pulsation Filter Bottle Design
Marybeth Nored, Sean Tavares, PhD & Eugene “Buddy” Broerman - Southwest Research Institute
A standard pulsation bottle design for reciprocating compressors utilizes two surge volumes connected by a single choke tube. The surge volumes and the choke tube work together to provide a low-pass filter system such that amplitude of the reciprocating compressor excitation orders above the low-pass filter frequency are reduced in the associated piping system. For modern variable speed compressors, tradeoffs exist between the necessary pressure drop in the pulsation filter bottle and its effectiveness at tuning out the compressor dynamic excitation. Large speed ranges tend to make the tradeoffs even more difficult. Higher horsepower machines have resulted in higher flow velocities and dynamic pressure losses. In many systems designed to filter 1x orders and above, the API limit of 1% pressure drop is easily approached, in order to provide sufficient pulsation control. Through the GMRC 2009 research, SwRI began investigating slight modifications to the filter bottle design to improve the inlet / outlet flow losses. This effort intends to remove the associated “pressure drop tax” on an effective pulsation bottle. Borrowing concepts for the aerospace and automotive industries, a number of design modifications have been modeled. These design modifications must still maintain the classic volumechoke- volume filter style in order to be effective pulsation control bottles. This paper will review the fluid dynamic simulations of high efficiency bottle concepts and the associated pressure drop predictions. These fluid dynamic models are supported by a solid physical basis for pressure recovery evidenced in the literature. The authors will review the fluid model stream patterns as a means of understanding the pressure recovery capabilities of the various concepts. Results showed the high efficiency bottle to be capable of 50-55% pressure drop recovery through modifications to the choke tube design alone. The practical adaptation of these high efficiency bottle concepts and their impact on future pulsation bottle design theory will be presented as well.
Subjects: Uncategorized
Eric R. Dufur & Kirby S. Chapman, PhD - ScavengeTech, LLC/Ronald Wachowiak, El Paso Corporation
This paper presents a follow-up study on the ability to turbocharge low-BMEP two-stroke cycle engines. A Worthington LTC twostroke cycle engine was upgraded with a re-aeroed turbocharger to provide additional waste gate margin at high ambient temperatures and at degraded turbocharger performance. The paper describes the engineering and diagnostic tools that were used, including engine modeling software and historical turbocharger performance data, to ultimately design and commission the re-aeroed turbocharger. The paper includes data collected prior to and after the upgrade. One of the key performance indicators was the forecasted waste gate margin before and after the upgrade at various ambient temperatures. The authors show that by using engineering models and key performance data, a performance matrix modeling the excess turbine power at different ambient conditions and engine operating parameters could be created. This information was then used to determine the necessary turbocharger performance parameters. This paper will investigate the modeling process and discuss the results used to evaluate the turbochargers ability to effectively increase the waste gate margin.
Subjects: Uncategorized
Long-Term Emissions Performance of Stationary Natural Gas Engines Equipped with NSCR System
Mohamed Toema & Kirby S. Chapman, PhD - Kansas State University NGML
This paper describes work to characterize pollutant emissions performance of non-selective catalytic reduction (NSCR) technology, including a catalyst and air-to-fuel ratio controller (AFRC), applied to four-stroke cycle rich-burn engines. Emissions and engine data were collected semi-continuously with a portable emissions analyzer on three engines in the Four Corners area. In addition, periodic emissions measurements that included ammonia were conducted several times. Data collected from October 2007 through December 2008 shows significant variation in emissions levels over hours, days, and longer periods of time, as well as seasonal variation. As a result of these variations, simultaneous control of NOx to below a few hundred parts per million (PPM) and CO to below 1,000 ppm volumetric concentration was not consistently achieved. Instead, the NSCR/AFRC systems were able to simultaneously control both species to these levels for only a fraction of the time the engines were monitored. Both semi-continuous emissions data and periodically collected emissions data support a NOx-CO trade-off and a NOx-ammonia trade-off in NSCR-equipped engines.
Subjects: Uncategorized
Motor Rotor Design & Life Evaluation Using Hybrid of Finite Element & Torsional Vibration Analyses
Rajanikanth Chundi - IDC Technical Services
Electric motors area commonly used as prime movers in reciprocating compressor applications. Dynamic torques generated by compressors are of concern. Motors and compressors are often connected through flexible disc couplings which provide minimal damping. Dynamic torques adversely affect motors as they are not built to absorb high torque variations. The response from reciprocating compressors is very unfavorable to the motor as a whole. When performed on drivelines, a torsional vibration analysis (TVA) can effectively predict shaft and coupling vibrations. However, this technique does not adequately predict the fatigue life of the rotor assembly attached/keyed to the motor shaft. Finite Element Analysis (FEA) in combination with TVA can be used to evaluate dynamic stresses in rotor assemblies and predict potential failures. Torsional responses predicted in the TVA are used as input forcing functions for the FEA. By using this hybrid analysis technique, modifications to the system can be made and verified prior to final manufacturing.
Subjects: Uncategorized
A New Valve Simulation Tool Using CFD for Valve Parameter Characterization
John Person - Klaus Enterprises Ltd.
A New Valve Simulation Tool Using CFD for Valve Parameter Characterization
Subjects: Uncategorized
Oil Stiction in Compressor Valves: Modeling & Mitigation
Timothy C. Allison, PhD & Klaus Brun, PhD - Southwest Research Institute
Experience shows that oil stiction forces negatively impact valve life in reciprocating compressors by delaying valve opening andcausing an increase in valve plate impact velocity. Although some research has been performed in the past to investigate and model oil stiction, a validated model for predicting stiction-induced forces is not available in the current literature. The research presented in this paper extends the work shown in previous publications by (1) developing a valve dynamics model with stiction forces included, (2) validating the model using data from shock tube testing of a valve, and (3) showing that stiction forces can be reduced by bead blasting on valve plate contact surfaces. The first section of the paper describes the development of a one-dimensional valve model that includes aerodynamic (pressure and drag), spring, and stiction forces on a valve plate. The stiction force component of the model uses flat plate stiction force equations developed in previous work and extends them to a valve environment by including the effects of valve geometry and static pressure differential on the oil film. This simulation predicts that the pressure differential across the valve will expel the oil film from between the contact surfaces prior to rupture of the oil film. Inclusion of this “blow out” effect is a new contribution to stiction modeling in valves and significantly reduces the predicted length of the stiction event.
Subjects: Uncategorized
Operation & Selection of Electric Motor Driven Stations
Marybeth Nored & Klaus Brun, PhD - Southwest Research Institute & Anders T. Johnson, El Paso Pipeline Group Rainer Kurz, PhD - Solar Turbines Incorporated
Electric motor driven compressors, both reciprocating and centrifugals, have become a more common choice for pipeline operators due to recent technology improvements, versatility for capacity control and lower point source emissions in most cases. In the last ten years, technology advancements for higher horsepower induction and synchronous motors combined with variable frequency/ variable speed drives have enabled the electric drive option for the gas transmission industry. However, in designing a new or retrofit electric motor driven compressor station, the components of an electric motor driven system must be carefully selected to ensure smooth start-up given the electric utility constraints, adequate power and torque over a range of operating conditions, and low life cycle costs. This paper will present options for start-up utilizing different system configurations, rotordynamic and torsional analyses to consider for both centrifugal and reciprocating compressors and operational issues with electric driven compressors. The operational issues will be presented from a pipeline industry perspective based on actual case studies to highlight some of the complex or unique operational issues with electric motor driven systems. The recommendations for design and selection will be based on the GMRC Application Guideline for Electric Motor Drive Systems developed in 2008.
Subjects: Uncategorized
Performance Control of Reciprocating Compressors: Devices for Managing Load & Flow
Chad Brahler, W. Norman Shade, PE & Dwayne A. Hickman - ACI Services, Inc.
This short course aims to provide attendees with the knowledge to fundamental understand the various types of unloading and capacity control devices, the ability to decipher product claims, and the skills to identify methods and equipment used to modify unit performance relative to their needs and budgets. Useful, and unbiased, comparisons between the various performance control devices are detailed via provided quick-reference charts. Additional information provided includes: diagrams, pictures and schematics; advantages and disadvantages; performance considerations; operational limitations; practical applicability. Upon course completion, attendees will be able to identify best possible means to achieve optimum performance control for both current and new units. Furthermore, participants will gain valuable knowledge that can be readily implemented when considering the full economics of real costs versus return on investments.
Subjects: Uncategorized
Physical Asset Management: Implement a Proactive Maintenance Strategy to Prevent Unexpected Failures
Brad Grieves - Panhandle Energy/William A. Couch, PE - El Paso Corporation/Sandra Chapman & Kirby Chapman, PhD - Kansas State University NGML
While the Gas Machinery Conference provides an excellent means to learn of new technologies and analytical techniques, many attendees question how to put these technologies and techniques to good use. The best way to maximize the potential benefits of today’s technologies and techniques is to integrate these into a Physical Asset Management (PAM) strategy. PAM is a business strategy to properly integrate all processes, tactics, and tools for more efficient and proactive maintenance practices. This short course will review the current state of maintenance practices within most industry organizations, identify the cultural change and the associated challenges required to move into a PAM environment, and examine how one company is currently implementing a PAM strategy. Panhandle Energy formally implemented a comprehensive PAM strategy in 2007. Learn how they implemented the PAM strategy and what tactics, technologies and processes they have in place to proactively strive to continuously improve asset reliability and eliminate unexpected failures.
Subjects: Uncategorized
Piezoelectric Sensors for Combustion Pressure Based Control Systems for Large Gas Engines
Thomas Walter - Kistler Instrument Corporation/Greg Beshouri - Advanced Engine Technologies Corporation
Combustion analysis is a basic tool for the development of reciprocating internal combustion engines and has been used for more than 100 years. The evaluation of combustion pressure and associated chamber volume provides superb information about the combustion process. However, in the past it was typically applied in a R&D laboratory environment and was not intended to be used for continuous monitoring or controlling of engine conditions in the field. More stringent regulations targeted for 2012 for the emissions of in-use Gas Engine Machinery, combined with the availability of field-useable data acquisition and evaluation hardware encourage the implementation of combustion pressure based engine control systems. With a wide measuring range, high temperature accuracy and excellent long-term stability, piezoelectric pressure sensors represent the technology of choice most commonly used for combustion measurement and analysis. Retrofitting existing large bore gas engines with piezoelectric pressure sensors and implementing a combustion pressure based engine control system significantly enhances engine operation, improves efficiency, reduces emissions, increases engine durability and provides sophisticated control capabilities. In this short course, the following topics will be covered in detail: potential emissions requirements for engines from 2012; anticipated combustion and monitoring related impact on pipeline engines based on ERLE (Emissions Reductions in Legacy Engines) program; the basics of combustion analysis; technology and design of piezoelectric pressure sensors; the application and installation of pressure sensors in engines for maximum life; case studies of sensor installations and sensor failures; advanced analysis methods for combustion pressure based monitoring, balancing and control; non-emission related benefits for engine operators. The objective of the course is to improve knowledge about the technology and application of basic components for combustion pressure measure measurement and to highlight opportunities for the implementation of combustion pressure based engine control system within the Gas Machinery Industry.
Subjects: Uncategorized
Quantification of Liquid Entrainment in Compressor Suction Streams
Paul Tenison & Daniel B. Winter, PE - BP Alaska
BP owns and operates the Milne Point oil production facility on Alaska’s North Slope. Processing facilities are enclosed in heated, adjoining modules. The gas compression module houses two 3,450 HP electric motor driven reciprocating compressors. Over time, the frequency and severity of compressor component failures have increased significantly. An intensive discovery effort identified both mechanical and process-related causes of failure, including entrainment of water and natural gas liquids (NGL) in the compressor suction. Damage caused or exacerbated by ingested liquids includes bearing failures, damaged cylinder lining, sheared wrist pins, sheared cylinder attachment bolts, and cracked pistons. The main focus of this paper will discuss the discovery and analysis, leading to better control of liquids in the process. Poor separation performance of existing suction scrubbers was predicted by computational fluid dynamics (CFD) modeling and confirmed by laser isokinetic probe sampling to quantify liquid entrainment. Analysis of operating data also indicated condensation of liquids in suction piping downstream of the scrubbers. Solubility of NGL in compressor lube oil was also determined to be a contributing factor to compressor damage, especially cracked pistons due to interstage slugging of diluted lube oil. NGL solubility issues became even more severe with a change from synthetic lube oil to mineral oil. Lab analysis confirmed significantly higher solubility of NGL in mineral oil compared to synthetic oil. A multi-faceted solution was required, including 1) reconfiguration of suction cooler temperature control logic, 2) upgrades to suction scrubber level control, alarm and shutdown systems, 3) installation of inline, axial flow cyclonic demisters immediately upstream of compressor suction bottles, and 4) heat tracing and insulation of piping and suction pulsation bottles downstream of the new demisters. Several other options were considered but rejected for various reasons.
Subjects: Uncategorized
Reciprocating Compressor Field Testing & Troubleshooting: Performance, Pulsation & Vibration
Melissa Wilcox, Jason Gatewood & Justin Hollingsworth - Southwest Research Institute/Warren Laible - Windrock, Inc./ Bob Webber - Dynalco, Division of Crane Co.
Field testing and troubleshooting of reciprocating compressors has become increasingly common due to the need to verify and correct issues related to efficiency, power, capacity, and safe operation of a compressor package. The performance test of a reciprocating compressor in the field is often necessary to assure that the manufacturer meets performance predictions and guarantee a customer’s return on investment. Economic considerations demand that the performance and efficiency of a reciprocating compressor package be verified at the actual field site. The field environment is not an ideal environment and an assessment of measurement uncertainties is necessary to characterize the validity of a performance test. As the working field environments shift further from the ideal case, the uncertainties increase. Previous field tests have shown that the compressor efficiency uncertainty can be unacceptably high when some basic rules for proper test procedures and standards are violated. Following a few basic principles when troubleshooting a compressor can lead to collecting more accurate data which will assist in pinpointing possible issues. Additionally, pulsation effects can negatively affect compressor performance and cause undesirable vibration. Pulsation and vibration field testing is required to identify excitation energies in the compressor which can be mitigated in order to lead to better performance, reduced maintenance, and safer operation. This short course will review the procedures and recommendations outlined for field testing from the recently published GMRC Reciprocating Compressor Field Performance Test Guideline as well as pulsation and vibration troubleshooting practices for reciprocating compressors.
Subjects: Uncategorized
Reciprocating Compressor Performance Analysis Using the PV Card Method
Warren Laible - Windrock, Inc.
This course is designed for engineers and technicians involved with the testing and evaluation of reciprocating compressors. If used properly, many companies already possess the equipment necessary to perform detailed and accurate performance analysis of their reciprocating compressors. The objective of this course is to provide an advanced discussion of using the pressure, volume and temperature relationships for the determination of reciprocating compressor performance by using the pressure-volume card method. The course will include: the pressure-volume-temperature relationship; potential mechanical faults that affect performance; preparation of the unit to be tested; selecting the measurement instrumentation; conduct of the data acquisition process; data reduction and verification; the pressure vs. crank-angle card; the pressure vs. displaced volume card; the log pressure vs. log volume card; calculating capacity, efficiency, discharge temperature, clearance volume, volumetric efficiency.
Subjects: Uncategorized
Reciprocating Compressor Performance Improvements with Radial Poppet Valves
Lauren Sperry, PE & W. Norman Shade, PE - ACI Services, Inc.
Over the past decade, radial compressor valves and unloaders have been successfully introduced into reciprocating compressors for the gas transmission industry. The unique radial valve system seats multiple rows of poppets over ports in a cylindrical sleeve the replaces the traditional cage and single deck valve used in a reciprocating compressor. The radial valve concept had been applied for both suction and discharge valves in a broad range of compressor models and pipeline cylinder classes. Use of these valves has resulted in significant increases in efficiency and reductions in HP/MMSCFD. For cylinder end deactivation, the cylindrical valve guard is moved to slide the poppets off their seats and away from the ports, providing a relatively unobstructed flow path for the gas. The resulting parasitic losses of the deactivated cylinder end approach the losses achieved by complete removal of a traditional valve. Use of radial valves has also been found to significantly increase unit capacity. Some of this increase stems from being able to operate the more efficient radial valve compressor with less unloading, so that there is more effective displacement utilized for the same power input. Moreover, in practice the significant added fixed volumetric clearance inherent in the radial poppet valves hasnot reduced the measured volumetric efficiency or the capacity as much as traditional theory would predict. This paper will present four case studies that show the actual field performance improvements obtained with radial poppet valves on both low speed and high speed compressors, along with laboratory test comparisons and an explanation of why the capacity can increase even though the fixed clearance increases.
Subjects: Uncategorized
Recommended Approach to Control Vibration from Cylinder Gas Forces
Bill Eckert & Walter Bratek - Beta Machinery Analysis/Everett Houdyshell – Anadarko Petroleum Corporation
Vibrations created by pressure pulsations are recognized as a common problem for reciprocating compressor facilities. There are design practices and API standards that direct designers in methods to minimize the likelihood of vibration problems from pressure pulsations. But, there are other dynamic forces in reciprocating compressors that can cause vibration problems. Foremost of these are the dynamic gas forces from the pressure inside the compressor cylinder. These dynamic gas forces cause motion of the compressor cylinder in the direction of piston motion at all orders of compressor speed. This motion is sometimes referred to as cylinder stretch or frame stretch. This cylinder motion can excite the attached piping and bottles resulting in excessive vibration, fatigue failures and, in extreme cases, a gas release and serious safety concerns. Currently, there are no industry standards that provide designers or fabricators a means of determining when dynamic cylinder gas forces will be a problem and measures that can be taken to mitigate these concerns. This paper will
provide an explanation of the dynamic cylinder gas forces and their effects by means of a technical description as well as a recent case study of an Anadarko facility. The case study includes computer simulations as well as field measurements demonstrating the cylinder gas force problem. A method of determining when a compressor installation may be susceptible to gas force vibration problems based on evaluating the compressor operating parameters will be described. This specification will fill a deficiency in API 618 5th Edition. Design practices for minimizing vibration from gas forces and recommended field analysis techniques will be discussed.
Subjects: Uncategorized
Reducing Compressor Maintenance Costs by Leveraging Remote Runtime Monitoring
Matt Begler - M2M Data Corporation/Robert Carter - Enerven Compression Services
Enerven Compression currently has a fleet of approximately 300 compressors with a wide range of horsepower. As with any compression services organization, maintenance accounts for a significant portion of Enerven’s day-to-day operating expenses. Enerven was looking for ways to reduce maintenance costs while still properly maintaining their equipment. They knew that maintenance was important in order to maximize the performance and longevity of their fleet. However, they also thought that there had to be a way to leverage technology to help bring down their maintenance costs. Many organizations reduce their maintenance costs by increasing the interval in the maintenance schedule. However, this approach has many pitfalls and while it could have short-term savings in operating costs, the long-term capital expenditure that may be required to replace poorly maintained equipment could far outweigh the benefits. This approach is essentially taking a short in the dark because the operator has no way of knowing when the maintenance is really needed. That is, unless one is able to remotely monitor run status. That’s Enerven decided to do. They realized that they could extend the maintenance window on their equipment and still comply with OEM guidelines if they could monitor equipment run hours. They realized that equipment is brought down for various reasons while in the field and that this time should not accrue against the maintenance schedule. After calculating reduced windshield time and increased intervals between regularly scheduled maintenance visits, Enerven anticipated a savings of 30% annually on their maintenance budget
Subjects: Uncategorized
Reducing the Risk of Vapor Cloud Fires & Explosions
Jogen Bhalla – AMOT Controls
Reducing the Risk of Vapor Cloud Fires & Explosions
Subjects: Uncategorized
Resolving Common Vibration Problems on Reciprocating Compressors
Bill Eckert, Walter Bratek & Rich Bennekemper, Beta Machinery Analysis
Vibration issues are still the major cause of mechanical problems on reciprocating compressors. Based on the authors’ experiences, many problems are due to: mechanical resonance in the piping, vessels, and supports – especially on the higher speed units; the compressor operating under new conditions that were not contemplated during its initial design; skid and/or foundation designs that are not adequate to resist the dynamic forces; cracks or failure of small bore piping. Drawing on field troubleshooting cases from around the world, the short course discusses these and other vibration problems, and methods to resolve them. This session will be valuable to those engineers and technicians involved in designing new compressors, field testing, maintenance or operations. The course will cover: overview of vibration terms (resonance, pulsations, dynamic forces, skid design, API 618 design methodology); root-cause issues that create vibration problems on compressor packages; case studies illustrating the most common vibration problems. Case studies will include engine and motor-drive applications, various foundation types (gravel, concrete, piles and offshore platforms), and small vs. large compressor installations; tips for assessing vibration problems in the field, including a checklist for addressing mechanical vibration problems; suggested approach when designing new installations (or retrofitting existing sites).
Subjects: Uncategorized
James J. McCoy, Jr., PE - Hoerbiger Engineering Services/Ronald Wachowiak – El Paso Pipeline Group Harley (Mac) Smith – Tennessee Gas Pipeline
In 2008, Hoerbiger Engineering Services began testing a new fuel injection concept for older, lower horsepower pipeline engines that were not under stringent air quality rules that might require the operating company to consider replacing the older horsepower. The goal was to offer a fuel injection system that would enable these older, usually pump- or blower-scavenged units, to operate more fuel efficiently and to give the engine the capability to automatically balance itself, as well as the ability to “lay down” or “skip” certain cylinders when the load is light enough to permit this feature without harm to the engine. In short, this fuel system will give these older engines, some in the 40 to 65 year old range, the “smarts” of some of the latest reciprocating engines. The system was first tested in conjunction with Tennessee Gas Pipeline, an El Paso company at Middleton, Tennessee and then further tested at the Tennessee Gas compressor station at Batesville. The testing immediately showed the system capable of improving the combustion stability of the engine, while also saving fuel in the range of 3% at full load to over 15% at loads in the 70% range. This light load range is where many of these older engines run because of the changes in pipeline conditions since they were initially commissioned. The method used (explained more fully in the paper) was to attach an electronic valve to each mechanical valve and have the electronic controller control the governing and fuel management functions of the engine.
Subjects: Uncategorized
Software Updates for the 2516A2 Engine Peak Meter/Difficult Sensor Installations in PCCs
Kistler Instrument Corp.
Software Updates for the 2516A2 Engine Peak Meter/Difficult Sensor Installations in PCCs
Subjects: Uncategorized
TCR, The Cutting Edge/TCA, The Benchmark
Bruce V. Horner - MAN Diesel North America, Inc.
TCR, The Cutting Edge/TCA, The Benchmark
Subjects: Uncategorized
Turbocharging for Optimized Performance
Hans Mathews - Hoerbiger Engineering Services/Dustin Malicke - Cameron Compression Systems Patrick Jacob - Williams Gas Pipeline
Over the last decade, federal emissions regulations have driven the upgrade of many turbocharged engines and the installation of turbochargers on many other engines that were originally mechanically scavenged. The need for increased air manifold pressure to drive NOx and other emissions to acceptable levels is well understood. However, there are many variables that the design engineer has to work with. How these variables are played off of each other greatly influence the performance of the final match. The paper will layout the basic design criterion that a design engineer uses when specifying a turbocharger. It will present the basic testing and modeling techniques and general design guidelines. The paper will fully develop a model for an engine and look at how the turbocharger match can be manipulated for different results. The paper will also include a case study of two different approaches for matching a turbocharger on GMW engines and how two different matches generated very different performance envelopes. The case study will include real world data, backed up with modeling show the different matches both satisfy the same goal but give very different operating characteristics. This paper has not been presented before but will use reference material from previous GMC’s and other published materials.
Subjects: Uncategorized
TurboShield: Turbocharger Management System for Informed Designs
Mark Lueger - Exterran
TurboShield: Turbocharger Management System for Informed Designs
Subjects: Uncategorized
Unloading Capabilities of the Dresser-Rand DDV Pipeline Cylinder
Gary Tas - Dresser-Rand
Unloading Capabilities of the Dresser-Rand DDV Pipeline Cylinder
Subjects: Uncategorized
Update on Caterpillar’s G3500 & GCM Engine
Wayne Longer - Caterpillar Global Petroleum
Update on Caterpillar’s G3500 & GCM Engine
Subjects: Uncategorized
Watching Expenses? Avoid Costly Shutdowns, Be Proactive and Insure Torque Tool Accuracy
Brad Anderson, Tom Smith & Keith Fitzgeralds – MobileCal/Scott Schubring & John Cordaway - El Paso Pipeline Group
“We don’t know!” These are three words you don’t want to hear when asking if proper torque was applied to your application. This paper will address important considerations when operating torque tools. The goal for this technical paper is to promote a plan of action within your organization addressing the topic of accurate bolting. We’ll answer the questions: What preventative steps can be taken to ensure the goal of accuracy? What is a calibrated or certified tool? What does out-of-spec mean? What are the potential consequences and hazards of using a torque tool that’s not certified? What can operators do in the field to ensure accurate tooling? What can managers do for their array of tools at multiple locations to ensure accurate tooling? There are many bolting applications in gas machinery. Each application requires a specific torque setting (chart). A short list of these applications includes: compressor head bolts, dog house bolts, foundation bolts, unloader valves, articulating/connecting rods and pipe flange connections. Fact: torque tools do not remain accurate. Whether the application calls for the use of a manual torque wrench, gear torque multiplier, hydraulic torque wrench or pneumatic torque wrench, the accuracy of the tool is controllable and a crucial step to ensure proper torque. You’ll learn how these tools get out of tolerance, what preventative measures can be taken for each type of tool, and why the certification process for each tool should be a standard operating procedure. Other considerations include: gasket choice, lubricant and condition of studs, nuts, washers, and mating surfaces. These will be mentioned but are not a focus of this paper. Proper bolting can decrease the chances of catastrophic events, needs to shutdown due to leaks and other time consuming situations. By implementing a thorough bolting procedure, your company will eliminate the “We don’t know” scenario.
Subjects: Uncategorized
