First Quarter 2005

GMRC AWARDED DOE CONTRACT

Gas Machinery Publicationsc/o GMRC

3030 LBJ Freeway, Suite 1300Dallas, Texas 75234

PRSRT STDUS POSTAGE

PAIDDALLAS, TEXAS

PERMIT 553

March 6-910th Annual Suppliers Expo andConferenceGas Compressor AssociationGalvestonwww.gascompressor.org

March 14-16GPA Annual Convention Gas Processors AssociationSan Antoniowww.gasprocessors.com

April 4-8Applied Principles Of EnginesAnd CompressorsGMRCColorado Springs, Colo.www.gmrc.org

April 19-20API Annual Pipeline Conference American Petroleum InstituteAustin, TexasWeb site: www.api.org

May 2-5Offshore Technology Conference Houston Web site: www.otcnet.org

May 17-18Foundation Design and RepairGMRCOklahoma Citywww.gmrc.org

May 19 The Bolted JointGMRCOklahoma City, Oklahomawww.gmrc.org

June 6-10 Applied Principles of High-Speed Engines And CompressorsGMRCSan Antoniowww.gmrc.org

July 18-21Transmission Conference withExhibitsSouthern Gas AssociationAlbuquerquewww.southerngas.org

July 26-28Engine Analyzer And ReliabilityWorkshopGMRCNashvillewww.gmrc.org

-see 2005 Industry Calendar, p. 8

Industry Calendar

Inside this issueGMRC Training Courses. . . . . . . 3

San Juan College’s CompressionTechnology Program. . . . . . . . . 4

The Power of Design/SwRI® . . . 6

Testing Large Bore EngineTurbochargers/NGML . . . . . . . . 8

GMC 2004 ReCap . . . . . . .10 - 12

On October 3, 2004, the U.S.Department of Energy announced thatthey have awarded a five-year $5 mil-lion research contract to the GasMachineryResearchCouncil(GMRC) for anAdvancedReciprocatingCompressionTechnology(ARCT)Program.

Theobjective of theARCT programis to developthe next gener-ation of recip-rocating com-pressor technology to enhance the effi-ciency, reliability, and integrity ofpipeline operations through improvedcompression. The suite of technologiesdeveloped by this program is aimed atprovidingpipeline opera-tors withimprovedaffordablechoices fornew compres-sion as well asinnovativeproducts thatcan be retrofit-ted to existingmachines tosubstantiallyimprove thecurrent infra-structure.

Advanced concepts for ARCTinclude intelligent compression tech-nology that monitors operational condi-tions and automatically adjusts internalgeometry to tune performance overthe full-extended operational range,

thereby opti-mizing per-formance andminimizinglife-shorteningmachine vibra-tion. Advanced pul-

sation controlwill monitorvibration fre-quency andmagnitude atcritical loca-tions as opera-tional speedvaries and shift

the filter cut-off frequency or dampingto lower magnitude.

Advanced valve concepts arepassive, active or semi-active. Passiveconcepts will focus on reducing thehigh parasitic pressure loss of current

designs. Advancedcapacity con-trol concept isto control flowrate and loadin concertwith the pulsa-tion controland valve con-trol. Advanced sen-sors andautomation isto implementself-powering

sensors with wireless data transmis-sion to provide the “intelligence”required for the advanced conceptsproposed.

All of thisadvanced technologywill be integrated intoan optimized compres-sor package and opti-mized station opera-tional strategy. Theprogram will culmi-nate in an overall sys-

tem demonstration of the next genera-tion of reciprocating compression.

DOE will provide 65% of thefunding for ARCT with the remaining35% funded by GMRC and its membercompanies. The first year of the pro-gram is being co-funded by El PasoCorporation, BP, Ariel Corporation,Caterpillar and Compressor Systems,Inc. The program will be managed byGMRC’s Project SupervisoryCommittee under the leadership ofDon Crusan, Columbia GasTransmission, PSC Chairman.Southwest Research Institute (SwRI) inSan Antonio is the research contractor.

The GMRC Project Supervisory Committee met January 25-26 to begin planning

for the ARCT program.

Bill Elston,Compressor

Systems, Inc.

Danny Deffenbaugh, SwRI®, leads discussion on the ARCT program.

First Quarter 2005page 3

GMRC Offers Leading-Edge Technical Training In 2005Technical training ranging

from field troubleshooting of gas machin-ery to understanding the most complexmachines in the industry is availablethroughout the year from the GasMachinery Research Council. The latestadvances in technology will be detailed,along with proven basics that have beensuccessful over the years.

Most classes also qualify for pro-fessional education credits.

Top experts in the field willpresent the information that attendeescan use immediately to enhance theirvalue in the organization. Student willlearn what they need to know to keeptheir company’s fleet of compressionequipment operating at its peak of effi-ciency, reliability and safety.

For more information aboutany of these courses or others that maybe announced during the year, pleasevisit the GMRC web site atwww.gmrc.org, or contact GMRC VicePresident Marsha Short at 972/620-4024.

Applied Principles Of Engines andCompressorsApril 4 - 8 – Sheraton HotelColorado Springs, Colo.

This engine fundamentals classprovides a solid foundation to anyoneinvolved in the operation of prime movers.Although the principles described byinstructor Randy Anderson of AndersonConsulting, Testing and Training/CECOare simple and easy to understand, theclass is both stimulating and challenging.

Upon completion, students willhave a basic understanding of the equip-ment configuration and operation and willbe capable of simple troubleshooting andproblem recognition for their gas compres-sion equipment.

Course content includes enginefundamentals, crankcase lubrication sys-tems, combustion theory, exhaust emis-sions and engine balance.

Twenty-eight ProfessionalDevelopment Hours will be given to eachparticipant at the end of the workshop.

Class begins each day at 8 a.m.and ends at 5 p.m. Monday throughThursday, and 8 a.m. until noon on Friday.

Foundation Design and RepairMay 17-18 - Holiday Inn NorthOklahoma City

Instructors Bob Rowan of Robt. L.Rowan & Associates Inc. and Pete Harrellof Southwest Research Institute will givethose responsible for reciprocating com-pressor design and installation the knowl-edge, tools, and practice needed to applythe latest compressor mounting and foun-dation design and repair techniques to helpmaintain machines reliability.

Class will cover foundation designbased on American Concrete InstituteCommittee 351 guidelines, components ofthe foundation, how the foundation reactsto compressor loads, and tools for conditionassessment.

Registration for the FoundationDesign Class also includes the Bolted JointClass on Thursday morning.

Ten Professional DevelopmentHours will be given to each student at theend of the workshop.

The workshop begins at 1 p.m.Tuesday and ends at 5 p.m. Wednesday’sclass is from 8 a.m. through 5 p.m., and thesession on Thursday session is from 8 a.m.through noon.

The Bolted JointMay 19 - Holiday Inn NorthOklahoma City

This course is intended for engi-neers, reliability and maintenance techni-cians, and construction technicians whoroutinely make up or close bolted joints.Instructor Peter Harrell will describe pipejoints, man-ways, inspection ports, andother structural members joined by bolts orby nuts on studs. The workshop begins at 8a.m. and ends at noon.

Course content include basicproperties of the bolted joint, design of thebolted joint, and design and selection ofthreaded fasteners.

Three Professional DevelopmentHours will be given to each participant atthe end of the Workshop.

Applied Principles of High-SpeedEngines and CompressorsJune 6-10 - Hyatt Regency RiverwalkSan Antonio

Instructor Randy Anderson willfocus his presentation on high-speedengines and reciprocating compressor fun-damentals.

This class provides a solid founda-tion to any employee involved in the opera-tion and maintenance of high-speed recipro-cating engines and separable reciprocatingcompressors. Information is intended forequipment operators, maintenance person-nel, supervisors, engineers, gas controllersand other personnel responsible for high-speed reciprocating compression equip-ment.

Participants will also have theopportunity to tour several labs atSouthwest Research Institute.

The class will cover 4-stroke cycletheory and operation; mechanical linkages;engine packages; horsepower, torque andbrake specific fuel consumption; emissionsformation theory and control technologies;compressor horsepower, pressure-volumecurves and rod load, and compressorvalves.

The workshop begins each day at8 a.m. and ends at 5 p.m. Monday throughThursday and at noon on Friday.

Twenty-eight ProfessionalDevelopment Hours will be given to eachparticipant at the end of the course.

Compressor Station DesignJuly 12-14 - Sheraton HotelColorado Springs, Colorado

This 2-day workshop will give engi-neers and senior design professionals infor-mation on how to design and integrate allthe various parts of a compressor stationinto an effective and efficient system. It willprovide practical knowledge on how todesign a new compressor station or evaluatethe design on an existing compressor sta-tion.

Course Content includes Plot PlanLayout, Horsepower, Gas Cleaning, YardPiping, Fuel Gas Piping, Division &Classification, Ventilation, Gas & FireDetection, Foundation, Air, Heating,Electrical Loads, Generators, Wire &Conduit, Lighting Systems, Tankage,Power & Power Gas Systems, CoolingWater System, Major Equipment,Automation, Exhaust, Air Intake, andCathodic Protection.

The instructor is Chuck Law fromAlliance Engineering.

A certificate indicating 16Professional Development Hours will begiven to each participant at the end of theWorkshop.

The workshop begins at 8:00 a.m.and ends at 5:00 p.m. Tuesday andWednesday and 8:00 a.m. through 12:00noon on Thursday.

Engine Analyzer and ReliabilityWorkshopJuly 26-28 - DoubleTree HotelNashville, Tenn.

The GMRC Engine Analyzer andReliability Workshop is designed to meetthe needs of analysts and engineers whoare involved in predictive and preventivemaintenance programs throughout the nat-ural gas industry.

The Workshop Committeeincludes Keith Schafer, Columbia GasTransmission; Brad Goodwin, CenterPointEnergy; David O’Kelly, Columbia GasTransmission; Gary B. Smith, TennesseeGas Pipeline; Ed Gerzina, Dominion EastOhio Gas Co.; Jerry R. Lewis, El PasoCorp.; and Randy Anderson, ACTT, div. ofCECO

Classes that range from basic toadvanced will allow the analysts and engi-neers to take home information that is use-ful now. Segments are included that willallow attendees to present their problems,challenges, and solutions to their peers.

The course will include ignitionanalysis, primary and secondary; powercylinder analysis; turbocharger vibrationanalysis; start-to-finish emission testing;compressor calculations; and how to inter-pret oil analysis reports

Eighteen ProfessionalDevelopment Hours will be given to eachparticipant at the end of the Workshop.

The workshop begins each day at8 a.m. and ends at 5 p.m.

Combustion CharacteristicsAug. 15-19 - University Park Holiday Inn*Fort Collins, Colo.

Combustion Characteristics is acomprehensive problem-solving class cov-ering the effects of operating conditionsand control adjustments on engine combus-tion. Instructor Randy Anderson will alsocover issues affecting the development anduse of horsepower performance curves.

The class will feature in-depth dis-cussions of combustion characteristicsincluding peak firing pressure, MEP,exhaust temperatures, turbocharger speed,brake specific fuel consumption, and NOxand CO emissions on various engines.

Other topics will include effects ofchanges in air/fuel ratio, ignition timing,fuel composition, torque, speed, and certainmechanical problems on the engine’s com-bustion characteristics.

Participants will have the opportu-nity to tour the Engine & EnergyConversion Lab at Colorado StateUniversity.

Twenty-eight ProfessionalDevelopment Hours will be given to eachparticipant at

The workshop begins at 8 a.m.and ends at 5 p.m. Monday throughThursday and 8\ a.m. through noon onFriday.

*Note: Effective May 1, theUniversity Park Holiday Inn will become theFort Collins Hilton.

Introduction To Gas Turbines AndCentrifugal Gas CompressorsSept. 8-9 - Hyatt RegencyNew Orleans

This two-day class is a uniqueopportunity to learn from the experts howto apply and operate gas turbines and gascompressors as well as to interact and net-work with others in the field of turboma-chinery applications. Instructors are RainerKurz and Miller Robison, both of SolarTurbines Inc.

In addition to the theoretical pre-sentations, case studies will be presentedby the instructors in an interactive forum.Students will also be able to participate in around table discussion concerning the lat-est trends and ask questions of interest that

can be submitted in advance of the seminar.Topics include gas turbine and

gas compressor components; gas turbineand gas compressor applications; perform-ance maps and what to do with them; gasturbine & gas compressor testing; andmaintenance.

Twelve Professional DevelopmentHours will be given to each participant atthe end of the course.

Engine Emissions Stack TestingAnd Analyzer WorkshopOct. 11-13 - Holiday Inn NorthOklahoma City

Co-sponsored by SGA and GMRC,this workshop provides an understandingof and familiarity with emissions testingthrough live demonstrations, hands-oninspection of equipment, and lectures andgroup discussions of actual field testingexperiences.

Topics to be covered include theprocesses and equipment for EPA stacktesting methods and protocols; functionand design of portable analyzer equipment;factors affecting accuracy and outcome oftesting and other calculations and flowmeasurements required; state and federalrequirements in lieu of Title V enhancedmonitoring and record keeping and report-ing requirements; evaluation of emissionsreduction technology for internal combus-tion and turbine engines.

The workshop also features aportable analyzer field test session at theCooper Ajax facility.

Instructors will include BruceChrisman, Cooper Compression/Ajax; JonTice, El Paso Corp.; Charles Ely, ACTT, div.of CECO; Rich Schoonover, Enginuity;Michael Callegari, Williams Gas Pipeline;Jeff Thomason, Cubix Corp.; QuinnBierman, Air Hygiene Inc.; Drew Wilsonand Jerry Jeffers, ECOM America, Ltd.;and Craig McKim, Testo, Inc.

Fourteen ProfessionalDevelopment Hours will be given to eachparticipant at the end of the Workshop.

The workshop begins each day at8 a.m. and ends at 5 p.m. Tuesday andWednesday, and at noon on Thursday.

Controlling Pulsations InCompressor and Piping SystemsOct. 18-20 - Southwest Research Institute,San Antonio

Material for this class has beenspecifically tailored to match today’s engi-neering environment where performanceand cost effectiveness are as important inplant design as safety and reliability.

While technically a short coursefor engineers, practical experience andcommon sense have proven to be the mostimportant prerequisites. Instructors includethe GMRC Design Facility staff atSouthwest Research Institute. All sessionsare held at SwRI.

The course begins at 1:30 p.m. onTuesday and ends at noon on Thursday.

Although this short course hasbeen oriented to the design and layout ofnew facilities, the material presented willalso assist in the solution of existing plantproblems. The detailed and practical ses-sions will present the skills and know-hownecessary for controlling acoustical andmechanical forces in compressors, pumpsand piping systems.

Topics will include compressiontechnology and pulsation problems; funda-mentals of piping acoustics; prediction andcontrol of vibration and stress; effect of pul-sations on compressor performance; andpulsations in centrifugal compressor sys-tems

Twelve Professional DevelopmentHours will be given to each participant atthe end of the course.

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First Quarter 2005page 4

Located in the prolificnatural gas fields of northernNew Mexico, San Juan Collegeprovides the gas machineryindustry with highly trainedemployees through its NaturalGas Compression Program · The community collegein Farmington began the NaturalGas Compression Program inAugust 2002 after professionalsin the local compression industryasked the college to implementthe program.

San Juan College has areputation for starting new pro-grams that fill the employmentneeds of the local industry. Mostof the major producers of naturalgas in the United States are rep-resented in Farmington; whichmakes it the perfect site for thiseffort.

Billy Hancock is theinstructor for the program. “Thistype of program is perfect for thetype of students we have inschool,” Hancock said. “They tend tobe a little older than the average col-lege student, and more focused onlearning.”

San Juan College initiated anational search to find an individualwho had compression experience aswell as training/teaching experience todevelop the program. They hiredHancock from Hanover CompressionCo., where he had eight years senioritywith POI and Hanover. Hancock has aBS in mathematics from New MexicoState University and taught highschool math, computer science, andphysical science for eight years.

The program provides an edu-cation that will last these students for alifetime, Hancock said. “I tell prospec-tive students that they can do anythingthey want with this type of education,”he said. “Whether they want to stay inthis area and settle down, or go outand see the world, they have the edu-cation that will allow them to do whatthey want with their life.”

The Natural Gas CompressionProgram is a six-month certificate pro-gram designed to provide the graduatewith the basic foundation in the funda-mentals of natural gas compression.

The program has earned a rep-utation for developing well-trainedgraduates, ready for employment in thenatural gas industry. Several compa-

San Juan College Program SpecializesIn Compression Technology

Billy Hancock, far right, and students from San Juan College.

nies have indicated an interest in hir-ing graduates and sponsoring new stu-dents into the program.

“This indicates an acceptancethat the program is providing studentswith the necessary foundation highlyneeded in the natural gas industry,”Hancock said. “This has been provenby the fact of each graduate has beenemployed directly from the class, andthat several companies have hiredmore than one graduate.”

To help with the startup of thisprogram several organizations provid-ed donations; The Gas CompressorAssociation helped purchase threerolling A-frame hoists. These allow thestudents to lift and roll the engines andcompressors being overhauled.Thestate Department of Labor providedhelp in purchasing tools for the toolroom, and the Navajo Nation alsohelped to supply much of the handtools used by the students.

Additional donations arealways helpful, Hancock said. Engines,compressors, tools and parts would bewelcome, and should qualify as a chari-table contribution, he said. Graduation Rate

Since its inception, 26 stu-dents, including two women, havegraduated with certificates from theprogram.

Of these graduates, there hasbeen 100% placement upon graduation.Some of the students have gone towork with some of the major compres-sion companies and others haveobtained employment with energy pro-ducers.

The companies and the num-ber of graduates they employ include:

· CSI – 5 students· Hanover – 5 students· XTO Energy – 3 students· Stewart and Stevenson – 2 students· Cooper – 2 student

For more information about the CompressionTechnology Program at San Juan College, please contactBilly Hancock at 505-320-9812 or visit the school’s website at www.sanjuancollege.edu.

· Compressco – 1 student· Twin Stars – 1 student· Henry Production – 1 student · JW Power – 1 student·· Richardson Production – 1 stu-

dent· Cordillera Energy – 1 student

There are eight studentsin the class that will graduate inthe first week of April. Their agesrange from 18 to 37.Curriculum

The course work is struc-tured to last six months.

“We try to give them agood mix of theory and actualfield practice with equipment,”Hancock said. “We want them tobe able to work with any type ofequipment and understand how itworks.”

Students also work forthree weeks with a sponsoringcompression company under acooperative education agreement.

Subject areas include:· Week 1-5: Engine Theory and Overhaul

· Week 6-9: Engine Preventive Maintenance

· Week 10-13: Compressor Theory and Overhaul

· Week 14-17: Compressor Preventive Maintenance

· Week 18-20: Cooperative Work Experience/On the Job Training

· Week 21-22: Electrical/Electronic Systems

· Week 23-24: Instrumentation/ Control Theory

Long-Term GrowthSan Juan College considers the

needs of the industry for the short-term; as well as long-term growth. Theprojections of demand for natural gasindicate that there are and will be asubstantial demand for natural gastechnicians in the future.

The natural gas industry mustlook at the feasibility of helping tosponsor this growth if the demands fortrained technicians are at a level thatcan be considered critical.

Two years of the programhave provided the gas machineryindustry the proof that San JuanCollege has developed a viable pro-gram conducive for the training of localworkers aiming to gain a place in avery rewarding industry.

Send to:

Subscription/Gas Machinery JournalGMRC3030 LBJ Freeway, Suite 1300Dallas, Texas 75234E-Mail: ads@gmrc.org

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By Klaus Brun, Ph.D. and Robert J.McKee

Excerpted from Winter 2004Technology Today®. Reprinted by per-mission of Southwest ResearchInstitute®.

Approximately 50,000 industri-al gas turbines are in use throughoutthe world, and these machines aresteadily gaining market share againstreciprocating engines and steam tur-bines in all industries. Gas turbinesgenerally require less maintenance,have a higher availability, and can pro-vide higher efficiency than reciprocat-ing engines and steam turbines.

Industrial gas turbines arecommonly used in applications wherehigh power-to-weight ratio, low emis-sions and high availability require-ments prohibit the use of reciprocatingengines, despite their lower cost. Inthe oil and gas industry,small industrial gas tur-bines are used forpipeline compression, oilpumping, water injection,gas lift and offshore plat-form power generation —all applications where effi-ciency is of secondaryconcern to low weightand high reliability.

Most modernindustrial gas turbines aretechnically complexmachines consisting ofmultiple rotating parts,bearings, seals, lubricat-ing oil systems andsophisticated electronic controls. Theyare so technically sophisticated thatmost users cannot perform basicrepairs and maintenance.

Industry is demanding simple,low-cost gas turbines that can functionunder very rugged environmental con-

ditions, are easy to repair or replace,can be operated by untrained staff andcan be moved easily. At present thereare few gas turbine products commer-cially available that satisfactorily meetthese market requirements. To meetthis growing demand, engineers atSouthwest Research Institute® (SwRI®)have developed a novel, prototype cen-

trifugal gas turbineusing internalresearch funding.

Turbine basicsCurrently,

most gas turbines usean axial flow com-pressor and an axialflow turbine. Thisdesign is a direct evolution of the jetengine and clearlyprovides the highestaerodynamic efficien-cy. However, the axialdesign does not typi-cally provide the low-est weight, smallest dimensions orgreatest ease of maintenance.

Simple, open-cycle gas tur-bines consist of three principal compo-nents: a compressor, a combustor anda turbine mounted on a single rotating

shaft. The compressoringests and compressesambient air, the combus-tor heats this air by fuelcombustion and the tur-bine expands the result-ing hot air to drive a shaftthat generates mechanicaloutput power. The SwRI®-designed centrifugal gasturbine is based on thissimple, open cycle.

The fundamental dif-ference between theSwRI® centrifugal gas tur-bine and conventional gasturbines is that the com-pressor and turbine sec-

tion are installed on the same side ofthe rotating wheel, while the combus-tor and nozzle are mounted on the sta-tionary shroud. Thus, the entire gasturbine assembly consists of only tworelatively easy-to-manufacture compo-nents: the rotating compressor turbine

wheel, which isdirectly coupled tothe generator/starter motor, andthe combustorshroud, whichholds the utilityline connections.Unlike convention-al gas turbines, noflow turning isrequired. Becausethe SwRI® designincorporates onlyone rotating part,costs of manufac-ture, maintenance,

repair and replacement are low.

Prototype development The objective of the SwRI®

internal research project is to developa 50-kilowatt centrifugal gas turbinedesign that can achieve simple cycleefficiency greater than 16 percentwhile maintaining rotordynamic and

mechanical integrity and stability.During the last year, SwRI® engineersdesigned the gas turbine’s compressor,turbine and nozzle using in-house andcommercial engineering codes, andbuilt a prototype machine. The finalhardware prototype was machinedfrom Inconel® super-alloy using a five-

axis milling machine.A one-dimensional gas turbine

thermodynamic cycle design code waswritten to predict the gas turbine per-formance and to serve as a preliminarydesign validation tool. For the com-pressor performance, the code usesempirical, characteristic-flow curvesand a highly radial flow compressordesign. For the turbine analysis, ahigh-impulse turbine design and exper-

The Powerof DesignSwRI® engineers develop a low-cost centrifugal gas turbine

This computer image illustratesthe final assembled gas turbine.A functioning prototype of theSwRI® gas turbine will be avail-able for demonstration in late2005.

imental data were used.A finite element stress analysis

was performed to evaluate the maxi-mum allowable rotational speed of theproposed centrifugal gas turbine. Thisdesign includes a 20-percent safetymargin on speed to protect themachine from sudden overspeed

excursions or operational upsets.Various possible rotor geometryoptions were evaluated. To maintainstructural integrity and durability, thespeed of the operational prototype islimited to less than 32,000 revolutionsper minute (rpm).

A combustion system designmust be appropriate to the unique radi-al-flow system. The system must stabi-

Dr. Klaus Brun (right) is a principalengineer in the Mechanical and FluidsEngineering Department in SwRI®’sMechanical and MaterialsEngineering Division. Brun is experi-enced in performance prediction, off-design function, degradation, uncer-tainty diagnostics and root cause fail-ure analysis of gas turbines, com-bined cycle plants, centrifugal com-pressors, steam turbines and pumps.Robert J. McKee is also a principalengineer in the Mechanical and FluidsEngineering Department. McKee’sexpertise includes fluid dynamicanalysis, centrifugal compressors andpumps, gas turbines, industrial fluidhandling systems and flow meters.

Engineers assessed the lateral rotordynamics of the turbine rotor to ensurethat the turbine would run well at all expected operating speeds.

Approximately 50,000 industrial gas turbines are in use throughout the world, and they are gaining in market shareagainst reciprocating engines and steam turbines. However, they tend to be technically complex and hard to maintain. Ateam of engineers at Southwest Research Institute® has designed a novel gas turbine engine, whose turbine disk is shownhere, that is intended to be simple to maintain and inexpensive to operate.

-see “Power of Design,” next page

First Quarter 2005page 6

Both SwRI®-developed and commercial engineering codes were used to design the turbineengine’s key components as shown in these compressor, turbine and nozzle designs.

This conceptual drawing shows the simplicity of the SwRI®-designed gas turbine. The turbine hasonly one rotating part and is easy to maintain and repair.

lize the flame while allowing for cool-ing of the walls and dilution of the com-bustion gases to achieve a temperaturethat is compatible with the turbineinlet. The combustor developmentphase will be initiated in early 2005.

Further developmentCompletion of gas turbine

hardware fabrication and final installa-tion are under way. A rapid prototypeof both the rotor and stator were alsobuilt and are being used for promotion-

SwRI® engineers performed finite element stress analysis to evaluate the maximum allowablespeed of the gas turbine. The design includes a 20-percent safety margin on speed to protect themachine from sudden over-speed excursions.

al activities. For prototype testing, thegas turbine will be mounted on a high-speed test rig driven by a 200-hp elec-tric motor with a dynamic brake ratherthan being directly coupled with ahigh-frequency AC motor/generator.This will allow SwRI® to test a widerange of prototype models rather thanbeing limited to a single speed andload. In this rig, the AC motor/genera-tor is coupled via an 11/1 rpm gearboxto the centrifugal gas turbine, and thegas turbine is fully supported on

inboard and outboard high-speed bear-ings. A functioning prototype of theSwRI® gas turbine will be available fordemonstration by late 2005.

ApplicationsThe SwRI® gas turbine is com-

pact, light and portable. These featuresmake the SwRI® gas turbine an idealcandidate for applications includingmilitary battlefield, oil production flaregas, and on-ship auxiliary power unitgeneration. Other possible applications

include nanotechnology gas turbines,distributed power generation, com-bined heat and power, and hydrogenpower generation.

SwRI® has applied for andreceived patent protection for its cen-trifugal gas turbine design. Discussionsare under way with a number of turbo-machinery manufacturers to commer-cialize the SwRI® gas turbine proto-type.

Power of Design -contd from page 6

First Quarter 2005page 7

First Quarter 2005page 8

By Dr. Kirby S. Chapman & Sandra J.Chapman The National Gas Machinery LaboratoryKansas State University

Turbochargers typically areremoved from service on a compa-ny-specific schedule and areshipped to a turbocharger over-haul facility. The substantial costassociated with turbochargerremoval and overhaul, as well ascosts associated with failure in thefield after re-installation illustratethe compelling need to ensure thata rebuilt turbocharger meets oper-ational needs before return toservice.

Post-overhaul turbocharg-er performance tests at Kansas StateUniversity’s National Gas MachineryLaboratory can verify that the tur-bocharger is mechanically sound andwill perform as expected wheninstalled on the engine. The operatoralso may acquire complete compressorand turbine performance maps thatcan be used to determine whether aturbocharger can provide sufficient airflow through an engine to meet man-dated pollutant emission levels.

Ultimately, this informationmay help operators avoid needless andcostly turbocharger replacement.

The NGML Industry AdvisoryCommittee worked with the staff at theNational Gas Machinery Laboratory todevelop guidelines that determinewhen and to what extent a turbocharg-er should be tested based on the costand benefits of various scenarios.

The five scenarios include atypical turbocharger overhaul, threetypes of turbocharger retrofits; and tur-bocharger technical development activ-ities.

Each scenario is assigned arisk from low to high that is basedupon the cost to the operating compa-

ny if the unit fails in the field. Fromthat risk exposure, the committeedetermined the necessity of a test; thetype of test that should be conducted;and which turbocharger in a series oflike models should be tested.

For example, in the casewhere third-party manufactured partsare installed for a rebuild, the lead tur-bocharger should be fully tested toensure compliance with that of OEMparts.

The consensus of the NGMLAdvisory Committee was thatScenarios 2 through 5 required testing.In some scenarios only the first tur-bocharger of a specific build needs tobe tested, whereas in other scenariosall turbochargers should be tested.

At first glance, the typical over-haul does not require a post-overhaulmechanical test. The risk is low if a testis not performed and a failure occursin the field.

Turbocharger fail-ures either happenquickly, or over aperiod of time. Afteran overhaul, somefailures are easy toidentify, such assurge or the enginewill not operate dueto low air flow. Otherturbocharger

mechanical problems may remain hid-den for a longer period, much like acancer.

In the experience of theNGML, mechanical failures primarilyhave been caused by abnormal vibra-tion from imbalance, bearing problemsor looseness; oil flow or pressure notwithin specifications; and cracks in thehousing that result in oil or waterleaks.

Information on how often over-hauled turbochargers fail in the field isanecdotal at best as no statistical analy-sis has been conducted. However, ofthe mechanical tests conducted at theNGML on high-profile units in the last

seven years, approximately 25% havefailed on the first test.

While arguable whether thesetests are indicative of the industry as awhole, this indicates the potential num-ber of hidden mechanical problems onoverhauled turbochargers that are re-installed in the field.

When these problems finallysurface in operation, whether by cata-strophic failure or through analysis, anunplanned and often costly overhaul isrequired to correct the problem.

Regardless of how the hiddenproblem is ultimately detected, a per-centage of untested turbochargers willhave significantly shorter time-

between-overhaul intervals. For highprofile turbochargers upon which criti-cal operations rely – such as nuclear,Coast Guard, and main line gas com-pression – this is not an acceptablerisk.

To determine whether amechanical turbocharger test is costeffective on a typical overhaul, theNGML Advisory Committee identifiedthe direct costs associated with a tur-bocharger field failure and comparedthat to the cost of a mechanical tur-bocharger test.

Table 2 illustrates two scenar-ios of direct costs incurred once a tur-bocharger mechanical problem is

detected in the field.A conserva-

tive estimate of thecost to remove a tur-bocharger from serv-ice and ship it for over-haul is $6,000. Thelabor to remove theturbocharger and pre-pare it for shippingwas estimated at$1,000. Other costsrepresent the cost ofthe overhaul as well as

additional costs such as crane rental,lost throughput, etc.

For the conservative scenario,$8,000 was established for the addition-al costs as shown in Table 2. The$15,000 total cost represents a conser-vative estimate to remove, repair, andreinstall a failed turbocharger. Theright column in Table 2 shows whatthe NGML Advisory Committee feltwere more typical direct costs to over-haul a failed turbocharger of $27,000.

A $3,000 turbochargermechanical test at the NGML providesthe assurance that the turbochargerwill be free of mechanical problemsbefore the warranty period starts andbefore it is placed in service.

To compare the cost of a$3,000 mechanical test to that of costsincurred should a field failure occur,the question arises as to how manyfield units suffer from pre-mature fail-ure that could have been preventedwith mechanical tests.

If the NGML historical per-centage of 25% of the overhauled unitscontain mechanical problems is cor-

- see “Need to Test” next page

- cont’d from p. 1August 8-10Offshore Gas OperationsConference with ExhibitsSouthern Gas AssociationLafayette, La.www.southerngas.org

August 15-19Combustion CharacteristicsGMRCFort Collins, Colo.www.gmrc.org

September 8-9 Introduction To Gas Turbinesand Centrifugal Gas CompressorsGMRCNew Orleanswww.gmrc.org

2005 Industry Calendar, cont’d.

The Need To TestLarge-Bore EngineTurbochargers

October 3-5Gas Machinery ConferenceGMRCCovington, Ky.www.gmrc.org

October 11-13Engine Emissions Stack Testing and Analyzer WorkshopGMRCOklahoma Citywww.gmrc.org

October 18-20 Controlling Pulsations InCompressor And Piping SystemsGMRCSan Antoniowww.gmrc.org

GMC TODAY and GAS MACHINERY JOURNAL are publishedby Watts Hall Communications, an independent, privately owned communi-cations company based in Dallas, Texas. Watts Hall Communications is notaffiliated with any other organization but maintains cooperative partnershipswith energy industry associations and groups.

GMJournal and GMC Today focus on the development, design,operation and maintenance of gas machinery used in the compression of nat-ural gas and other applications in the energy industry.

Managing Editor: Jim Watts editor@gmrc.orgBusiness Manager/Art Director: Victoria Osborne ads@gmrc.org

Gas Machinery Journal8509 Sawgrass LaneRowlett, TX 75089972-475-7880

First Quarter 2005page 9

rect, then one in four turbochargersare placed in the field with mechanicaldeficiencies.

By performing mechanicaltests on all four turbochargers for atotal cost of $12,000, then the operatorcan avoid the $15,000 or higher cost ofa field failure. This represents a sav-ings of $750 to $3,750 per turbocharg-er.

Lowering the percentage ofturbochargers released to the field thathave unidentified mechanical problemsto 20%, or one in five turbochargers,then the breakeven point is reached forthe conservative total cost scenario.

Here, the cost of five mechani-cal tests equals the conservative$15,000 cost of a field failure for one infive turbochargers. The savings perturbocharger for the typical scenario,however, is $2,400 per turbocharger.

While the percentage of pre-mature overhauls on turbochargershas not been formally studied, a well-experienced operator will be able todetermine a reasonable percentage ofpremature turbocharger field failures.

A similar financial analysiscan then be conducted at a companylevel to determine if all overhauled tur-bochargers should be mechanicallytested or if such testing should be lim-ited to high profile units.

In the absence of costly well-documented quality assurance pro-grams within turbocharger overhaulfacilities, a mechanical turbocharger

test after an overhaul may in manycases be a cost-effective mean toassure the operator that the overhaulmeets specifications before it is placedin the field.

Field MonitoringAs of early 2005, field tur-

bochargers do not contain sufficientinstrumentation to determine andtrend turbocharger performance.While several past NGML researchprojects pertained to developing theability to monitor and trend tur-bocharger performance in a laboratorysetting, that information is now beingmodified for field settings.

A turbocharger performancemonitoring system for a field tur-bocharger entered the prototypingstate in early 2005. This monitoringsystem will calculate, normalize, andtrend turbocharger performance overtime. Using this data, engine operatorswill have the ability to determinewhether a turbocharger will providesufficient air to meet engine emissionrequirements in the coming months.

The installation of this moni-toring system is expected to be a sim-ple process.

After an overhaul, the monitor-ing system can be installed, validated,and calibrated for field conditions atthe NGML. The cost of a test then pro-vides two benefits: verification that theturbocharger is mechanically soundand can satisfy the design conditions;

Need to Test Large-Bore Engine Turbochargers- cont’d from p.6

and a means to calibrate and certifythat the installed turbocharger moni-toring system will provide perform-ance-based maintenance schedulinginformation for future turbochargeroverhauls.

Because this monitoring sys-tem is at the heart of the entire enginesystem, additional control and diagnos-tic packages can easily and inexpen-sively be added to the system.

Match Point TestsA match point test requires

special consideration. This case typically falls under

the scenario where an engine is under-going an upgrade to meet emissions.The air requirement typically includesa very specific turbocharger specifica-tion. The turbocharger specificationincludes the required turbochargercompressor discharge pressure, andthe turbocharger turbine inlet pressureand temperature.

As there are several potentialrisk factors when upgrading an engine,the match point test is viewed as low-cost insurance to make sure that theturbocharger will operate as expectedwhen installed on the engine.

The match point test verifiesthat the turbocharger will operate as acomplete system, as opposed to verify-ing compressor performance only. Theacceptable means to accomplish thematch point test is to literally dial-inthe design conditions at the turbineinlet (pressure and temperature), andload the compressor to its design dis-charge pressure and air flow rate. If

the turbocharger can operate at thispoint as a system, then it will operate atthis point on the engine.

If any of the design parameterscannot be achieved, then the tur-bocharger will most likely not reachthe design conditions on the engine.

Testing NeedsThere are several scenarios

under which a turbocharger should betested. These include the use of thirdparty parts in place of OEM parts,modification of blades, diffusers, andnozzle rings, and retrofitting a tur-bocharger to a given engine system.

In almost all cases, a mechani-cal and/or performance test is cost-effective. Historical data also suggeststhat tests following a typical overhaulfor a high profile turbocharger arecost-effective.

When the decision is made totest a turbocharger, the test procedureand facility must satisfy a minimumstandard to ensure that the test resultsindicate the true mechanical integrityand performance capabilities of the tur-bocharger.

Instrumentation must beinstalled according to accepted stan-dards, and that instrumentation mustbe calibrated on a schedule that is justi-fiable and traceable to the NationalInstitute of Standards and Technology.

Finally, the end-user shouldensure that the reporting requirementsare sufficient enough so that the datacan be referenced later in the life of theturbocharger.

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Bob Rajeski (left) president of Cooper Compression, and KirbyChapman (right), Director of Kansas State’s NGML are excited about theiralliance for cooperative efforts in engineering research and commercializationpotential for Ajax engine compressors, Superior compressors and legacyCooper products.

Bob Rajeski emphasized Cooper’s present and future strategies in arecent interview. “We are focused on growth initiatives and comprehensivesolutions to our customers’ needs by continuing to search for alliances, part-nerships and acquisitions both internationally and domestically,” he said.

Winston A. Johnson of El Paso Pipelinehonored with first

GMRC Distinguished Service AwardWinston A. Johnson, II, Senior VicePresident of Engineering for El PasoPipeline Group, has been named therecipient of the first GMRCDistinguished Service Award. Thisaward was presented to Mr. Johnsonfor his years of dedication to thegrowth and success of GMRC and itsresearch program. He has been achampion of research programs in theindustry and has served as Chairmanof the Board for both GMRC and PRCI.

Mr. Johnson assumed his present roleat El Paso in 1996 and provides engi-neering support to ANR Pipeline, ElPaso Natural Gas, Colorado InterstateGas, Southern Natural Gas, andTennessee Gas Pipeline for onshoreand offshore facilities. He began hiscareer in 1972 at El Paso Natural GasCompany in the machinery and pipingsection of Central Engineering, wherehe designed the installation of newcompressor facilities and the modifica-tion of existing facilities.

He earned his master’s degree inmechanical engineering at NewMexico State University and is a regis-tered professional engineer in the Stateof Texas. He served with the UnitedStates Army in Vietnam.

GMRC is a financially self-sufficient,not-for-profit corporation that providesfocused, cost-effective research, technolo-gy and training for the global market-place in the rapidly changing naturalgas, oil and petrochemical industries.Founded in 1952, GMRC maintains itsoffice in Dallas, Texas.

Leaves cover the court-yard of the hotel after fiveinches of hail fell onTuesday night.

A record crowd (below) turned out toenjoy lunch and hear the special pres-entation “Making Good ThingsHappen: A Challenge to Excellence”by Bryan Townsend (right) on theopening day of the GMC 2004. Sixhundred attendees and more than 70spouses resulted in standing room onlyin the short courses and plenty ofopportunities to learn and share fromcolleagues and friends.

GMRC would like to extend a hugeTHANK YOU to all of you - attendees,speakers and sponsors for making thisour biggest and best year ever!

GMC 2004 Sets Record Attendance

First Quarter 2005page 10

The DOE Technical Review of ongoing research projects co-fundedby industry and DOE was well attended on Sunday afternoon.

Left - the crowd at the DOEResearch Review on Sundayafternoon.

Below - Rodney Anderson andRichard Baker from the DOEand Gary Bourn from SwRIprepare for the DOE ResearchReview.

DOE Research Review

GMC 2004 Re-Cap

GMC 2005 Set For Cincinnati Area

The greatest collection of gasmachinery talent and technology inone spot will come to the GreaterCincinnati area this fall. The GasMachinery Conference 2005 is set forOct. 3 through 5 at the NorthernKentucky Convention Center inCovington, Ky., just across the OhioRiver from downtown Cincinnati.

Abstracts for papers to beconsidered for presentation at theGMC must be in the GMRC offices inDallas no later than March 4.

The GMC PlanningCommittee will accept papers for theConference based on the informativeabstract. All abstracts will be evaluat-ed on the information supplied. Thisinformation should be a synopsis ofthe paper and should be very specific.

Preference will be given topapers that involve or are presentedby users.

Abstract may be presented for

a technical paper presentation (45 min-utes), a short course (3 hours), or anew technology update (10 minutes).All papers must be free of unneces-sary commercialism.

Papers submitted must berelated to gas compression machinery.The committee will give preference topapers that:

n Present a properly con-structed informative abstract asopposed to a descriptive abstract.

nAre pertinent to current gascompression machinery issues.

nDiscuss new, innovative,and/or successful technologies,processes or methodologies

n Present the results of scien-tific studies (may be in support oftechnologies, process or methodolo-gies)

nCase studies involving gascompression machinery and relatedissues.

Above: The team at the Hyatt preparefor Ariel’s Monday Night Reception.

They gave us a true Albuquerque Welcome!

Our hosts, at left, Ariel President andCEO Karen Wright with Ariel VicePresident of Sales John Mowery

First Quarter 2005page 11

GMC 2005 Planning CommitteeKriss McDonald, Chairman Ariel CorporationJon K. Tice, Vice Chairman El Paso Corp.Donald E. Crusan Columbia Gas TransmissionHans Mathews Hoerbiger Service, Inc.Curt Pedersen ANR PipelineGreg Phillippi Ariel CorporationRainer Kurz Solar Turbines Incorporated Donna M. Sterrick Duke EnergyGene McClendon Cooper Compression, Ajax Division Charles Stanford Columbia Gulf Transmission Michael P. Duffy Altronic, Inc.Steven Braswell Southern Natural GasChristine M. Scrivner Southwest Research Institute Charles G. Ely, II ACTT, division of CECOMichael A. Smith, Past Chairman Texas Gas Transmission, LLC Kirby Chapman, Ph.D., Advisor Kansas State University Eric Thomas, ex officio member Southern Natural GasMarsha Short, GMRC Staff Liaison Gas Machinery Research Council

Emeritus MembersLewis E. Bishop, Jr. ExxonMobil (retired)Davis Conkling ChevronTexaco (retired)Randy Raymer El Paso Corp.

Thanks to Hoerbiger for a fabulous Tuesday breakfast!

Below, pictured left to right are BrianStewart, Steve Jackson, JohannesWunderlich, Tom Thomas, Bret

Hightower, Kathy Boutin and Dave Belser.

Thanks to Dresser Rand for the bestt Monday Night Football Party yet!The KC Chiefs made our K-State students’ night by beating Baltimore!

At Right, The Siemens Group welcomed the GMC attendees in style with a lavish buffet and open bar. Thank you Siemens!

First Quarter 2005page 12

These K-State students are among the group which did an outstanding job facilitating the meetings, short courses and registration at the GMC 2004.

For information regarding interviewing any of these students, please contact Sandra Chapman, schap@ksu.edu

K-State students spent all Sundaymorning assembling registrationpackages. This pile represents 1/2 ofthe materials for this year’s record-set-ting number of conference attendees!

Damian Kuiper Andrew Lindgren

Andrew Lindgren, B.S.Manufacturing SystemsEngineering, Graduation date: Spring2005. Awarded Associate of Science in2001. Andrew has recently spent twosummer internships as aManufacturing Engineer with EatonCorporation in the Fluid Power Division.While there, he engineered a program-mable 4-spindle nut runner system.Since 2002, he has held the positions ofboth Research Assistant and LabTechnician for the National GasMachinery Laboratory where hedesigned and implemented a modularturbine exhaust system for a turbocharger test cell. In addition, he is aSupervisor over turbocharger receiv-ing, installation, and removal, and over-sees manufacturing, operation, mainte-nance and supply. He also assists stu-dents in learning machine shop prac-tices; basic foundry principles, weldingskills, mill operation, lathe operationand inspection management. He hasexperience with various computer soft-ware systems.

Damian Kuiper, B.S. MechanicalEngineering, M.S.M.E. Emphasis:Turbomachinery & ComputationalFluid Dynamics, Graduation date:December 2004. Damian is currentlyat the National Gas MachineryLaboratory where he is serving as aGraduate Research Assistant. HisThesis project: “Fluid DynamicAnalysis of Turbo Machinery withComputational Real Time Results,” iscomplemented by his GraduateResearch project: “Quantifying a CostEffective Efficiency Increase usingTurbocharger Tip Seals.” Damian hasdeveloped and designed devices whichhave demonstrated improved tur-bocharger efficiency and are capable ofincreasing combustion engine air mani-fold pressure. He has had four pub-lished industry articles in the last twoyears and was a speaker at the 2004GMC Conference (Numerical andExperimental Investigation ofPerformance Losses in a ClarkTurbocharger Compressor)

Eric Figge

Heath Mireles

Diana Grauer

Eric Figge, B.S. MechanicalEngineering (Physics Minor), A.S.Mechanical EngineeringTechnology, Graduation Date:December 2005. Eric is currently aSenior Technical Advisor at KSU in theNational Gas Machinery Laboratory.While working toward two degrees,Eric manages and supervises other stu-dent employees, coordinates, logs andperforms laboratory calibration,designs mechanical and plumbing sys-tems, designs, implements and trou-bleshoots electrical and control sys-tems, operates the turbocharger testcell, maintains a 3,000 hp gas turbineand axial compressor package and, ontop of all that, he also maintains thelaboratory computer systems. He is sohard-working, we couldn’t get him tostop long enough to take a picture.

Diana Grauer, Mechanical andNuclear Engineering Major,Graduation Date: December 2006.With graduation two short years away,Diana is looking for an internship tohelp her better prepare for a future inthe Engineering field. She is currentlythe Research Coordinator for theNGML, assisting the research directorin his efforts. She has completed aninternship at the Kiewitt IndustrialCompany where she was responsiblefor document control, piping take-offs,quantity tracking, scheduling and costanalysis. Project work for Kiewittincludes design, installation, inspectionand quality control for small bore pip-ing design. Diana has served as thePresident of both the Mechanical andNuclear Engineering Student AdvisoryCouncil and Mechanical and NuclearEngineering Women. She also coordi-nated the Mechanical and EngineeringNewsletter.

Heath Mireles, B.S. MechanicalEngineering, Graduation Date: May2006. Heath is currently the NGML’sLab Assistant Researcher, a position hehas held for two consecutive schoolterms. He spent this past summer inAlaska as a Reservoir Engineer Internfor BP Exploration where he per-formed an Enhanced Oil Recovery(EOR) Reconciliation study in PrudhoeBay and developed a program for PadEngineers to use in calculating recov-ery due to EOR. He also discoveredtrends in injector/producer communi-cation and performance that led to theformation of new conformance/per-formance mapping in the area. His2003 summer internship was with BP’sAmoco Production Company as aProduction Engineer Intern. Whilethere, he learned the basics of offshorewell work through field visits, devel-oped a successful gas lift re-design foran offshore well, wrote three well workprocedures and identified future pro-duction opportunities in the Gulf ofMexico Shelf.

KSU Students keep the GMC Runnng

Allen Adriani is currently specializingin mechanical engineering fields ofThermodynamics and Fluids Dynamicsat Kansas State University. Allen com-pleted his undergraduate studies at theUniversity of New Haven, receiving aBachelor’s of science degree inMechanical Engineering in the springof 2001. While studying for hisBachelors degree, he received twoundergraduate fellowships awarded bythe NASA Connecticut Space GrantCollege Consortium. He served as thepresident of the student ASME sectionat the University of New Haven andwas awarded the ASME a StudentAchievement Award. With Allen’shands on experience and capability ofcombining textbook knowledge hasenabled him to build an internal com-bustion engine test cell at KSU. Allen isplanning to use this test cell to applydifferent emission control strategies tolarge bore engines. Allen plans tograduate in August of 2005.

Christopher Bret Grier, B.S.Mechanical Engineering, Graduationdate May 2005. Bret is currently aSenior Undergraduate ResearchAssistant, at the NGML where he hasassumed a leadership role with the tur-bocharger test cell horsepowerupgrade, conducted 3-D static structur-al analysis for the turbocharger testcell frame using finite element analysiswith modal and solid state analysis,conducted vibration analysis of rotatingequipment, fabricated large test celltransitions and machine base fabrica-tion, provided troubleshooting duringtesting, and calibrated control dataacquisition instrumentation. He alsohas experience as a Teaching Assistantin Thermodynamics at KSU, and as theChief On-Site Mechanic, UtilityContractors in Wichita KS where hemaintained all on-site machines andequipment for the Victoria, KS site thatsupported a 14 mile I-70 constructionproject. In addition, he is no strangerto fast-pace and high pressure - havingserved as a Sauté Cook during hisundergraduate studies. In college, hehas ohoned his leadership skills as thePhi Gamma Delta FraternityPhilanthropy Chair, and as a memberof the Judicial Board.

Allen Adriani

Eric and Heath work the registrationtable and welcome conference atten-dees.

Christopher Bret Grier