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Cooper-Bessemer Type GMV Integral-Angle Gas Engine-Compressor
Cooper-Bessemer Type GMV Integral-Angle Gas Engine-Compressor
INTEGRAL-ANGLE GAS
ENGINE-COMPRESSOR
1
HISTORIC MECHANICAL
ENGINEERING LANDMARK
COOPER-BESSEMER TYPE GMV INTEGRAL-ANGLE GAS ENGINE-COMPRESSOR
1938
THE GMV INTEGRAL-ANGLE GAS ENGINE-COMPRESSOR WAS AMAJOR CONTRIBUTOR TO THE
WORLD’S ECONOMY FOR MORE THAN HALF A CENTURY, PROVIDING COMPRESSION ENERGY
FOR THE NATURAL GAS TRANSMISSION, GAS TREATMENT, PETROCHEMICAL, REFINERY AND
POWER INDUSTRIES IN THE UNITED STATES AND FORTY-FOUR COUNTRIES AROUND THE
WORLD.
THE BASIC MECHANICAL DESIGN OF THE GMV IS UNIQUE IN ITS SIMPLICITY AND PROVIDES
HIGH EFFICIENCY AND RELIABILITY FOR CONTINUOUS, HEAVY-DUTY INDUSTRIAL
APPLICATIONS. DESIGN IMPROVEMENTS DURING THE GMV’S EVOLUTION DOUBLED ITS POWER
OUTPUT, IMPROVED THERMAL EFFICIENCY TO 37 PERCENT, AND LED THE WAY IN EXHAUST
EMISSION REDUCTION FOR NATURAL GAS ENGINES.
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Introduction engines with cylinders, connecting rods, crankshaft,
bearings, and frames. First introduced in 1898, these
The modern industrial world became dependent engines became universal in the oil field (see Fig. 3).
upon large scale exploitation of fossil fuels in the
latter half of the nineteenth century. Energy use
from fossil fuels began with coal, and was
supplemented with petroleum production,
beginning in 1859. Extraction of petroleum was
usually accompanied by natural gas, which was at
first considered to be a nuisance and was flared.
Gaseous fuel had the disadvantage that it could not
be transported in batch quantities like coal and
petroleum, but required pipelines for economical
transportation from the well-head to the consumer.
The first pipelines were short affairs where the
available gas could be sold in towns near the oil and
Fig.2 Bessemer Conversion of Innis Steam Engine
gas fields. In these short distribution networks, the
gas would flow to the consumer simply from the
well pressure. Later, as markets for natural gas
developed far from the oil and gas fields, and as
pressure declined in the older fields, compression of
the gas was required to move the fuel through
pipelines.
The earliest compressors in the oil and gas fields
were stand-alone reciprocating piston type
compressors with their own connecting rod,
crankshaft, bearings, and frame. They were powered
by stationary steam engines usually via a belt drive.
Operating a steam plant requires a steady supply of
Fig.3 Early Bessemer Gas Engine
clean water for the gas fired boiler, but at most sites
in the oil field, clean water was not available and
Once stand-alone market gas compressors driven by
boiler life was short. In the last decade of the
stand-alone gas fired engines became the norm, it
Nineteenth Century, some enterprising individuals
was not too much of a stretch for someone to
with knowledge of the petroleum industry decided to
conceive of joining the gas fired power cylinder and
try burning natural gas directly in a power cylinder,
the compression load cylinder on a common frame to
hoping to eliminate the need for a boiler.
share flywheels, crankshaft, bearings, and frame.
In 1898, Dr. Edwin J. Fithian and John Carruthers
Thus began the integral gas engine- compressor, first
formed the Bessemer Gas Engine Company and
introduced in 1909.
produced kits to convert steam engines into new
The horizontal double-acting power cylinder design
internal combustion engines, fueled with oil-field
of these first integral gas engine- compressors was a
natural gas. The Bessemer Conversion Engine,
logical development from previous steam engine
designated an ASME Historic Mechanical
experience. By arranging the double-acting power
Engineering Landmark in 1997, is a kit conversion
cylinders in tandem it was possible to have four
of an 1880’s Innis steam engine with a Bessemer
power ends working per crank-throw, and by
natural gas burning power cylinder. (see Fig. 2)
locating a “twin” unit on the other side of the
The success of these converted gas engines in the
flywheel a total of eight power ends became
field quickly led manufacturers to offer complete gas
available for driving, via tie-rods,
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two compressor cylinders on the opposite ends of the with Cooper-Bessemer in Mount Vernon, Ohio, and
frames (see Fig. 4) Clark Brothers in Olean, New York, utilizing two-
stroke cycle power cylinders; Ingersoll-Rand in
Painted Post, New York, using a four-stroke cycle
power cylinder design, and Worthington Pump and
Machinery in Buffalo, New York, following later
with a “Uniflow” two-stroke design. All of these
products featured vertical power cylinders and
horizontal compressor cylinders. This improvement
was to prove to be only a step toward the ultimate
economic solution.
Sometime during 1936 the Mount Vernon
Engineering Department of Cooper-Bessemer
Fig. 4 Cooper-Bessemer Type 22 decided to adopt the “Vee-Angle” concept,
Ingersoll-Rand had introduced their XVG engine
In all human endeavor, economics provides with success in California. This engine was of the
incentive for technological improvement. As Vee-Angle design and incorporated an articulated
pipeline and process gas flows increased, the connecting rod arrangement. This configuration
compression plants became larger and larger, and the permitted placing twice the number of power
search was underway for ways to reduce the floor cylinders on a frame with dimensions not
space required by these horizontal behemoths. The significantly larger than an in-line vertical unit. The
development of a compact gas engine-compressor, new engine design was designated the GMV. It was
more readily transportable and easier to install than rated at 100 BHP per cylinder and was produced in
the "classic" horizontal twin-tandem, became a great haste and secrecy in 1937 and put to work on a
priority in the industry in the 1930’s. The first step pipeline in 1938.
in that direction was that of the integral-angle gas
engine-compressor. In this development, the power Worldwide Use of the GMV
cylinders were mounted vertically above the
crankshaft, while the compressor cylinders were The number and variety of GMV installations during
mounted horizontally in their traditional location for pre World War II and the immediate post-war period
the convenience of the high pressure process gas is impressive. Gas pipelines and field gas production
piping. and treating plants represented primary markets, but
the engine found numerous other applications.
GMV gas engines were also used in petrochemical
plants and for driving water and oil pumps, as well
as a number of DC and AC generating plants in
Alaska, Arkansas, New Mexico, Peru, and
Venezuela.
That preparations for the war were underway were
evidenced by the delivery of 24 units to Dow
Chemical at Velasco, Texas in 1941 and the
shipment of fifty GMV-10 (ten cylinder unit) DC
Generating units to the Alcoa aluminum plant at Hot
Fig. 5 Cooper GMR Engine Springs, Arkansas during 1941-42.
War led to a large part of Cooper’s capacity being
The Cooper GMR Engine illustrated in Fig. 5 was of allocated to Diesel engine production (marine and
this type. generator applications) and GMV production was
Production of integral-angle gas engine- held steady at about sixty units per year. Large
compressors got underway during the mid-1930’s
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users in the United States during this period were satisfaction of customers. The following is an
Lion Chemical; El Dorado, Arkansas, (24 units), engineering description of the salient features.
Humble Oil; Baytown, Texas, (26 units), and
Tennessee Gas for four stations on their new The GMV design uses a master connecting rod attached
pipeline, (31 units). directly to the compressor crosshead pin and
incorporating power cylinder articulated rod pin
After the war, GMV production was increased connections via bolting, unique to the GMV, directly to
rapidly, reaching a peak of 189 units in 1950, with the master rod pins and the power pistons (see Fig, 6).
engines being exported to Peru, Venezuela, Sumatra, This design provides much greater bearing area for the
Mexico, Belgium, and France. Major US users were piston pins; extremely important for two-cycle engines,
Cities Service (73 units), Shell Chemical, Panhandle since the load on the piston pins in two-stroke engines is
never relieved. Connecting rod bearing area is also
Eastern (89 units), greater than conventional “side-by-side” Vee-Rod
Tennessee Gas Transmission (168 units), Dow Design, and the crankshaft overall length is reduced.
Chemical (56 units), El Paso Natural Gas (236 The “standard” GMV is a two-cycle “loop scavenged”
units), Humble Oil Company (58 units), Magnolia, engine of 14-inch (355.6 mm) bore and 14-inch (355.6
Southern Natural Gas (103 units), Warren Petroleum mm) nominal stroke. The early, so-called, ‘short-stroke”
models had a master connecting rod design that provided
(38 units), Lone Star Gas, Texas Eastern (40 units), a 14-inch (355.6 mm) stroke for the compressor cylinder
Pure Oil Company (36 units), United Fuel Gas, Lion and also for each of the “Vee” power cylinders (see Figs.
Oil, Tennessee Eastman, and Mathieson Chemical, a 6 & 7). In 1946 the master rod geometry was changed to
veritable “Who’s Who” of the United States Oil, eliminate “piston knuckling”, and advantage was taken
Gas, and Petrochemical Industries. of the elliptical orbit of the articulated piston pins to
increase actual stroke of the power cylinders to
The impact of the GMV on the gas engine world approximately 14.6-inches (370.8 mm), the so-called
marketplace was also pronounced. Various models “long stroke” GMV which continued as standard for the
of the engine were produced, under a number of rest of the engine’s history.
different contractual arrangements in eight foreign The 300 rpm for compressor service remained standard
countries: Cooper-Bessemer of Canada; Harland & until the introduction of the GMVE and GMVG models
in the 1960’s, running at 330 rpm.
Wolff in the United Kingdom (Ireland); Creusot- The supply of scavenging air, required for two-stroke
Loire in France; Conjunto Manufacturero in Mexico; engine operation was provided in a most logical manner
Termomechanica in Italy; Bremer-Vulkan in by utilizing the “dead space” around each compressor
Germany; Kobe Steel in Japan and Dvigatel crosshead to accommodate a 22-inch (558.6 mm)
Revolutsii in the Soviet Union. The first 24 engines diameter single-acting piston to pump air to the power
cylinders (see Fig. 6). The scavenging versus power
in the USSR were shipped under a “Lend-Lease” piston areas gave a theoretical “excess air” ratio of 1.24,
agreement in 1945 and installed in six stations of the for removal of exhaust gases and the supply of fresh
first major natural gas pipeline in Russia. The 25th combustion air each stroke.
unit went to the Dvigatel Revolutsii Engine Works in Air supply for the GMV was via cored inlet passages in
Gorky where 1591 GMV “clones” (Russian Type the crankcase base (see Fig. 6) at each throw center-line,
then via the scavenging pistons to another cored volume
10GKN) were produced during the 1952-1991 in the upper base frame which was common to the
period. Excluding the United States, Canada and the bottom inlets of the power cylinders, which are
Soviet Union, 225 units were produced by the other individually bolted to the crankcase. The various air
licensees. In all, 4667 GMV engines were produced, passages and volumes made the crankcase casting rather
making it one of the most prolific of its kind, and it complicated, but also did serve to make the base
structure quite rigid, which was beneficial for absorbing
made an important contribution in the oil, gas, and compressor loading.
chemical industries over a 55 year period. The GMV cylinder design utilizes what is known as
“Curtiss” porting. It has proven very successful and was
Unique Mechanical Engineering Features used without major modifications throughout the GMV’s
history. High speed photography taken inside the
The GMV incorporated special features for cylinder, during operation, confirm the presence of high
Integral-angle gas engine-compressors. These turbulence, to assist in fuel-gas and air mixing.
features were unique and contributed to the
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Fig. 6 GMV Cross-Section, Showing scavenging
air flow
GMV
The GMV started life with a rating of 100 BHP per
cylinder and a 300 rpm operating speed. It was
manufactured in 4, 6, 8, 10 and 12 cylinder
configurations; 937 units were produced.
GMV-TF
In 1948, the first “Turboflow” GMV-TF’s were
introduced. “Turboflow” was a cover word for going to
high compression heads, increasing the compression
pressure from 120 psi (8.4 kg/cm2 ) to 250 psi (17.6
kg/cm2 ). The application of high compression allowed
raising the GMV power rating to 110 BHP per cylinder Fig. 7 GMV Components
and improved fuel thermal efficiency from 25% to 30%
(see Fig. 8).
A total of 604 GMV-TF’s were installed from 1948
through 1963
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Fig. 9 GMV-STF Supercharging
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GMVB
Following Cooper-Bessemer’s success in
manufacturing turbochargers for its line of four- stroke
engines, it was logical to examine the possibilities of
turbocharging the GMV.
The problem was that turbocharger component
efficiencies, turbine and compressor, were not yet up to
levels permitting “pure-turbocharging” of a two-stroke
engine, so alternate methods would have to be found.
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GMVH
Finally, by 1964 Cooper-Bessemer “got-it-right”. “The engine was one of the most advanced engines
Turbocharger technology had improved to the of its day, and one of the very first to be designed
point where a “constant-pressure” system having all cylinder
exhausts connected to a common manifold, leading to the using modern diagnostic techniques.
turbine inlet, would provide the required differential air The effectiveness of the basic design is seen in the
pressure for engine scavenging and combustion without any fact that the engine was in continuous production for
intermediate boosting. 55 years. Many of the engines produced in the
Elimination of the gear-driven centrifugal blower 1940’s are still in use, operating “24hours/7days”
removed parasitic load, which improved the engine’s
thermal efficiency. with high reliability and good efficiency. The
The application of “pure” turbocharging has a beneficial pipeline industry still operates over 2500 GMV
effect for a two-stroke engine in that the back-pressure model engines”; and,
requirement of the exhaust turbine in effect raises the so-
called “density level” of the combustion process. That is, “From an operating standpoint the GMV series of
the mass of combustion air trapped in the power cylinder
each stroke is increased, meaning that a corresponding engines have an unparalleled Safety, Reliability, and
amount of more fuel can be burned without exceeding Cost of Operation record. Our station operators have
allowable mixture richness which would lead to detonation. always viewed the GMV series units as first on, last
off compression"
Engineering Credit
Specifications
Fig. 12 GMVH Engine
The GMV-4 Landmark engine is SN-42290 and was
The GMVH (see Fig. 12) started its career at a modest 200 manufactured in 1944 as a shop air compressor and
BHP per cylinder at 330 rpm and the rating was increased was installed in the Mount Vernon Power House.
in 1973 to 225 BHP per cylinder when the ambient The engine was used until 2002. The unit is
temperature rating base was changed from 100 0 F (37.8 equipped with the two
0
C) to 80 0 F (26.7 0 C). The engine thermal efficiency
original air compressor cylinders: First stage
improved to 37%; 6800 BTU/BHP-HR
(26616 Kg.Cal/CV-HR), (see Fig. 8). cylinder; Class CF-14, SN-12119, 27-inch (685.8
The number of GMVH’s installed totaled 392 units. mm) diameter by 14 inch (355.6 mm) stroke,
In 1978, in response to the increasing pressure being Second stage cylinder, Class CD-14, SN-11666, 17
brought by the Environmental Protection Agency (EPA), inch (431.8 mm) diameter by 14 inch (355.6 mm)
the GMVH was the first gas engine to adopt the
stroke. Although the engine is capable of operation,
“CleanBurn R” combustion
it is not set up to run.
This unit was rated at 400 BHP at 300 rpm and 61.3
bmep (4.2 Bar). Piston Speed: 700 ft,/min. (3.5
In summary, the impact of the GMV line of engines m/sec.)
can best be summarized by industry spokesmen
associated with the engines operation:
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Key Dimensions:
Length 12 ft. 0 in. (3.7 m)
Width 16 ft. 0 in. (4.9 m)
Height 9 ft. 9 in. (3.0 m)
Weight 55000 lbs. (25000 kg) (engine only)
Key engine part dimensions
Main Bearings, End 9 ½ in. x 8 ¼ in.
(241.3 x 209.6 mm)
All others 9 ½ in. x 7 in.
(241.3 x 177.8 mm)
Crankpin Bearings 9 ½ in. x 9 ½ in.
(241.3 x 241.3 mm.
Piston Pin Bearings 4 in. x 9 ¼ in.
(101.6 x 235.0 mm)
Crosshead Pin Bearings 6 in. x 18 ½ in.
(152.4 x 469.9 mm)
Diameter of Flywheel 5 ft. 8 in. (1.7 m)
Weight of Flywheel 3,788 lbs.(1722 kg)
Minimum Foundation Requirement
27 cu. Yds. (12.2 m3 )
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THE HISTORY AND HERITAGE PROGRAM OF ASME
The History and Heritage Landmarks Program of ASME (the American Society of Mechanical Engineers)
began in1971. To implement and achieve its goals, ASME formed a History and Heritage Committee
initially composed of mechanical engineers, historians of technology, and the curator of mechanical
engineering at the Smithsonian Institution, Washington, D.C. The History and Heritage Committee provides
a public service by examining, noting, recording, and acknowledging mechanical engineering achievements
of particular significance. The Committee is part of the ASME’s Center for Public Awareness. For further
information, please contact Public Information at ASME, Three Park Avenue, New York, NY, 10016-5990,
1-212-591-8614 and http://www.asme.org/history.
DESIGNATION
Since the History and Heritage Program began in 1971, 238 landmarks have been designated as historic
mechanical engineering landmarks, heritage collections or heritage sites. Each represents a progressive step
in the evolution of mechanical engineering and its significance to society in general. Site designations note
an event or development of clear historical importance to mechanical engineers. Collections mark the
contributions of a number of objects with special significance to the historical development of mechanical
engineering.
The Landmarks Program illuminates our technological heritage and encourages the preservation of the
physical remains of historically important works. It provides an annotated roster for engineers, students,
educators, historians, and travelers, It helps establish persistent reminders of where we have been and where
we are going along the divergent paths of discovery.
The 120,000-member ASME is a worldwide engineering society focused on technical, educational and
research issues. ASME conducts one of the world’s largest publishing operations, holds some 30 technical
conferences and 200 professional development courses each year, and sets many industrial and
manufacturing standards.
BIBLIOGRAPHY
Cooper-Bessemer Gas Engine Compressors
1899 – 2001 The Story of the GMV Engine
Donald A Harnsberger Ralph L. Boyer
The Woodlands, Texas February 24, 1939, Revised October 27, 1943
ACKNOWLEDGEMENT
The Author wishes to thank the following
individuals for their contributions.
Donald A. Harnsberger
Jay M. Wilson
James K. Gibson
Ken McCandless
Tom Mulkey, President & CEO, GMRC
Randall R. Raymer, El Paso Pipeline Group
Bryan Willson, Ph.D, Colorado State University
Tom Gardner, President/Owner, PostNet
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