APRIL 2023

COW
POWER
STRONG PARTNERSHIP
TO SERVE
CUSTOMERS WORLDWIDE

Burckhardt Compression AG KB Delta Inc.

info@burckhardtcompression.com info@kbdelta.com
www.burckhardtcompression.com www.kbdelta.com
 APRIL2023
ON THE COVER
Cow Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

FEATURES
Hydrogen Report: Neuman & Esser Technology
For Green Hydrogen Production In Germany . . . . . . . . . . . . . . . . . . . . .20

-QTEGX3J8LI-R¾EXMSR6IHYGXMSR%GX´W
WORDS
Editorial Chair Methane Fee Charge Explained . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Joe Kane

Publisher One-On-One: A Conversation With Scott Buckhout,

Brent Haight
President And CEO Of Cooper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Editor, Latin America
Débora Gonzalez de Galdeano RMS Acquires Hot Gas Expander Product Line
Technical Editor From Siemens Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Angela Jarrell

Managing Editor Surge Control Systems

Raeanna Toussaint
For Centrifugal Compressors: Part 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Senior Editor
Daniel Foelber
7MQTPM½IH7EQTPMRK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
GRAPHICS 1109 Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Art Director
Amanda Ryan

ADS IN EVERY ISSUE

VP, Advertising & Business Development
Sarah Gonzalez Contracts & Permits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Manager, Advertising & Circulation Mergers & Markets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Kara Kane
Reliable Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
SUBSCRIPTIONS Machinery In Motion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Manager, Advertising & Circulation
Kara Kane
What Went Wrong? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
DIGITAL In The News. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
&KLHI7HFKQRORJ\2I¼FHU
Jason Bainbridge Index Of Advertisers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Digital Content Manager 'PEWWM½IHW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Raeanna Toussaint

Evil Genius, Media & Digital Marketing

Haight Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Amanda Ryan
Lagniappe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

APRIL CONTRIBUTORS:
SCAN HERE TO SUBSCRIBE Klaus Brun, Mohsen Eshaghi, Daniel Foelber, Brent Haight, B. Henry Henderson,
Angela Jarrell, Chris Kipp, Rainer Kurz, Marybeth McBain, Robert X. Perez,
Mary Savalle, W. Norm Shade, and Raeanna Toussaint.
Gas Compression Magazine
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 CONTRACTS & PERMITS
Information is gathered from Federal Energy Regulatory Commission (FERC) records and other public documents and is intended to
provide details on construction projects that involve natural gas compression equipment. Every effort is made to ensure the completeness
and accuracy of the information presented; however, project details (including but not limited to dates, equipment, locations, etc.)
are subject to change without notice. Additional information may be found at http://gascompressionmagazine.com/contracts-permits
PROJECT
APPALACHIA TO MARKET II
AND ENTRIKEN REPLACEMENT;
TEXAS EASTERN TRANSMISSION
PLANNED COMPRESSION:
Armagh Compressor Station;
Entriken Compressor Station
STATUS: Environmental Assessment
PROJECT DETAILS:
Texas Eastern Transmission (Texas Eastern) has re-
ceived a favorable environmental assessment from FERC
for its Appalachia to Market II and Entriken Replacement
project, allowing it to move forward. The proposed fa-
cilities are in Lebanon, Indiana, and Huntingdon Counties
in Pennsylvania. The purpose of the project is to provide
YTXSHIOEXLIVQWTIVHE]SJEHHMXMSREP½VQREXY-
ral gas transportation service from the Appalachia supply
basin in southwest Pennsylvania to existing local distribu-
tion company customers in New Jersey. Texas Eastern
will also improve reliability in its system by replacing a
1950s-era gas-driven compressor unit with an electric
motor-driven (EMD) compressor unit at each of the two
compressor stations.
The project consists of adjustments to the Line 28
Pipeline Loop in Lebanon County. Texas Eastern will
install approximately 2 miles (3.2 km) of 36-in. (0.9-m)
looping pipeline adjacent to Texas Eastern’s existing
Lines 12, 19, and 27 pipelines beginning at existing Line
28. At the western terminus of the Line 28 Loop, an
existing receiver and valve site will be abandoned and
removed, and at the eastern terminus a new receiver,
valve, and crossover site will be constructed.
Adjustments to both the Armagh and Entriken Compres-
sor Stations are as follows:
Armagh Compressor Station
Located in Indiana County, Texas Eastern will install
a 27,000-hp (20,142-kW) centrifugal EMD compressor
YRMXKEWGSSPIVW½PXIVWITEVEXSVWWSYVGIGSRXVSPJEGMPM-
ties, associated buildings, and piping at the existing com-
pressor station to replace an existing 22,000-hp (16,412-
kW) GE Frame 5 gas-driven turbine compressor unit,
which will be abandoned and removed. The other com-
pressor unit at the station, an 18,000-hp (13,428-kW)
Solar Titan 130, will remain in operation. Additionally,
a new electric substation will be constructed to provide
4 gascompressionmagazine.com | APRIL 2023
power to the new EMD compressor. The station modi-
½GEXMSRW[MPPMRGVIEWIXLIWXEXMSR´WXSXEPLSVWITS[IVF]
5000 hp (3730 kW).
Entriken Compressor Station
Located in Huntingdon County, Texas Eastern will
install a 24,000-hp (17,904-kW) centrifugal EMD com-
TVIWWSV YRMX KEW GSSPIVW ½PXIV WITEVEXSVW EWWSGMEXIH
buildings, and piping at the existing compressor station
to replace an existing 22,000-hp GE Frame 5 gas-driven
turbine compressor unit, which will be abandoned and
removed. The other compressor unit at the station, a
26,000-hp (19,396-kW) Solar Titan 250, will remain in
operation. Additionally, a new electric substation will be
constructed to provide power to the new EMD compres-
sor unit, and a new 1289-kW emergency generator will
replace an existing 620-kW generator. The proposed sta-
XMSRQSHM½GEXMSRW[MPPMRGVIEWIXLIWXEXMSR´WXSXEPLSVWI-
power by 2000 hp (1492 kW).
PROJECT
VIKING LINE MNG2207B-100; VIKING GAS
TRANSMISSION COMPANY
PLANNED COMPRESSION:
Angus Compressor Station
STATUS: Notice Of Application
PROJECT DETAILS:
Viking Gas Transmission Company (Viking) is seeking
FERC approval to construct, own, maintain, and operate
the Viking Line MNG2207B-100 project in Polk County,
Minnesota. The project would add a single compressor
unit with the purpose of supporting an additional 30,000
HIOEXLIVQWTIVHE]SJ½VQXVERWTSVXEXMSRWIVZMGISR:M-
king’s mainline.
The Angus Compressor Station currently consists of
JSYV REXYVEP KEW½VIH GSQTVIWWSV YRMXW SRI IQIVKIRG]
generator, and one water jacket heater. These existing
units include two 1700-hp (1268-kW) two-stroke lean-
burn reciprocating internal combustion compressor en-
gines, one 3400-hp (2536-kW) two-stroke lean-burn re-
ciprocating internal combustion compressor engine, and
one lean pre-mix combustion turbine compressor engine.
Viking is proposing to add one new 2500-hp (1865-kW)
REXYVEP KEW½VIH ;EYOIWLE  HVMZMRK ER %VMIP /&8
compressor unit.
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 EQUINOR BUYS SUNCOR FOR
US$850 MILLION, EXPANDS
MERGERS & MARKETS
&=(%2-)0*3)0&)6 NORTH SEA EQUITY STAKES
BUZZARD OIL FIELD AND ROSEBANK DEVELOPMENT TO ADD
15,000 BOE/D TO EQUINOR’S 2023 PRODUCTION

The Troll A Platform In The North Sea

Image Courtesy Of Harald Pettersen/Equinor

N orwegian integrated oil and gas major, Equinor,

signed an agreement to acquire Suncor Energy
“
With this transaction, we strengthen
our position in one of our core areas on
UK (Suncor) for US$850 million. Equinor entered 2023 the Norwegian continental shelf.
¾YWL[MXLGEWLEJXIVTSWXMRKVIGSVHVIZIRYISJ97

billion in 2022, record net income of US$28.8 billion,
ERHVIGSVHJVIIGEWL¾S[SJ97FMPPMSR±;IEVI
FYMPHMRKSRSYVPSRKWXERHMRKTSWMXMSREWEFVSEHIRIV-
K]TEVXRIVXSXLI9/WXVIRKXLIRMRKSYVTSWMXMSREWE
VIPMEFPIIRIVK]TVSZMHIVMR)YVSTI[LMPIGSRXMRYMRKXS
HIPMZIVSRSYVEQFMXMSRSJFIGSQMRKERIX^IVSGSQ-
TER]²WEMH4LMPMTTI1EXLMIYI\IGYXMZIZMGITVIWMHIRX
JSV)UYMRSV)\TPSVEXMSRERH4VSHYGXMSR-RXIVREXMSREP
in a statement.
-REHHMXMSRXSXLI7YRGSVHIEP)UYMRSVWEMHMXI\-
TIGXW SVKERMG GETMXEP I\TIRHMXYVIW SJ 97 FMPPMSR
XS 97 FMPPMSR MR  JSPPS[IH F] ETTVS\MQEXIP]
97 FMPPMSR TIV ]IEV JVSQ  XS  (IWTMXI
XLMWWTIRHMRK)UYMRSVWEMHMXSRP]I\TIGXWSMPERHKEW
TVSHYGXMSRXSKVS[F] MRGSQTEVIHXS
EW MX GSRXMRYIW XS MRZIWX MR PS[GEVFSR EPXIVREXMZIW
ERH VIRI[EFPI IRIVK] XS GYX KVIIRLSYWI KEW IQMW-
WMSRWF] F]
”
()8%-073*8,)792'36()%0
8LIX[SQEMRNI[IPWMR7YRGSV´WGVS[R[IVIMXW RSR
TIVEXMRK MRXIVIWX MR XLI &Y^^EVH 3MP *MIPH &Y^^EVH  ERH E  
STIVEXMRK MRXIVIWX MR XLI 6SWIFERO (IZIPSTQIRX 6SWIFERO 
&Y^^EVHMWPSGEXIHRSVXLIEWXSJJXLIGSEWXSJ%FIVHIIR7GSXPERH
[LMPI 6SWIFERO MW PSGEXIH  QMPIW  OQ  [IWX SJ XLI 7LIX-
PERHEVGLMTIPEKSSRXLI9/'SRXMRIRXEP7LIPJERHEFSYX QMPIW
 OQ WSYXLIEWXSJXLI*EVSI-WPERHW
&Y^^EVHMWSTIVEXIHF]'EREHMERSMPERHKEWKMERX'233'-X
GSRWMWXWSJJSYV½\IHTPEXJSVQWERHXLVIIWYFWIEQERMJSPHW)UYM-
RSVWEMHXLI½IPHMWTVSHYGMRKEFSYXFEVVIPWSJSMPIUYMZE-
PIRXTIVHE] FSIH 8LI*SVXMIW4MTIPMRI7]WXIQI\TSVXWPMUYMHWXS
XLI,SYRH4SMRX8IVQMREP[LIVIGVYHIMWWSPHSRXLISTIRQEVOIX
8LI*9/%W]WXIQSRISJXLIQEMRREXYVEPKEWXVERWTSVXEXMSRERH
TVSGIWWMRKRIX[SVOWMRXLI2SVXL7IEI\TSVXWKEWZSPYQIWJVSQ

6 gascompressionmagazine.com | APRIL 2023

&Y^^EVH)UYMRSVWEMHXLIVIMWERIPIGXVM½-
cation initiative to reduce carbon dioxide
(CO2) emissions at Buzzard.
Equinor acquired operatorship of
Rosebank in 2019 and holds a 40% equity
stake, which will increase to 80% once
the Suncor deal goes through. Ithaca En-
IVK] LSPHW XLI SXLIV   6SWIFERO ½XW
Equinor’s strategic initiative to boost
shareholder returns while also lowering
emissions across its oil and gas portfolio.
Rosebank has yet to begin production be-
cause Equinor has spent years optimizing
the development to achieve a low-emis-
WMSRW TVS½PI [LIR MX GSQIW SR WXVIEQ
A key pillar of Equinor’s decarbonization
strategy is sustained natural gas produc-
Offshore Rig At The Buzzard Oil Field
XMSREXEPS[½\IHGSWXXLVSYKLGSRXMRYIH Image Courtesy Of Suncor Energy
returns from mature plays. The best way
XSTVSPSRKEQEXYVITPE]MWXSSYX½XMXJSV
the future. Equinor is thinking decades In January, Aker Solutions (Aker) won the Rosebank Petrojarl Knarr FPSO
ahead with Rosebank by preparing for a contract from Altera Infrastructure. In a joint venture with Drydocks World-
¾SEXMRK TVSHYGXMSR WXSVEKI ERH SJ¾SEH- (YFEM%OIV[MPPYTKVEHIXLI*473WSMXGERFIOITXMRXLI½IPHJSVERSXLIV
ing (FPSO) vessel that will take produc- years without drydocking. Aker said the engineering, procurement, and con-
XMSR JVSQ XLI ½IPH XLVSYKL WYFWIE [IPPW WXVYGXMSR[SVOMWTPERRIHXSWXEVXYTHYVMRKXLI½VWXLEPJSJ-XMWWGLIHYPIH
JSVTVSGIWWMRKERHSJ¾SEHMRK Continued on page 8

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AXH air-coolers Fax: (918) 283-9229

gascompressionmagazine.com | APRIL 2023 7

 Buzzard Oil Field And Rosebank Development (Above) Location Of Equinor Equity Interests Acquired From Wellesley (Below)
Images Courtesy Of Equinor

to be completed by the end of 2025. The Petrojarl Knarr Steps are being taken to prepare Rosebank for addition-
FPSO was transported to Aker’s yard at Stord, Norway, al low-carbon investments down the road. For example,
in August 2022, and it will be kept there until the planned tow )UYMRSVWEMHXLI*473[MPPFIVIEH]JSVJYXYVIIPIGXVM½GE-
to Dubai during the second half of 2023. tion, which is in line with the North Sea Transition Deal

8 gascompressionmagazine.com | APRIL 2023

(NSTD). Launched in March 2021, NSTD is fo- Equinor Equity Stake Equinor Equity Stake
cused on transitioning the North Sea to net- Oil And Gas Field License
Before Transaction After Transaction
zero emissions by 2050 through investments Toppand 50% 95% PL630/PL630CS
in hydrogen production; carbon capture, uti-
Grosbeak 40% 85% PL925
lization, and storage (CCUS); offshore wind;
and decommissioning. UK public and private Atlantis 40% 80% PL878/878B/878C
investment is estimated to be US$19.2 billion Røver Nord/Sør 40% 60% PL923/PL923B
F]  MRGPYHMRK 97 FMPPMSR WTIGM½GEPP] Grosbeak 40% 55% PL248I
toward CCUS. According to the International
Data Source: Equinor
Energy Agency, the deal is expected to cut
pollution by up to 66.1 million tons (60 million
tonnes) by 2030, including 16.5 million tons Equinor said it has made seven discoveries in the region since 2019.
(15 million tonnes) from oil and gas production The area is one of the more mature parts of the North Sea. However,
on the UK Continental Shelf, while supporting Equinor has spent decades lowering its cost of production across the
up to 40,000 jobs across the supply chain. North Sea. Thanks to the geological advantages of the NCS and Equi-
nor’s decades of experience in offshore exploration and production, the
ADDITIONAL INVESTMENTS company currently sports one of the lowest costs of production of the
Equinor’s announcement to buy Suncor integrated oil and gas majors. “With this transaction, we strengthen our
came just days after the company signed an position in one of our core areas on the NCS,” said Kjetil Hove, Equinor’s
agreement with Wellesley Petroleum AS executive vice president for Norwegian Exploration and Production.
;IPPIWPI] XSEGUYMVIIUYMX]MRXIVIWXWMR½ZI “These discoveries can be put into production with low costs and low
discoveries in the Troll, Fram, and Kvitebjørn CO2 emissions by being connected to the suitable infrastructure in the
areas in the North Sea on the Norwegian area. Discoveries close to infrastructure are important for our ambition
Continental Shelf (NCS). to maintain production at current levels from the NCS beyond 2030.”

What ’s In Yo
ouur

START
Don’t Roll The Dice On Your
Cooling System Solutions!

NO NO

YES YES
YES

YES
S YES

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RESTORED!

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gascompressionmagazine.com | APRIL 2023 9

 RELIABLE COMPRESSION
BY MOHSEN ESHAGHI AND ROBERT X. PEREZ
PISTON ROD PACKING:
INSTALLATION AND STARTUP TIPS
PART 1
Piston Rod
Packing Case
Figure 1. A distance piece with the cover removed, showing the
packing case.
P iston rod packing cases (PRP) are used in all API 618 re-
ciprocating compressors for the piston rod sealing on the
crank-side of compression cylinders, as shown in Figure 1. The
contact of the sealing elements with the oscillating piston rod
subjects these elements to continuous wear. Therefore, users
must monitor their condition and replace them when they
wear out and begin leaking excessively.
Figure 2. Typical piston rod packing seal-
MRK EVVERKIQIRX [MXL PIEOEKI ¾S[MRK
from right to left.
10 gascompressionmagazine.com | APRIL 2023
Generally, PRP can be divided into two basic categories:
• Dry-running PRP are used if contact between lubricating oil
and the gas compressed must be prevented due to process
contamination concerns.
• Lubricated PRP are used when the gas compressed may
contact the lubricating oil. The advantages of the lubricated
type over the dry-running PRP are longer running times of
the internal seal parts, lower leakage, lower wear on the
piston rod, and the ability to handle considerably higher dis-
charge pressures.
PRP typically consist of several sealing chambers with mul-
XMTPIWIEPMRKIPIQIRXWERHEQSYRXMRK¾ERKIEWWLS[RMR*MK-
ure 2. The oscillating piston rod runs in the center of the PRP.
The sealing elements are designed so the piston rod can freely
move within the sealing chambers and adjust automatically ac-
cording to wear and tear, until reaching their wear limit. Be-
cause of the working pressure in the compressor cylinder, the
sealing elements are pressed onto the piston rod and against
the chamber base of the piston rod packing. By doing so, the
packing rings seal the cylinder and control leakage. The tight-
ening of the sealing elements is carried out automatically by
the working gas pressure acting on the outside diameters of
the seal rings. After reaching steady-state thermal conditions,
a leakage gap arises at the inside diameter of the sealing rings
that restricts atmospheric gas leakage to acceptable levels.
Packing Cup (One Of Several)
MOUNTING OF PISTON ROD PACKING
Working with PRP requires care and cleanliness. Damage
to the sealing surfaces has to be avoided during the assembly.
Each of the sealing chambers, or packing cups, must be as-
sembled according to the manufacturer’s assembly drawings.
In all cases, the existing axial clearance must be examined.
The mounting clearances of the internal parts must corre-
WTSRH[MXLXLSWIWTIGM½IHF]XLIQERYJEGXYVIV%QSYRXMRK
clearance that is too small may cause jamming of the sealing
ring pair due to thermal expansion. On the other hand, an ex-
cessive mounting clearance could jam internal parts and lead
to accelerated wear. Before mounting the sealing rings, each
MRHMZMHYEPWIEPMRKWIKQIRXWLSYPHFIRSXIHERHZIVM½IH8LI
sealing chamber code numbers are vertically engraved on all
individual segments of the completed sealing ring, so incorrect
mounting of the individual segments can be prevented. Figure
3 shows an installed piston rod packing ring set.
Figure 3. An installed
packing box without
Packing Rings
the compressor rod
installed. There are
multiple packing ring
sets in the center of
the packing box.
All lubricated PRP component parts and the piston rod have to
be oiled evenly to ensure reliable performance. Uniform oil distri-
bution is accomplished by injecting oil at the top of the PRP to en-
sure an even distribution of oil on the piston rod. Before tightening
the packing case bolts, the chamber rings of the PRP have to be ad-
justed under each other using a ruler to prevent assembly errors.
Failure to carefully follow the manufacturer’s assembly procedure
GSYPHPIEHXSGSRWMHIVEFPIWXEVXYTHMJ½GYPXMIWERHXMQIHIPE]W
2I\XXMQI[I[MPP½RMWLSYVHMWGYWWMSRSJTEGOMRKFS\FIWX
practices by covering startup and monitoring tips.
ABOUT THE AUTHORS
Mohsen Eshaghi leads the rotary department of a company
that manufactures API-compliant compressor packages. He has
an M.Sc. and B.Sc. in mechanical engineering, is a lecturer of me-
GLERMGIV]GSYVWIWERHLEW[VMXXIREVXMGPIWEFSYX½IPHSTIVE-
tions and maintenance of API-compliant compressors. Eshaghi
can be reached at mohsen.eshaghi.job@gmail.com.
Robert Perez is mechanical engineer with more than 40 years
of rotating equipment experience in the petrochemical indus-
XV],ILEW[SVOIHMRTIXVSPIYQVI½RIVMIWGLIQMGEPJEGMPMXMIW
and gas processing plants. He earned a BSME degree from Texas
A&M University at College Station, an MSME degree from the
University of Texas at Austin, and holds a Texas PE license.
Perez has written numerous technical articles for magazines
ERHGSRJIVIRGIWTVSGIIHMRKWERHLEWEYXLSVIH½ZIFSSOWERH
coauthored four books covering machinery reliability. He is
also the technical editor of Kane’s Rotating Machinery Dictionary.

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 WHEN PREDICTIVE
   
BY MARY SAVALLE
MAINTENANCE FAILS
“Torture the data, and it will confess to anything”
– Ronald Coase
I was drawn to numbers from a young age and excelled
in math throughout my education. I would test myself
by seeing how many phone numbers I could memorize,
XMQIQ]WIPJXEOMRKI\EQW ERH½RHXLVMPP MRMHIRXMJ]MRK
patterns in almost anything I encountered. At a young
age, entering a position with unlimited data seemed like
EHVIEQGSQIXVYI%W-IRXIVIHXLI½IPHXLSYWERHW
of data points became available from a single asset. It
quickly dawned on me that not all data are created
equal. It took a team of us years to prioritize thou-
WERHWSJHEXETSMRXWMHIRXMJ]GVMXMGEPMX]½PXIVSYXVIT-
etition, audit alarm/shutdown set points, and establish
algorithms between points to create a robust preven-
tative and predictive maintenance program. We spent
so much time working on the equipment and analyzing
data that I struggled at times when others couldn’t see
what we could. It took an incredibly rare opportunity,
the perfect mix of individuals, and the draw to under-
standing data that led me to build the case study pre-
WIRXIH-XHIXEMPWEWTIGM½GWMXYEXMSR[LIVI-WXVYKKPIH
to see what others could, a failure that not only built
my engine/compressor knowledge, but it also helped
me grow as a leader and project manager.
W330 MASS IMBALANCE CASE STUDY
Problem Statement
Two 4000-hp (2984-kW) Cooper-Bessemer W330
units experienced compressor failures due to lubrica-
XSV QEPJYRGXMSRW 9RMX  JEMPIH ½VWX [MXL HEQEKI I\-
ceeding internal expertise, so the original equipment
QERYJEGXYVIV 3)1 [EWGSRXEGXIHXSHMWTEXGLE½IPH
service crew to the site. Unit 3 started to replace Unit
2 but soon failed as well. Internal personnel repaired
Unit 3 and returned it to service.
Disassembly of the compressor was in progress
when the crew arrived. Because of the extensive
HEQEKIERHXLIMRXIKVEPGSR½KYVEXMSRSJXLI;
the rest of the unit was evaluated. Where the re-
mainder of the unit was in good order, unexpected
damage was found in the Compressor 4’s cylinder.
%JXIVJYVXLIVMRZIWXMKEXMSRXLIPIEH½IPHWIVZMGIVIT-
resentative (FSR) discovered a mass imbalance within
the unit. The decision was made to perform an in-
spection on all three units, at which time an imbal-
ance was also found in Unit 3.
12 gascompressionmagazine.com | APRIL 2023
Mass balance description, relevant history, timeline overview,
failure theory/repair, and lessons learned are shared below.
What Is Mass Balance?
Mass balance within a reciprocating engine/compressor refers
to how the forces are balanced, ensuring safe, smooth operation.
These forces are not only generated directly by the mass of rotat-
ing/reciprocating components and the combustion process but are
also impacted by installation location conditions. Foundation com-
TSWMXMSRXIQTIVEXYVI¾YGXYEXMSRERHSZIVEPPFYMPHMRKLEVQSRMGW
among other aspects, are taken into consideration. Mass balance
drives reduction in vibrations and undesired stresses to ensure re-
liability across the asset’s life cycle.
Where some engines are inherently balanced by necessary com-
ponents connected to the crankshaft such as pistons, connecting
rods, and compressor materials, others require the use of addi-
tional mass in the form of counterweights that are strategically
inserted. For some units, like those in this case study, a portion
of the mass balance is dependent upon removable, and sometimes
damageable, components.
Other factors that impact balance can include engine speed,
maintenance practices, asset utilization, operational conditions, and
combustion stabilization. Considering the number of contributing
factors, and variability in those factors as the footprint of the unit
MRGVIEWIWMXMWTSWWMFPIXSLEZIHMJJIVIRXQEWWFEPERGIGSR½KYVEXMSRW
for the same model type. In this case study, the Cooper-Bessemer
W330 mass balance is evaluated for a particular compressor station
where three identical units are installed in the same building.
Relevant History
• 1998 — Units Installed (Last Three New W330 Cooper-Besse-
mers Produced)
• 1998 To 2006 — Internal Engine/Compressor Analysis
 ¯(IHMGEXIH-RXIVREP'IVXM½IH%REP]WX;MXL=IEVW´)\-
perience
„ Transitioned Companies In 2006
– Detailed Maintenance History
• 2006 To 2010 — No “Documented” Engine/Compressor Analysis
– Units Balanced Internally, But Not Formally Analyzed
– Some Internal Knowledge, But No Expertise
– No Structured Maintenance History
– Unit Failures
„Units 2 And 3 Both Experienced Compression-Side
*EMPYVIW 6IUYMVMRK 7MKRM½GERX 1EXIVMEP 6ITEMV6I-
placement
„Repairs/Replacements Not Fully Documented
Continued on page 14
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 • 2010 To 2018 — Contracted Analysis
– Unit Analysis Contract Put In Place To Evaluate
Units Twice Per Year
– Preventative And Predictive Maintenance History
Available
– No Formal Process To Document Failure Repairs

• 2018 To Present — Contracted Analysis

– Unit Analysis Contract In Place To Evaluate Units
Twice Per Year
– Fully Structured Maintenance And Repair History

Overview Of Timeline
Monday, October 29 — FSR discovered a mass imbal-
ance potential in two W330s. FSR contacted the proj-
ect manager and compression subject matter expert to
obtain the original mass balance sheet for these units.
Tuesday, October 30 — FSR brings the concern to the
reliability team and makes the recommendation to return
to the original conditions. The reliability team met with
station management to explain the discovery and gave *MKYVI3VMKMREP3)11EWW&EPERGI7LIIX
FSR the go-ahead to gather materials to return the unit
to its proper state. The imbalance was mapped out and Figures 2 and 3 provide more simplistic views.
showed counteracting forces. NOTE: The repair timeline
was only possible because of the availability of required
materials in critical spare stock.
Wednesday, October 31 — Team met with the OEM
and collectively agreed the units needed to return to
XLI SVMKMREP GSR½KYVEXMSRW 8LI VSSX GEYWI JSV HEQEKI
to Unit 2 was discussed and although lubrication failure
initiated the damage, imbalance exacerbated the failure.
Thursday, November 1 — Unit 2 was returned to its
TVSTIV GSR½KYVEXMSR ERH VIEWWIQFP] GSRXMRYIH 9RMXW
1 and 3 were inspected, locating another imbalance in
Unit 3.
Friday, November 2, through Wednesday, November
7 — Units 2 and 3 were fully reassembled, returned to
SVMKMREP 3)1 QEWW FEPERGI GSR½KYVEXMSR ERH FEWIPMRI
analysis was completed.

ORIGINAL BUILDING MASS BALANCE *MKYVI9RMX'SR½KYVEXMSR%RH*EMPYVI(ITMGXMSR%W*SYRH

CONFIGURATION
The original OEM mass balance sheet for these three
units, dated July 1997, is shown in Figure 1. Note the
following:
1. Mass balance is impacted by two variants of the
crosshead shoe design, separated by 154 lb. (70 kg).
2. LM-38-B, or “light,” crosshead shoes are designed
for Throws 1 and 4.
3. LM-38-H, or “heavy,” are designed for Throws 2
and 3.
4. The crosshead shoe, although rare, is a component
that can experience damage, resulting in required
repair and replacement. This can be done on-site
or in a machine shop if time is available to remove
and ship.
5. Mass balance is unique to each installed unit.
Continued on page 16 *MKYVI9RMX*EMPYVI8LISV]

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During the failure that took place sometime between
2006 and 2010, the lower crosshead shoe on Compressor
4 was damaged and replaced. Instead of the required “light”
shoe, a “heavy” shoe was installed in its place, increasing
the weight in the cylinder by 154 lb. Once the lubrication
was compromised in this failure, excess force was exerted
on the crankshaft. The friction also created excess vibra-
tion in the cylinder. Where the initial damage was due to
lubrication loss, the extent of damage was exacerbated by
the opposing mass imbalance.
During a failure that took place sometime between 2006
and 2010, the upper crosshead shoe on Compressor 3 was
damaged and replaced. Instead of the required “heavy” shoe,
a “light” shoe was installed in its place, decreasing the weight
in the cylinder by 154 lb. Once the lubrication was compro-
mised, excess force was exerted on the crankshaft. The
friction also created excess vibration in the cylinder causing
damage in Cylinder 4 as expected. The unexpected damage
to the top of the crank-end side of the crosshead shoe is now
explained by the mass being removed.
Although the unit had been repaired from the lubrica-
tor malfunction and returned to operation, once the mass
MQFEPERGI [EW MHIRXM½IH E JYPP MRWTIGXMSR [EW GSQTPIXIH
similar to Unit 2. Further damage on Unit 3 included:
Crosshead Shoe Damage — Multiple crosshead shoes
were found with wear marks that are not typical for stan-
dard operation. The worst was found on the top shoe of
Compressor 3’s cylinder.
Crosshead Guide Assessment — Once the damage was
found on the crosshead shoes, it was determined that the
entire guide assemblies should be assessed.
Compressor Liner Damage — All four compressor liners
had large steps in the midsection and wear marks on the
bottom. In addition, the cylinders were egg-shaped, pre-
venting honing from being a viable method of repair. While
the cylinders were in the shop, a full evaluation and non-
destructive testing (NDT) took place to see if the vibration
caused any further damage.
16 gascompressionmagazine.com | APRIL 2023
Figure 4. Unit 3 Failure Theory
Cracked Exhaust Bellows — Two large sections of the ex-
LEYWXQERMJSPHLEHWMKRM½GERXJVEGXYVIWMRXLIMRXIVREPPMRIV8LMW
is not typical unless high-frequency vibrations are present, con-
sistent, and in a continual plane. Another potential contributor
is a hard stop or jolt to the system, which did not take place
prior to shutdown.
Head Plug Damage — All four head plugs showed evidence of
wear and did not match the expected dimensions. Instead of paying
to evaluate and repair/modify the existing head plugs, it would be
QSVIFIRI½GMEPXSTYVGLEWIRI[[MXLXLI3VMRKMQTVSZIQIRX
SUMMARY
Figures 5 and 6 were provided in each W330 manual. The ge-
RIVMGGSR½KYVEXMSRHITMGXWEPMKLXWLSISRXLIXSTERHLIEZ]WLSI
on the bottom. It takes both a deeper assessment of the drawing
and foundational understanding of unit mass balance to recog-
nize that the original balance sheet would need to be referenced.
If someone were to look at this drawing without understanding
this, a light shoe would be installed on the top and a heavy on the
FSXXSQI\EGXP]LS[FSXLYRMXGSR½KYVEXMSRW[IVIJSYRH
Further assessment was completed to determine if or when
the crosshead shoes were replaced. It was concluded that the
YRMXW [IVI SVMKMREPP] MRWXEPPIH EGGSVHMRK XS 3)1 WTIGM½GEXMSRW
and that the repairs and replacements were completed at some
point between 2006 and 2010.
LESSONS LEARNED
• Mass Balance
The mass balance of an integral unit is critical to long-term reli-
ability. This balance is impacted by components in both the engine
and compressor, because both tie directly to the crankshaft. A
mass balance sheet should be made available for each asset in the
QERYEPW YWIH F] FSXL ½IPH IQTPS]IIW ERH IRKMRIIVW 'SQTS-
RIRXWXLEXMQTEGXQEWWFEPERGIJSVIEGLEWWIXWLSYPHFIMHIRXM½IH
and taken into consideration in future maintenance efforts. The
mass balance for the W330 was impacted by the availability of
two crosshead shoe variations, separated by 154 lb.
• Maintenance History
Continued on page 18
RIWHFKQRORJ\WRVLJQLILFDQWO\ORZHUHPLVVLRQVIRU\RXUFRPSUHVVRUV
 Figure 5. W330 Manual
Maintenance history is a vital part of successful equipment
analysis. The gap in analysis efforts and structured maintenance
log led to poor baseline data once a structured program was
reestablished.
• Maintenance Plan
A structured predictive and preventative maintenance plan is
critical to true business success. It is important to highlight that
these two units operated for thousands of hours with an imbal-
ERGI8LMWMWEVIWYPXSJXLIWPS[WTIIHMRXIKVEPGSR½KYVEXMSRSJ
the W330, but also because the team routinely monitored and
worked on the equipment. Without this investment, it is likely
that damage would have occurred much sooner.
• Knowledge Is Power
The complexity of the equipment in this industry can be over-
whelming at times. As nearly all legacy units were installed years
before current staff, it is important to look at each unit as its
own individual creation. With anywhere from 20 to 75 years of
operation, an unknown number of repairs, installation of after-
market parts, upgrades, and more, having an open mind can be
powerful. Leaning on the expertise of others in this industry can
open new possibilities. Resources are available and it is encour-
aged to ask questions.
8LIWI VITEMVW LEH E WMKRM½GERX MQTEGX SR SYV XIEQ ERH
highlighted a potential none of us had considered. We had
spent years building a comprehensive maintenance plan, im-
plementing semi-annual analysis for more than eight years.
Where little items would come up on occasion that required
attention, there was no blatant indication in the analysis re-
ports that would directly indicate an imbalance. I personally
struggled with how we could miss something of this magni-
tude, but it took formulating this case study to see the whole
picture, because contributing factors pre-dated the majority
of our team.
18 gascompressionmagazine.com | APRIL 2023
Figure 6. W330 Manual
Had these failures not occurred exactly as they did,
and the right set of expertise and resources hadn’t been
available, these units would have continued to experi-
ence failure as the true root cause would continue to go
YRHMWGSZIVIH - WXVYKKPIH XS WII [LEX XLI ½IPH WIVZMGI
representative on-site that day saw because I didn’t have
all the information. Our team spent years putting faith in
analysis results that were based on assets in the incorrect
GSR½KYVEXMSR 8LMW GEWI WXYH] [EW LEVH JSV EPP SJ YW XS
accept, but as we tortured the data enough, it ultimately
confessed, and our team gained invaluable knowledge.
ABOUT THE AUTHOR
Mary Savalle is an internal combustion
engine and natural gas compression en-
thusiast currently serving as the senior
manager of Committee Strategy for the
Southern Gas Association. She holds a
BS in mechanical engineering, a project
management professional license, a re-
PMEFMPMX] IRKMRIIVMRK GIVXM½GEXMSR ERH MW GYVVIRXP] X[S
thirds of the way through her Master of Engineering in
engine systems. Mary started in natural gas compression
in 2007. More than 15 years later, she is more passionate
than ever to share knowledge and work to continuously
improve the industry she loves.
 HYDROGEN
NEUMAN & ESSER TECHNOLOGY
H 2
FOR GREEN HYDROGEN
REPORT
BY B. HENRY HENDERSON PRODUCTION IN GERMANY

E NERTRAG, one of the largest renewable energy com-

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“ENERTRAG is very proud to accomplish this project,
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Development at ENERTRAG. “With this reference plant,
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The Elogen electrolyzer will produce up to 4.4 tons (4 tonnes)
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20 gascompressionmagazine.com | APRIL 2023

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*SVXLIGSQTVIWWMSRWXSVEKIERH½PPMRKRIGIWWEV])2-
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 IMPACT OF THE INFLATION
REDUCTION ACT’S METHANE
FEE CHARGE EXPLAINED
BY CHRIS KIPP
T he two greenhouse gases (GHGs) most abundant in
the oil and gas industry are carbon dioxide (CO 2) and
methane (CH 4). One way to look at GHGs and create
an equal comparison is on a carbon dioxide equivalent
(CO 2 e) basis. This equation normalizes the ability of a
molecule to trap heat in the atmosphere to that of a CO 2
molecule, using a Global Warming Potential (GWP) fac-
tor. The United States primarily uses the 100-year GWP
as a measure of the relative impact of different GHGs that
results in a GWP factor of 25 for CH 4 . In 100 years, 1 ton
(0.9 tonnes) of CH 4 emitted would have the same warm-
ing potential as 25 tons (22.7 tonnes) of CO 2 , resulting in
this equation:
CO 2 e = CO 2 + (CH 4 × 25) + others
However, CH 4 molecules break down much faster in the
atmosphere and have a higher short-term global warming
impact; therefore, other metrics have been developed to
compare one GHG to another. For example, the 20-year
GWP is sometimes used as an alternative to the 100-year
GWP; the 20-year GWP is based on the energy absorbed
over 20 years. Since all GWPs are calculated relative to
CO 2 , GWPs based on a shorter time frame will be larger
for gases with lifetimes shorter than CO 2 , and smaller
for gases with lifetimes longer than CO 2 . Using the 20-
year GWP results in a GWP factor for CH 4 several times
higher than the 100-year GWP.
CH 4 emissions have become an important topic with
an increasing number of industry conferences focusing
strictly on CH 4 mitigation. The CH 4 -focused conferences
typically consist of oil and natural gas producers present-
ing and demonstrating technology used to capture all
vented CH 4 and reducing every possible source, at times
going above and beyond current regulations. This is a
FIRI½XJVSQETYFPMGTIVGITXMSRTIVWTIGXMZIERHFIRI½XW
investors, shareholders, communities, as well as the en-
tire oil and gas industry. By responsibly producing oil and
natural gas today, the industry is helping pave the way for
a strong future.
What are the typical emissions sources and where do
the CO 2 and CH 4 emissions originate on a compressor
station? CO 2 emissions are almost directly correlated
22 gascompressionmagazine.com | APRIL 2023
to the amount of fuel burned on-site, with the largest
sources being any engines or turbines and smaller sourc-
es like heaters. CH 4 emissions are more complicated to
measure and are emitted in two different ways: from
vented or leaked sources and through engine exhausts.
The CO 2 e footprint of a typical lean-burn compressor
station, from engine exhaust and vented CH 4 , comprises
67% CO 2 and 33% CH 4 using the 100-year GWP. The
CO 2 emissions are almost entirely from the engine’s ex-
haust, while the CH 4 emissions are split almost equally
between uncombusted CH 4 in the engine exhaust and
CH 4 from leaks and vents. With the major sources iden-
XM½IH TVSHYGMRK GSQTERMIW GER XEVKIX VIHYGXMSRW MR
XLSWIWTIGM½GEVIEW
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2022, includes a few provisions related to CH 4 emissions
impacting the oil and gas industry. Section 60113 of the
-6%EHHW7IGXMSRXSXLI'PIER%MV%GXMQTSWMRKXLI
½VWXIZIVHMVIGX±GLEVKI²SR', 4 emissions. The premise
of the regulation is that GHG emissions are contributing
to climate change and that reducing CH4 emissions is the
fastest, most economical way to protect the environment.
The CO 2 component comes from the combustion of gas.
While small incremental reductions in fuel consumption
can trim CO 2 , CH 4 emissions are easier to cut. Fugitive
CH 4 can be relatively easy to capture, and the unburned
CH 4 in the exhaust can be almost eliminated with Miller
cycle, rich-burn combustion technology.
To enforce and facilitate CH 4 reductions, a CH 4 waste
fee will be imposed on facilities that exceed segment-
WTIGM½GXLVIWLSPHW8LI', 4UYERXM½GEXMSRQIXLSHW[MPP
FIFEWIHSRXLI97)RZMVSRQIRXEP4VSXIGXMSR%KIRG]´W
)4%´W  +VIIRLSYWI +EW 6ITSVXMRK 4VSKVEQ +,+64 
This fee will be US$900 per metric ton of CH 4 for 2024,
US$1200 for 2025, and US$1500 for 2026 and each
year thereafter. The CH 4 intensity calculations are a ra-
tio of the amount of CH 4 emitted to the total natural
gas throughput of the station. This means a producer’s
potential fee can be reduced by either decreasing CH 4
emissions or increasing the station’s throughput. The al-
lowable fee thresholds range from 0.05% for gathering
and boosting stations to 0.2% for onshore or offshore
production segments.
 The GHGRP is used by the EPA to quantify GHG emis-
sions, as the name implies. However, there is a proposed
ruling that would revise emissions factors to correct in-
accuracies that have been brought to the EPA’s attention
through various measurements and studies completed
by academic institutions. The largest impact comes from
how CH 4IQMWWMSRWEVIUYERXM½IH,MWXSVMGEPP]XLI)4%
correlated engine CH 4 emissions to the industry in which
the engine was operating (Subpart C for Transmission,
Subpart W for Gathering & Boosting and Natural Gas
Processing). The new proposed rule now considers the
combustion technology an engine is using and assigns a
different factor depending on whether the engine is a
rich- or lean-burn.
To help define the difference between a rich-burn
(stoichiometric) and lean-burn engine, we can go back to
high school chemistry class. Natural gas engines combust
fuel and air to create mechanical power. Writing out a
perfectly balanced chemical equation — CH 4 + 2 O 2 =
CO 2 + 2 H 2 O — provides the stoichiometric ratio for
the balanced amount of air to fuel. (This is a simplified
equation for pure CH 4 and O 2 .) Other constituents like
N 2 will be present, and those help form NO x , etc. A rich-
burn engine operates at almost this exact air-fuel ratio. A
lean-burn engine runs with excess air in the combustion.
This extra air allows for cooler combustion tempera-
tures, lower engine out NO x , and better fuel consump-
tion to a certain extent. However, to keep up with NO x
regulations, these engines must continually increase the
amount of air in the combustion chamber, which leads
to a less complete combustion and results in an increase
of CH 4 emissions. The rich-burn engine runs at a stable
air-fuel ratio and uses a three-way catalyst to reduce
NO x and other pollutants. Due to the exhaust composi-
tion and exhaust temperatures, three-way catalysts are
not effective on a lean-burn engine. The EPA has pro-
posed updated emissions factors that are more repre-
sentative of operational emissions and would improve
the accuracy of emissions data submitted to the EPA
because current Subpart W methodologies do not dis-
tinguish between rich- and lean-burn engines, as shown
in both theoretical lab and field testing. The proposed
emissions factors significantly change the impact of the
IRA’s CH 4 fee since the proposed lean-burn GHGRP fac-
tor for CH 4 slip is more than 11 times higher than that
of a rich-burn engine.
To demonstrate the impact of the proposed emis-
sions factors, a sample compression site was modeled
independently as both a 100% rich-burn site and a 100%
lean-burn site, as shown in Figure 1. The site includes six
compressor skids, each running at 1380 hp (1029 kW)
and compressing 6 MMscf/d (169,901 m3/d). With the
compressor vents, tank vents, and blowdowns, the site is
permitted to emit 82.7 tons (75 tonnes) of CH 4 per year
outside of the engine’s exhaust. In 2026, with a fee of
Continued on page 24

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 ,Q½DWLRQ5HGXFWLRQ$FW$QG*UHHQKRXVH*DV5HSRUWLQJ3URJUDP5HVXOWV
5HVXOWV2I1HZ(PLVVLRQV)DFWRUV
Tonnes Of CH4 /Year
;/HDQ%XUQ ;0LOOHU&\FOH
5LFK%XUQ
Figure 1. Sample Lean- And Rich-Burn Compression Sites
US$1500 per metric ton of CH 4 , using the EPA’s old Sub-
part W factors, both the modeled rich- and lean-burn site
would have to pay just under US$20,000 to satisfy the
CH 4 fee. By applying EPA’s proposed GHGRP factors, the
lean-burn site would pay more than US$400,000 while
the rich-burn site would pay US$0 in CH 4 fees.
The producing companies most severely impacted by
IRA’s Methane Emissions Reductions Program are mid-
WXVIEQ SMP ERH KEW STIVEXSVW [MXL PEVKI ¾IIXW SJ PIER
FYVRIRKMRIW8LIWI¾IIXW[MPPLEZIXLIPS[IWXJIIXLVIWL-
old factor and the highest engine CH 4 emissions factors.
Overhauls and reducing emissions are expensive. Where
does the budget come from to do both? A lean- to rich-
burn engine conversion at the time of a major overhaul
can accomplish both goals. For example, original equip-
ment manufacturer (OEM)-remanufactured engine ex-
change programs can help facilitate engine swap-outs or
exchanges, seamlessly transitioning from lean-burn com-
bustion into the latest Miller cycle rich-burn technology.
This is on par with lean-burn fuel consumption but with a
much lower CH 4 , and therefore CO 2 e, footprint. Other
emissions such as NO x and volatile organic compounds
(VOCs) can also be reduced during the transition from
lean to rich burn.
Additionally, the CH 4JIIMWEZIVEKIHSZIVIRXMVI¾IIXW
not only at individual sites. There is still time to act be-
fore the CH 4 fee goes into effect. To target package emis-
sions, a quick remediation is to reduce the CH 4 emitted
from the package, especially pneumatic items powered by
gas or vents. Targeting and mitigating engine CH 4 emis-
24 gascompressionmagazine.com | APRIL 2023
Balance Of Plant (BoP) CH4
Engine CH4
CH4 Untaxed
;/HDQ%XUQ ;0LOOHU&\FOH
5LFK%XUQ
sions requires additional planning. Since an engine is typi-
cally overhauled once every six plus years, this interval
becomes the most economical time to target an upgrade
and start reducing or eliminating applicable CH 4 fees. Fur-
ther, combining engine overhauls with emissions reduc-
XMSRWKIRIVEXIWQYPXMTPIW]RIVKMIWMRGVIEWIHTVS½XEFMPMX]
reduced emissions, cleaner communities, attraction of
a new skilled workforce, and the continued investment
in the technologies required to grow economies and im-
prove the quality of life around the globe.
The world needs access to hydrocarbons, now more
than ever. The United States has the reserves, infrastruc-
ture, and technology to grow the production and export
capacity to bring clean-burning natural gas to places it is
needed most. The oil and gas industry is well-positioned
to continue innovating, supported by collaboration be-
tween industry and policy makers, to implement the tech-
nologies available to achieve the lowest CH 4 and carbon
footprint. The world needs more energy and lower emis-
sions. Technologies are available today to do both.
ABOUT THE AUTHOR
Chris Kipp is a senior business development manager at
INNIO’s Waukesha Engine. Over his 12-year tenure with
the company, he has held technical positions in the ar-
eas of application engineering, product management, and
sales. He has a bachelor’s degree in mechanical engineer-
ing from the Milwaukee School of Engineering and an
MBA from the University of Wisconsin-Madison. He can
be reached at chris.kipp@innio.com.
 INSANITY.
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 ONE-ON-ONE:
A CONVERSATION WITH SCOTT BUCKHOUT,
PRESIDENT AND CEO OF COOPER

Q: In your opinion, what are the biggest challenges facing the gas compression
industry today? What is Cooper doing to meet these challenges?

A: As we look across the industry, we see three primary challenges: supply chain
ZSPEXMPMX]ERHMR¾EXMSRTSXIRXMEPIQMWWMSRWVIKYPEXMSRWERHEREKMRK[SVOJSVGI
The most immediate challenge we have is the post-COVID-19-related volatility
ERHMR¾EXMSRMRSYVWYTTP]GLEMRW;LMPIHIQERHJSVREXYVEPKEWI\TSVXWMRGPYHMRK
97PMUYI½IHREXYVEPKEW?02+AMWVIEGLMRKEREPPXMQILMKLQENSVFSXXPIRIGOWERH
elevated costs still exist in critical supply chains, especially for new equipment. Op-
erators attempting to add new horsepower are confronted with long lead times
and higher prices. Cooper has avoided the worst of the supply chain delivery issues
as we have actively increased our parts inventory so operators can maintain their
equipment and return “retired” horsepower to service as quickly as possible. Cost
MR¾EXMSRLS[IZIVGSRXMRYIWXSFIEHMJ½GYPXMWWYIXSSZIVGSQI
Another immediate challenge is uncertainty among our customers regarding
SCOTT BUCKHOUT potential emissions regulations, like the US Environmental Protection Agency’s
?)4%´WATVSTSWIH+SSH2IMKLFSVVYPI8LIIQMWWMSRWVIHYGXMSRWVIUYMVIHF]XLMW
TVSTSWIHVYPIGSYPHLEZIQENSVMQTPMGEXMSRWJSV'SSTIVIUYMTQIRXSTIVEXSVWERH
BY BRENT HAIGHT
is causing delays in equipment investment decisions. Cooper, however, is ready

S cott Buckhout has been named presi-

dent and CEO of Cooper Machinery
Services (Cooper). He takes the reins of
if and when the rule is implemented. Thanks to our research and development
efforts and investments, all engine models Cooper supports, both OEM and non-
OEM, can achieve 0.5 g NOx TIV FLT ;I´VI EPWS EGXMZIP] I\TERHMRK SYV ½IPH
the Houston-based provider of natural WIVZMGIGETEFMPMXMIWXSIJ½GMIRXP]MRWXEPPIQMWWMSRWVIHYGXMSRWIUYMTQIRXSREPEVKI
gas engines, compressors, and aftersales scale if the rule passes.2
products and services four years after
BHGE sold its Reciprocating Compres-
sor Division to Arcline Investment Man-
agement, returning Cooper to indepen-
dent operation.1 Since 2019, the company
has made myriad investments that have
expanded its product and service offer-
ings and streamlined operations.
Buckhout has more than 20 years of
senior leadership with global industrial/
energy original equipment manufactur-
ers (OEMs). Most recently, he was the
CEO of CIRCOR International Inc. Be-
fore that, he led the Fire and Security
Division of United Technologies Corp.
Buckhout has an aerospace engineer-
ing degree from Texas A&M University
and an MBA from J.L. Kellogg Graduate
School of Management at Northwest-
ern University.
Gas Compression Magazine spoke with
Buckhout about the challenges and op-
portunities facing the industry today Cooper has actively increased its parts inventory so operators can maintain their equipment
and what lies ahead for Cooper. and return “retired” horsepower to service as quickly as possible.

26 gascompressionmagazine.com | APRIL 2023

 The biggest long-term challenge we see is our industry’s
aging workforce. Over the next few years, many of our most
talented people will be retiring and taking decades of knowl-
edge with them.3 Our industry is key to the energy security
of the United States and other countries, so it is essential that
operators have the skills and knowledge necessary to perform
their work safely and reliably. To help ensure this, Cooper
launched the Mazerole Training Center in 2022. The center
provides theoretical and hands-on training programs to new
industry talent as well as existing professionals who need to
hone their skills. Most of our classes sell out, which is great
to see — operators are clearly taking this challenge seriously
and we’re enjoying working with them to tackle it. Cooper
also has a robust engineering internship program that keeps
XLITMTIPMRISJXEPIRXIZIV¾S[MRKXLVSYKLSYVLEPP[E]WERH
½IPHNSFWMXIW
Q: Market strength varies by location. In your opinion,
which geographic locations hold the most promise for the gas
compression industry? Why?
A: We see several geographic areas that hold promise. The
GSR¾MGXMR9OVEMRILEWGLERKIHXLI[E])YVSTIPSSOWEXIRIVK]
security, so we will see them implement new energy projects
both locally and internationally to enhance that security. In
Asia, China and India continue to grow their economies, and
they will be powered by increases in natural gas. LNG is reshap-
ing how gas moves, and we are seeing projects developing LNG
GETEFMPMXMIWMRXLI9RMXIH7XEXIWEW[IPPEWXLI1MHHPI)EWXERH
northwestern African region. In fact, LNG could surpass pipe-
line gas quantities within 15 years, so we expect that other gas
producing countries around the world will enter that market.
Q: What market indicators do you follow/track to forecast
the short- and long-term health of the gas compression industry?
A: Keeping track of what is happening in each market
Cooper serves can be a challenge. The worldwide gas, pro-
cess, and power generation markets are really a series of
submarkets with different drivers. The growth in hydrogen
and LNG may simplify this by creating a more homogeneous
global market, although that remains to be seen.
We track common indicators such as volume produced,
volume consumed, and gas price. We keep an eye on geo-
TSPMXMGEPWMXYEXMSRWEVSYRHXLI[SVPHEWGSR¾MGXGERGLERKIE
QEVOIXPMOI[I´ZIWIIR[MXLXLIGSR¾MGXMR9OVEMRI*SVXLI
massive installed base of engines and compressors Cooper
supports, we keep a close eye on environmental regulations
ERHGLERKIWXLEXQE]GVIEXIWMKRM½GERXHIQERHJSVIQMWWMSRW
reductions technologies and equipment upgrades; we intend
to be ready and able to meet that need.
In addition, Cooper always stays close to our customers
XSYRHIVWXERHLS[EPPXLIWIJEGXSVWMR¾YIRGIXLIMVFYWMRIWW
needs. Customers are impacted differently by these changes,
WS[IVIQEMR¾I\MFPIERHSTIR[LIRLIPTMRKIEGLSJSYVGYW-
tomers navigate the markets. Continued on page 28

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 Second, we’re making improve-
ments in our manufacturing facilities.
Our new power cylinder hard-iron
plating initiative will eliminate more
than 2 tons [1.8 tonnes] of chrome,
a pollution risk, from our manufac-
turing process annually and will pro-
vide customers a high-quality OEM
alternative to purchasing new power
cylinders. Our new Mo2 power ring
cell also produces chrome-free power
rings. 5 Finally, our ability to overhaul
and upgrade engines and compressors
to zero-hour conditions provides tre-
QIRHSYWFIRI½XWF]EPPS[MRKGYWXSQ-
ers to maintain existing equipment
instead of buying new engines and
compressors.

Q: Cooper is actively investing in

hydrogen development. How do Coo-
Caterpillar G3600 Inventory
TIV´WIRKMRIWERHGSQTVIWWSVW½XMRXS
the hydrogen economy?

Q: Cooper has invested heavily in developing new products and services to opti- A: The use of hydrogen is an excit-
mize legacy assets, extend equipment life, and ensure environmental compliance. In ing development for the compression
your opinion, what opportunities do environmental, social, and governance [ESG] industry, and it is expected to play a
mandates and requirements present for the gas compression industry? greater role in our industry over the
next 10 years. Cooper has supported
A: ESG mandates allow everyone in the industry to think critically about how their hydrogen compression applications for
company’s practices affect the world socially and environmentally. These efforts create decades, and we are fully capable to
new programs and processes that can be transformational. Cooper sees this as an op- support existing hydrogen compressors
portunity to help customers meet their ESG goals by offering innovations on products and produce new ones. On the engine
and technologies that will enhance their equipment performance and reliability. fuel side, Cooper has demonstrated
blending 30%+ hydrogen by volume
Q: What challenges does ESG present? with natural gas on AJAX and Cooper-
Bessemer integrals in both our in-house
A: 3RI SJ XLI QSVI HMJ½GYPX LYVHPIW [I IRGSYRXIV MW E QMRHWIX XLEX ±RI[² MW test lab and with several customers on
FIXXIV XLER ±IRLERGIH I\MWXMRK² IUYMTQIRX -X MW LEVH JSV WSQI SJ SYV GPMIRXW XS their equipment.6 We’re also expanding
recognize that the application of upgrades and technology to the existing installed our research and development pro-
equipment is cheaper and better because it extends the useful life, meets or exceeds grams so we can learn more about the
emissions standards, and does this with lower capital and operating costs. IQMWWMSRWERHIJ½GMIRG]FIRI½XWSJL]-
drogen and ensure we can support the
Q: As a company, what environmental initiatives has Cooper undertaken? needs of customers who want to con-
sider hydrogen options.
A: Cooper is reducing its environmental impact in several ways. First, our Clean-
Burn Plus technology, which we began developing in the mid-1970s with our traditional Q: ;LEXXVIRHWLEZI]SYMHIRXM½IH
CleanBurn technologies, reduces emissions on the legacy engine models we support throughout the gas compression val-
— such as AJAX, Clark, Cooper-Bessemer, Enterprise, IR, Superior, and Worthington ue stream and what impacts do these
— to comply with or achieve better-than-new source performance standards [NSPS] trends have on the gas compression
and various state standards.4 It reduces total hydrocarbons, including methane, and re- market?
HYGIWJYIPGSRWYQTXMSRYTXS F]MQTVSZMRKGSQFYWXMSRIJ½GMIRG];I´ZIEPWSHI-
ZIPSTIHSXLIVTVSHYGXWXSMQTVSZIGSQTVIWWSVIJ½GMIRG]F]MQTVSZMRKKEWXLVSYKL- A: We’ve seen, especially since
put and reducing overall fuel consumption. The new CleanBurn Plus differs from our XLI WXEVX SJ XLI GSR¾MGX MR 9OVEMRI
traditional CleanBurn technologies in that our upgrades are electronics-based and that countries are prioritizing their
eliminate the need, in most cases, to replace hard-iron products like cylinders lines energy security and recognizing the
and cylinders, power heads, and power pistons. This brings the cost of upgrades down key role that natural gas production
substantially for legacy gas engines. and transport plays in that security.

28 gascompressionmagazine.com | APRIL 2023

We’re seeing end users all over the world investing in
critical compression infrastructure, and we expect that
trend to continue.
In the United States, with the emergence of LNG, we
see “retired” compressors getting overhauled, upgraded,
and put back into service to meet this new demand for
natural gas deliveries to new liquefaction plants. Power
generation customers, including government installations,
have become more active as their Cooper-Bessemer and
Enterprise engines now run more frequently to meet in-
creased power demands.
Q: When Cooper “returned to independence” in 2019,
its goal was to “get back to basics.” The company quickly
made substantial investments to expand product and ser-
vice offerings, streamline operations, and strengthen cus-
tomer ties. How does the Cooper today compare to the
Cooper of 2019?
A: The business shifts Cooper made in recent years
positioned us well for the opportunities that appear in
the market today.7 Through the addition of organic pro-
grams and multiple complementary acquisitions, we now
offer more aftersales support technologies, products,
and services than any company in the world. Cooper
invested in both inventory and our people to meet new
demand, adding more parts to our shelves, increasing
our already large engineering staff, and adding more
members to our service team. We expanded our prod-
uct lines to include aftersales support for Caterpillar
3600 and Waukesha VHP engines, and we grew our in-
ternational presence, creating new partnerships around
the world. 8
Q: As its new CEO, what are your short-term plans and
priorities for Cooper?
A: In the near-term, we will focus on expanding our
project management capabilities to get prepared for
the upcoming large compression and power genera-
tion projects we see on the horizon. To that end, we
recently won large multiyear projects with the US De-
partment of Defense, a large utility district, and a major
pipeline. We plan to leverage the successful completion
of large aftermarket projects into nontraditional mar-
kets including power generation and process facilities.
We are investing heavily in our manufacturing processes
as well. We are currently commissioning a new plating
cell in our Houston factory that plates power cylinders
and pistons with environmentally friendly materials
that replace chrome and tin. We also plan to bolster
our ability to provide refurbished parts like engine and
compressor bases, cylinder blocks, compressor bodies,
and crankshafts to give customers more choices when
they are planning engine-compressor overhaul and up-
grade projects.
Q: What are your long-term plans and priorities?
A: In the long-term, we will continue our program of growth
by acquiring adjacent products and technologies that capitalize on
our expertise and knowledge of the market and our customer
base. Cooper’s overriding goal is to be a complete and best-in-
class OEM and aftersales support provider for our global customer
base. That is what they deserve. I believe our plans for the future
put us in a strong and strategic position to achieve that goal and
keep the engines and compressors of our industry operating for
the long-term.
NOTES
1
See “A Return To Independence,” September 2019 Gas Compres-
sion Magazine, p. 62
2
See “Cooper Expands After-Sales Support Offerings,” August
2021 Gas Compression Magazine, p. 16
3
See “Guys On The Wrench,” December 2019 Gas Compression
Magazine, p. 20
4
See “4 In 4,” February 2020 Gas Compression Magazine, p. 40
5
See “Hydrogen/Natural Gas Fuel Blend Lowers Emissions For
AJAX Integral Engine,” July 2022 Gas Compression Magazine, p. 22
6
See “Cooper Integral Engine-Compressor Burns 30% Hydrogen
By Volume,” October 2022 Gas Compression Magazine, p. 32
7
See “Cooper Powers Up,” August 2020 Gas Compression maga-
zine, p. 36
8
See “Cooper Acquires Truerock,” November 2021 Gas Com-
pression Magazine, p. 8
.,(1( Indicator Valves for Gas
Engine/Power Cylinder Analysis
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ASK US ABOUT SPECIALS TO MEET
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gascompressionmagazine.com | APRIL 2023 29
 RMS Director Of Fluid Catalyst Cracking Unit (FCCU) Expander Engineering, Don Shafer, At A Customer Site For Inspection
RMS ACQUIRES HOT GAS EXPANDER
PRODUCT LINE FROM SIEMENS ENERGY
ACQUISITION BOLSTERS RMS PORTFOLIO AND EXPANDS ITS INTERNATIONAL REACH
BY BRENT HAIGHT
R otating Machinery Services Inc. (RMS) has acquired
XLI ¾YMH GEXEP]WX GVEGOMRK YRMX *''9  LSX KEW I\-
TERHIV TVSHYGX PMRI JVSQ 7MIQIRW )RIVK] -RG 7MI-
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MRZIRXSV]ERHEWWSGMEXIHXSSPMRKSJXLI*''9I\TERHIV
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30 gascompressionmagazine.com | APRIL 2023
617 [EW IWXEFPMWLIH MR  [MXL XLI KSEP XS VIMRZIRX XLI
GSRGITXSJEREJXIVQEVOIXXYVFSQEGLMRIV]FYWMRIWW8[IRX]½ZI
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WMKRW JSV XLI GIRXVMJYKEP ERH E\MEP GSQTVIWWSVW SJJIVMRK HIZIP-
STIHYRHIVXLIFYWMRIWWORS[REW'321)'
-R617EGUYMVIH%\MW8IGLRMGEP7IVZMGIW8LIGSQTER]´W
I\TIVMIRGIH XIGLRMGEP ½IPH EHZMWSVW VSXEXMRK IUYMTQIRX TPER-
RIVW ERH WGLIHYPIVW JSV XYVFMRI GSQTVIWWSV ERH KIRIVEXSV
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 The following year, in July 2022, RMS purchased
Breaux Machine Works, bringing its machining capabil-
ities into the RMS portfolio of aftermarket upgrades,
repair, maintenance, and rebuilding/overhaul services
for large, highly engineered rotating equipment.
±;MXLMR SYV TSVXJSPMS [I MRGPYHI ½IPH WIVZMGI ERH
turnaround support; engineering consisting of ma-
chine design, rerates, rotordynamics, aerodynamics,
and structural analysis; control panel upgrades; emer-
gency repairs; service of ‘orphaned equipment;’ parts;
remaining life analysis; and repair and refurbishment for
all manufacturers and models of industrial turbomachin-
ery,” said Bartos. “We consider the FCCU expander
product line to be a core part of RMS’ offering. We fo-
cus on engineered solutions to mission-critical, highly
complex turbomachinery. The FCCU expander product
line checks all the boxes in that respect. RMS currently
supports the majority of FCCU expanders in North
%QIVMGE ERH XLIWI EHHMXMSREP YRMXW [MPP ½X [IPP MRXS An FCCU Expander During Assembly Post Overhaul
XLI 617WIVZMGIH ¾IIX SJ I\TERHIVW 617 MW JSGYWIH
on supporting these specialized machines with an un- tomers whose FCCU expanders we currently service, we look for-
matched team of engineers and shop staff.” ward to introducing our broad range of capabilities to new customers
With locations in Texas, Wisconsin, and Pennsylva- we might not have yet done business with,” said Bartos. “This acqui-
nia, RMS has a strong foothold in the North American sition allows RMS to be more engaged in the many expander units
marketplace. The acquisition of Siemens’ FCCU hot gas outside of North America and gives RMS an international presence
expander product line gives RMS access to a broader in the FCCU expander product line. RMS looks forward to providing
range of international customers. “In the same way that international customers with the same service our current customers
RMS has established a trusted relationship with the cus- have grown to rely on.”
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 Vanguard is the owner and operator of the largest anaerobic digester in the Northeast, which is located at the Goodrich Family Dairy Farm in
Salisbury, Vermont. The facility converts food waste and manure into renewable natural gas (RNG).
BY DANIEL FOELBER
B iogas, now commonly referred to as renewable natural
gas (RNG), is taking the US energy sector by storm be-
GEYWISJMXWIGSRSQMGERHIRZMVSRQIRXEPFIRI½XW1YRMGM-
TEPWSPMH[EWXI 17; [EWXI[EXIV]EVHERHGVST[EWXIW
food waste, and manure are all feedstocks that can be used
XS QEOI 62+ 17; ERH [EWXI[EXIV X]TMGEPP] JIIH MRXS
PERH½PPW[LMPI]EVHERHGVST[EWXIJSSH[EWXIERHQE-
RYVIEVITVSGIWWIHXLVSYKLEREIVSFMGHMKIWXIVW,S[IZIV
these organic sources of biogas only contain 45% to 65%
QIXLERI &] VIQSZMRK QSMWXYVI TEVXMGYPEXIW GSRXEQM-
nants, and other gases such as carbon dioxide (CO2), oxy-
gen, nitrogen, and volatile organic compounds (VOCs), the
methane content is increased to a pipeline-quality concen-
XVEXMSRXLEXMWX]TMGEPP]KVIEXIVXLER QIXLERI
34 gascompressionmagazine.com | APRIL 2023
8LITVSGIWWSJXVIEXMRKPERH½PPKEWZIVWYWEREIVSFMGHMKIW-
tion is a bit different, but both methods involve multiple com-
pression stages that are essential for creating pipeline-quality
KEW3ZIVXLIPEWXHIGEHI62+LEWXVERWMXMSRIHJVSQWTIGY-
lation to one of the fastest-growing industries in the energy
WIGXSV -R .ERYEV] 1EVOIX +VS[XL 6ITSVXW TYFPMWLIH E 
page paper that estimated the value of the US RNG market
XSFI97FMPPMSRMR8LIVITSVXJSVIGEWXIHXLEXXLI
US RNG industry will grow at a compound annual growth
VEXISJ XSVIEGLEWXEKKIVMRK97FMPPMSRF]
°MRGVIEWMRKF]QSVIXLERJSPHMRPIWWXLEREHIGEHI8LMW
growth represents a unique opportunity for the gas compres-
WMSRMRHYWXV]XSHMZIVWMJ]VIZIRYIWXVIEQWKVS[TVS½XWERH
EGLMIZIIRZMVSRQIRXEPXEVKIXW
 COW POWER
AN INSIDE LOOK AT HOW VANGUARD
RENEWABLES IS BRINGING EXPONENTIAL
GROWTH TO THE RNG INDUSTRY
THE PATH TOWARD 150 ANAEROBIC DIGESTERS
Vanguard Renewables (Vanguard) is one of the major players in the
RNG space that is contributing to the industry’s breakneck growth
rate. “Simply put, Vanguard Renewables takes inedible food and bev-
erage waste from the manufacturing sector and repurposes it with
cow manure to create RNG,” said Neil Smith, CEO of Vanguard Re-
newables. “We are working to decarbonize supply chains by building,
owning, and operating anaerobic digester facilities.”
In July 2022, a fund managed by BlackRock Real Assets acquired Van-
guard from Vision Ridge Partners. BlackRock Real Assets will partner with
Vanguard’s management team to build on the company’s track record and
drive its next phase of growth. “The recent deal with BlackRock Real
Assets has accelerated the rapid expansion of our projects nationwide,”
said Smith. “We aim to have 150 digesters nationally by 2026 to generate
enough energy to power hundreds of thousands of homes. We needed a
TEVXRIV[MXLGETMXEP[MPPMRKXSHITPS]97FMPPMSRMRXLIRI\X½ZI]IEVW
and as a global leader in environmental, social, and governance [ESG] ini-
XMEXMZIWERHMRZIWXQIRXW&PEGO6SGO6IEP%WWIXW[EWXLITIVJIGX½X²
HUMBLE BEGINNINGS
With more than 200 employees and billions of dol-
lars at its disposal, it’s hard to imagine that it was only
2014 when Vanguard Renewables was founded. It’s
purpose was to revolutionize how the food and bev-
erage industry views inedible waste from manufac-
XYVMRKF]TVSZMHMRKEREPXIVREXMZIXSPERH½PPWSVLEVQ-
ful incinerators. “Greenhouse gas [GHG] emissions
from inedible food waste and on-farm emissions are
X[SWMKRM½GERXGPMQEXIGVMWMWGLEPPIRKIW²WEMH7QMXL
“However, these challenges are also the easiest to
address. The company began by purchasing two op-
erational facilities and quickly expanded to develop-
ing, owning, and operating anaerobic digesters on
dairy farms across New England. When I joined the
company in October 2021, I began accelerating the
nationwide growth of our anaerobic digestion facili-
ties. Today, we have eight projects under construc-
tion, six projects in development, and we operate 10
anaerobic digesters — six are in New England, three
in Colorado, and one in Georgia.”
In addition to its anaerobic digester facilities, Van-
guard owns and operates an organics receiving area
(ORA) in the northeast. The site decontaminates ex-
pired goods, off-spec batches, and unsafe-to-eat food
Continued on page 36
gascompressionmagazine.com | APRIL 2023 35
 :ERKYEVH6IRI[EFPIWLEWSYX½XXIHXLI+SSHVMGL*EQMP](EMV]*EVQ[MXLEREREIVSFMGHMKIWXIVXLEXGSRWMWXWSJX[SQMPPMSRKEPPSR QMPPMSR
PMXIV HMKIWXIVXEROW8LIJEVQLEWERO;SRWMXIGSQFMRIHLIEXERHTS[IVW]WXIQXLEXKIRIVEXIWIRSYKLTS[IVJSVXLIIRXMVIJEGMPMX]
and beverage products. The extracted food is transported and
recycled at a New England-based anaerobic digester, where it is
combined with manure and converted into renewable energy.
“As the company continues to grow, we are committed to adding
ORAs nationwide alongside our anaerobic digester sites,” said
Smith. “We have two facilities in Nevada that will be coming on-
line this year and are expanding the scope of our work to look at
new technologies and other synergistic business opportunities.”
Since its inception, Vanguard has recycled more than
650,000 tons (589,670 tonnes) of food waste and more than
250,000 tons (226,796 tonnes) of manure, mitigating emis-
sions equivalent to more than 540,000 tons (489,880 tonnes)
of CO2 , which is comparable to taking more than 119,000 cars
off the road for one year. It has also generated more than
86,000 MWh of renewable electricity, equal to powering more
than 7500 homes for one year, and more than 145,000 MMBtu
of RNG, equivalent to fueling 418 buses for one year. Vanguard
said it has also produced enough liquid fertilizer to sustain-
ably fertilize more than 33,000 acres (13,354 ha) of farmland at
its co-digestion sites alone, with additional methane emissions
mitigation impacts from its manure-only facilities.
PROCESSES AND BENEFITS OF ANAEROBIC DIGESTION
“Anaerobic digesters are large tanks or lagoons with attached
gas-capturing mechanisms that harness biogas, composed of
methane and CO2, expelled from decomposing cow manure
with or without food and beverage waste,” said Smith. “Our two
farm-based anaerobic digestion platforms create RNG that is
then upgraded and cleaned of impurities to create pipeline-ready
RNG. Hosting a facility minimizes on-farm methane emissions
by recycling farm manure. A standard manure-only waste-to-
energy project consists of a cluster of two to four farms and
10,000 to 30,000 dairy cows. A typical farm in our co-digestion
program has 350 to 1500 milking head and approximately 1800
acres [728 ha] of cropland. Vanguard’s two platforms also cre-
EXIEHHMXMSREPFIRI½XWJSVSYVJEVQTEVXRIVWMRGPYHMRKFIHHMRK
36 gascompressionmagazine.com | APRIL 2023
for the farmer’s herd and a nutrient-dense low-carbon fertilizer.
Each is a byproduct of the anaerobic digestion process. Due to
supply chain issues and the rising costs of traditional fertilizers,
XLIWIFIRI½XWWEZISYVJEVQTEVXRIVWXLSYWERHWSJHSPPEVWIEGL
year depending on the farm size.”
Vanguard is the owner and operator of the largest anaerobic
digester in the Northeast, which is located at the Goodrich
Family Dairy Farm in Salisbury, Vermont. The facility converts
food waste and manure into RNG. The process starts at the
facility’s 264,000-gallon (999,349-liter) hydrolyzer tank. “The
food waste comes in the form of liquid and slurry, and gets de-
posited and pumped in through hoses, and we also accept more
solid material that comes in through the solids hatch,” said Billy
Connelly, New Markets and National Accounts manager for
Vanguard Renewables. “There are two deck-mounted agita-
tors, and those push the food waste material around. The resi-
HIRG]XMQIJSVXLIJSSH[EWXIMWEFSYX½ZIHE]WFIJSVIMXXLIR
gets pumped from the hydrolyzer into the anaerobic digester,
where it gets mixed with the manure to generate methane that
becomes RNG.”
The anaerobic digester consists of two, 1-million-gallon
(3.79-million-liter) digester tanks. “The manure and food
[EWXI KIX GSQFMRIH MR XLI HMKIWXIV [MXL XLI KYX ¾SVE JVSQ
the cows,” said Connelly. “It consumes that material and gen-
erates methane, which is a very potent gas that gets captured
in the head space in these membranes, and that is the RNG
XLEX´PPFIVI½RIHERHXLIRWIRXMRXSXLITMTIPMRIERHHS[RXLI
line to the customers.”
The farm has an on-site combined heat and power system.
“This 800-kW system generates enough power for the entire
facility,” said Connelly. “The heating system generates enough
heat to keep the hydrolyzer tank and all the material in it,
as well as the digesters, between 100°F to 102°F [37.8°C to
38.9°C], the optimal temperature for the methanogens. Meth-
anogens are microorganisms that generate the methane.”
Continued on page 38
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Reduced carbon footprint using hydrogen or carbon neutral fuels.
Carbon reduction through equipment upgrades.
Emissions reduction solutions to help customers achieve near-zero
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38 gascompressionmagazine.com | APRIL 2023
Trucks pull up to Vanguard’s Organics Receiving Area. The extracted
food is transported and recycled at a New England-based anaerobic
digester, where it is combined with manure and converted into re-
newable energy.
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 What Went Wrong?
BY W. NORM SHADE
No company, product, or individual is immune from
experiencing failures or shortcomings. The solution to
these problems can often result in new “best practices.”
By relating some of these real case histories, it is hoped
that the lessons learned will be educational to the read-
ers. In each case, a failure or incident is described and the
question is asked, “What went wrong?” In each case, the
answer (or at least the best speculation) and the solution
that was applied to the problem will be explained.
Figure 1. Pipeline centrifugal compressor with overhung rotor as
in Compressors 1 and 2 and similar to Compressors 4 and 5.1
A bout 40 years ago, a major gas transmission pipe-
line operator was experiencing problems with car-
bon deposits on bearings and seals in several of its large
centrifugal compressors. In some cases, bearing and seal
failures were resulting from the deposits. Oddly, in each
case, the machinery had run successfully for long periods
of time prior to encountering problems, and operating
conditions were essentially unchanged from past experi-
ences. Mechanical inspection revealed no misassembled
or deviated components. This left the pipeline operator
asking the question, “What went wrong?”!
Five of the compressors were investigated in detail and
smoking guns were discovered with the care and mainte-
nance of the lubricant in each case. All the gas turbine-driv-
en compressors were lubricated with synthetic phosphate
ester lubricants (SPELs). Several types of SPELs had been
widely used in gas turbines and centrifugal compressors
JSVHIGEHIWQEMRP]FIGEYWISJMXWWYTIVMSV½VIVIWMWXERGI
Compressor 1 was a large 29,100-hp (21.7-MW),
4950-rpm centrifugal compressor with an overhung ro-
tor design as shown in Figure 1.1 Under normal operating
conditions, the axial position monitor showed the rotor
thrust toward the inboard direction, carried by a 15-in.
(381-mm) direct-lubricated tilting pad thrust bearing. The
40 gascompressionmagazine.com | APRIL 2023
CASE N
What caused the carbon buildup
o
28
on the compressor bearings?
highest thrust pad temperature had been 217°F (103°C), but af-
ter about 13,000 hours of problem-free operation, the position
monitor showed the rotor was gradually moving away from the
inboard thrust bearing and the thrust pad temperature had ex-
cursions as high as 248°F (120°C) over a period of about two
weeks. The compressor thrust bearing was inspected and found
to have a 0.007-in. (0.18-mm) thick black carbonaceous deposit
on the inboard bearing thrust pads. The thrust disc had simi-
lar deposits on its inboard face. The outboard thrust bearing
pads and disc face were free of deposits. The axial clearance of
the thrust bearing had decreased from 0.021 in. (0.53 mm) to
0.007 in. The carbonaceous material was water-soluble and after
washing, both the pads and disc were reusable.
A review of maintenance records showed that the total acid
number (TAN) of the tertiary-butylphenyl diphenyl SPEL had in-
creased to 0.89 about three months before the problems began
and was even higher when the carbonaceous deposits were dis-
covered. The lubricant had received occasional activated alumina
½PXVEXMSR)\GIWWMZIEQSYRXWSJERXMJSEQEKIRXLEHFIIREHHIH
in the preceding six months to combat a foaming problem. Also,
some problems with lubricant cooling had occurred prior to the
unit’s shutdown.
8LIPYFVMGEXMSRW]WXIQ[EWXLSVSYKLP]¾YWLIHERHXLIPYFVM-
cant was replaced with new SPEL of the same type. The cleaned
thrust pads and disc were reinstalled. With the new lubricant,
the inboard thrust pad temperature was under 199°F (93°C) at
the design condition. After two months, the unit continued to
VYR[MXLSYXTVSFPIQWERHXLI¾YMH8%2[EWFIMRKQEMRXEMRIHMR
XLIXSVERKI[MXLGSRXMRYSYWEGXMZEXIHEPYQMRE½PXVEXMSR
and it was still operating without problems after accumulating an
additional 18,000 operating hours.
Compressor 2 was similar to Compressor 1, but was direct-
driven by a 5900-rpm, 16,360-hp (12.2-MW) gas turbine. The
unit used an isopropyl phenyl SPEL, with occasional Fuller’s earth
½PXVEXMSRERHRSETTEVIRXTVSFPIQWJSVQSVIXLERLSYVW
The compressor had no thrust pad temperature instrumenta-
tion, but some erratic axial rotor position and outer seal drain
temperature indications had been observed in the last few weeks
of the operating period. When the compressor was disassem-
bled to add bearing pad temperature instrumentation, the out-
FSEVHXLVYWXTEHW[IVIJSYRHXSLEZILIEZ][MTMRKERHWMKRM½-
cant Babbitt loss as shown in Figure 2.1 The inboard thrust pads
had 0.040 in. (1.02 mm) of heavy black carbonaceous deposits.
Similar deposits and some resulting Babbitt loss were found on
XLISMP½PQFYWLMRKWIEPWERHSRXLIMRFSEVHJEGISJXLIXLVYWX
disc. The compressor journal bearings and all turbine bearings
were discolored, but free of deposits. After the black deposits
were washed off the inboard pads, pitting and corrosion damage
was evident on four of the eight pads, as shown in Figure 3.1
Figure 2. Outboard thrust bearing was found
in Compressor 2 with heavy wiping and sig-
RM½GERX&EFFMXXPSWWEWEVIWYPXSJXLMGOHITSW-
its on the inboard pads that reduced running
GPIEVERGI1
Figure 3. Inboard thrust bearing from Com-
TVIWWSVEJXIV[EWLMRKE[E]XLIXLMGOFPEGO
HITSWMXWVIZIEPIHTMXXMRKERHGSVVSWMSRHEQ-
age on four of eight pads.1
Figure 4. Inboard thrust bearing from Compres-
WSVEJXIVPIWWXLERLSYVWSJSTIVEXMRK[MXL
W]RXLIXMGTLSWTLEXIIWXIVPYFVMGERXLEHEXSXEP
EGMH RYQFIV SJ  4MXXIH ERH GVEGOIH &EF-
bitt was discovered after washing away 0.004 in.
QQ SJFPEGOGEVFSREGISYWQEXIVMEP1

A new thrust disc, thrust bearing pads, and pad tem- ½PXIVIHXLVSYKLEGXMZEXIHEPYQMRE3TIVEXMRK[MXLGSRXMRYSYWEG-
perature instrumentation were installed. After startup, the XMZEXIHEPYQMRE½PXVEXMSRXLIYRMXVER[MXLSYXER]JYVXLIVFIEVMRK
thrust pad temperatures increased with time at comparable TVSFPIQWEJXIVEGGYQYPEXMRKEREHHMXMSREPSTIVEXMRKLSYVW
WTIIHW ERH XLVYWX PSEHW ;MXLMR ½ZI HE]W XLI XLVYWX TEH 'SQTVIWWSV[EWETMTIPMRIGSQTVIWWSV[MXLEFIEQWX]PIVS-
temperatures were limiting both the compressor speed XSV HVMZIR EX  VTQ F] E LT 1;  KEW XYVFMRI
ERHPSEHXSFIPS[VEXIHGSRHMXMSRWIZIR[MXLVIHYGIHPY- %JXIVEFSYX½ZI]IEVWSJVIPMEFPISTIVEXMSRHYVMRKEVITEMVSJE
FVMGERXWYTTP]XIQTIVEXYVI-RWTIGXMSRSJXLIGSQTVIWWSV Continued on page 42
XLVYWX FIEVMRK VIZIEPIH XLEX XLI MRFSEVH TEHW LEH EPVIEH]
accumulated a 0.004-in.- (0.1-mm)-thick black deposit near
the outer diameter of the bearing pads. The deposits were
washed off the undamaged pads, which were reinstalled.
2MRIX] LSYVW EJXIV VIWXEVXMRK XLI YRMX I\TIVMIRGIH XLI
same temperature problems that limited speed and load.
-RWTIGXMSREKEMRJSYRHEHITSWMXSJEFSYXMRSRXLI
inboard thrust pads, as shown in Figure 4.1 After washing the
TEHWWYFWYVJEGITMXXMRKERHEGVEGOIH&EFFMXX[IVIHMWGSZ- One source for precision, quality,
IVIHYRHIVXLIEVIESJLIEZMIWXHITSWMXW*MKYVIWLS[WSRI
SJXLITEHW[MXLXLIHITSWMX[EWLIHE[E]SRLEPJXLITEH and capability.
surface.1 Under a microscope, the Babbitt cracks had the
appearance of a stress corrosion attack. At this time, high
8%2[EWHMWGSZIVIHERHXLI¾YMH[EWGMVGYPEXIHXLVSYKL
EGXMZEXIHEPYQMREJSVX[SHE]WVIHYGMRKXLI8%2JVSQ
XS3XLIVPYFVMGERXTVSTIVXMIWWYGLEWZMWGSWMX][EXIV
content, foaming characteristics, metal content, etc. did not
MRHMGEXI ER] SXLIV TVSFPIQW [MXL XLI ¾YMH % RI[ XLVYWX
bearing was installed and, after the unit was restarted, some
initial foaming was controlled through the addition of an
ERXMJSEQ EKIRX %X EFSYX  LSYVW EJXIV VIWXEVXMRK XLI
YRMXI\TIVMIRGIHWYGGIWWMZIWLYXHS[RWHYIXSLMKLMRFSEVH
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www.hfwindustries.com
QIRX;LIRXLISTIVEXSVF]TEWWIHXLIXVMTWERHVIWXEVXIH
to keep the unit online during a critical pumping period, the HFW Industries, Inc.
MRFSEVHXLVYWXFIEVMRKERHXLVYWXHMWG[IVIHIWXVS]IH8LI 196 Philadelphia St.
outboard thrust bearing was in perfect condition as were all Buffalo, NY 14207-0008
the compressor and turbine journal bearings. Compressor
bushing seals had thin deposits of black carbonaceous ma- sales@hfwindustries.com
XIVMEP(YVMRKXLIGSQTVIWWSVVITEMVXLI¾YMHW]WXIQ[EW Ph: 716-875-3380 / Fax: 716-875-3385
¾YWLIH RI[¾YMH[EWEHHIHERHXLIVIQEMRMRK¾YMH

gascompressionmagazine.com | APRIL 2023 41


Figure 5. One of the pads from the bearing in Figure
4 after washing away the deposits on half the pad
surface. Under a microscope, the Babbitt cracks had
the appearance of stress corrosion attack.1
HEQEKIH FEPERGI WIEP WMKRM½GERX GSEXMRKW SJ
black carbonaceous material were discovered
on the non-drive-end journal bearing, the
bushing seals on both ends, and the outboard
TEHWERHXLVYWXHMWGSJXLIMR QQ 
XLVYWXFIEVMRKWLS[RMR*MKYVI8LIVI[EW
RS &EFFMXX PSWW JVSQ ER] SJ XLI FIEVMRKW SV
seals. The damaged balance seal caused the
seal differential pressure to increase, causing
some lubricant ingestion into the gas stream
on the non-drive end. There, the lubricant had
migrated along the rotor shaft, leaving black
carbonaceous deposits and some evidence of
chemical attack on the labyrinth seals. The
XIVXMEV]FYX]PTLIR]P HMTLIR]P 74)0 LEH SG-
GEWMSREP½PXVEXMSRXLVSYKL*YPPIV´WIEVXLERH
generous doses of silicone antifoam agent
LEH FIIR EHHIH SZIV WIZIVEP ]IEVW 3RP]
310 hours after the compressor rebuild, the
compressor non-drive-end bearings and seals
were reinspected following an increase in
the journal bearing pad temperature. The in-
ner bushing seal had accumulated a buildup
of deposits in the bore, causing a diametral
clearance reduction of 0.002 in. (0.05 mm),
which was 40% of the design running clear-
ance. Analysis of the lubricant indicated that
XLI 8%2 [EW  XLI ZMWGSWMX] [EW  
LMKLIV XLER WTIGM½GEXMSR ERH JSEQMRK XIR-
dency was high. Waxy deposits were found
MRXLI½PXIVWERHXLIVIWIVZSMVLIEXIVWLEHE
thick black deposit of carbonaceous material.
The lubrication system was cleaned,
¾YWLIH ERH VI½PPIH [MXL RI[ 74)0 SJ XLI
same type. The inner seal bore geometry
[EWQSHM½IHXSTIVQMXQSVI¾S[JSVGSSP-
ing; however, the original seal design had
been successfully used for many years on well
over 100 units operating at up to 10% higher
42 gascompressionmagazine.com | APRIL 2023
speeds on mineral oil. After problem-free operation for about six months, the
non-drive-end journal bearing temperature began to increase. Fluid quality was
RSXGLIGOIHFYXJSYVXS½ZILSYVWSJEGXMZEXIHEPYQMRE½PXVEXMSRGSRXVSPPIHXLI
TVSFPIQ;MXLTIVMSHMGEGXMZEXIHEPYQMRE½PXVEXMSRXLIYRMX[EWWXMPPSTIVEXMRK
with minimal deposits 30 months later.
Compressor 4 was another single-stage, overhung pipeline booster driven by
a 12,300-hp (9.2-MW), 4950-rpm gas turbine. The compressor encountered in-
board bearing and seal problems after more than 50,000 hours of operation. The
synthetic lubricant had never been replaced during that time, although makeup
¾YMH LEH FIIR EHHIH 8LI XIVXMEV]FYX]PTLIR]P HMTLIR]P 74)0 LEH SGGEWMSREP
*YPPIV´WIEVXL½PXVEXMSRERHSYXIVFYWLMRKWIEPPMJILEHI\GIIHIHSRI]IEV,S[-
ever, major problems were encountered following a six-month idle period during
[LMGLXLIVIWIVZSMVLIEXIVW[IVIWSQIXMQIWIRIVKM^IH[MXLSYX¾YMHGMVGYPEXMSR
About 1000 hours of operation after this idle period, the compressor seal drain
XIQTIVEXYVIFIKERXSMRGVIEWIERHXLIWIEPHVEMR¾S[VEXIHIGVIEWIH[MXLXMQI
Inspection revealed black carbonaceous deposits on the inboard journal bearing
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*YPPIV´WIEVXL½PXVEXMSR%JXIVXLIFIEVMRKWERHWIEPW[IVIVITPEGIHMRERSXLIV
1000 hours of operation, the inboard journal bearing failed, scoring the shaft. The
bushing seal bores and shaft area under each seal were coated with black deposits.
8LI¾YMH8%2LEHMRGVIEWIHXSERHXLIRLEHFIIRVIHYGIHXSPIWWXLER
F]½PXVEXMSREXXLIXMQISJXLIJEMPYVI8LIVIFYMPXYRMX[MXLXLIPYFVMGEXMSRW]WXIQ
¾YWLIHERHVI½PPIH[MXLRI[XIVXMEV]FYX]PTLIR]PHMTLIR]P74)0VER½RIEKEMR
Compressor 5, with almost 73,000 operating hours, was virtually identical to
Compressor 4. It experienced similar behavior at about the same time following
EWMQMPEVMHPITIVMSH8LIQENSVHMJJIVIRGI[EWXLEXXLI¾YMH8%2[EWSRP]EX
XLIXMQISJXLITVSFPIQ,S[IZIVJSVXLITVMSVX[S]IEVWTIVMSHMG¾YMHEREP]WMW
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WMSREPP]JSVQER]]IEVWFIJSVIW[MXGLMRKXSEGXMZEXIHEPYQMRE½PXVEXMSR3RXLVII
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HVEMRXIQTIVEXYVI3RSRISGGYVVIRGIHITSWMXW[IVIJSYRHEPWSSRXLIMRFSEVH
thrust bearing pads and the mating thrust disc face. Following reassembly after the
third occurrence, the inboard journal bearing and seals failed in only 30 hours of
operation, preceded by an increasing outer seal drain temperature. The bearing
failure also damaged the shaft. After rebuilding, another failure occurred in only
seven hours of operation. After this failure, the compressor was rebuilt with 20%
increased inboard journal bearing clearance, although original design clearance
had run successfully for more than a decade on this unit and on many other units.
8LISPH¾YMH[EWVITPEGIH[MXLRI[XIVXMEV]FYX]PTLIR]PHMTLIR]P74)08LIVIEJ-
XIVXLIYRMXVERWYGGIWWJYPP][MXLGSRXMRYSYWEGXMZEXIHEPYQMRE½PXVEXMSR
8,)713/-2++927
As a result of extensive investigations of the compressor problems, sev-
eral smoking guns were discovered that answered the question, “What went
wrong?”! All were related to the maintenance procedures and condition of
XLI74)0¾YMHWMRXLIGSQTVIWWSVW4VMSVXSXLMWWIVMIWSJIZIRXWSXLIVYWIVW
ERHETTPMGEXMSRWLEHVITSVXIHTVSFPIQW[MXL74)0W)EVP]YWIVWHMWGSZIVIH
XLEXXLI¾YMHWEVII\GIPPIRXTEMRXVIQSZIVWERHEVIMRGSQTEXMFPI[MXLQER]
common elastomers such as polychloroprene or acrylonitrile polymer.2,3 As
IEVP]EWMX[EWVITSVXIHXLEXI\XIRHIHI\TSWYVIXSQSMWXYVISVLMKL
XIQTIVEXYVI PIH XS WMKRM½GERX ZMWGSWMX] ERH EGMHMX] MRGVIEWIW GSPSV GLERKI
from yellow to black, and formation of black brittle deposits.4 For example, at
„* „' XLI¾YMHHIXIVMSVEXIHEXEWPS[VEXI&YXEX„* „' XLI
YWIJYPPMJI[EWEJI[[IIOWERHEX„* „' MX[EWEJI[LSYVW
8LII\MWXIRGISJELMKL8%2GEYWIWEREYXSGEXEP]XMGVIEGXMSRXLEXWTIIHWYT
the oxidation of the lubricant at relatively low temperatures.5 For quite some
Continued on page 44
 KANE’S
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Figure 6. Pipeline centrifugal compressor with beam-type rotor as in Compressor 3.1
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VIGSQQIRHIHJSVXYVFMRIPYFVMGERXW-JEPPS[IHXSMRGVIEWIWMKRM½GERXP]
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44 gascompressionmagazine.com | APRIL 2023
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FVMGERXW0EFSVEXSV]6ITSVX142SZIQFIV

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gascompressionmagazine.com | APRIL 2023 45
 SURGE CONTROL SYSTEMS FOR
CENTRIFUGAL COMPRESSORS
AN APPLICATION GUIDELINE: PART 15
BY KLAUS BRUN, MARYBETH MCBAIN, AND RAINER KURZ
EDITOR’S NOTE: First published in 2008 in cooperation with the Gas Ma-
chinery Research Council (GMRC), the “Application Guide for Centrifugal Com-
pressor Surge Control Systems” has been revised and updated by the original
authors and will be presented in sections in upcoming issues of Gas Com-
pression Magazine. Part 1 is published in the September 2021 issue of Gas
Compression Magazine, p. 28, with additional parts published in subsequent
issues. Figures, references, and tables follow in consecutive order from Part 1.
10.0 ANTI-SURGE VALVE AND COOLED RECYCLE VALVE SIZING
FOR MULTIUNIT CENTRIFUGAL COMPRESSOR STATIONS
This summary will help operating engineers verify sizing for the
anti-surge valve (ASV) and the recycle valve for centrifugal compres-
sor stations. The criticality of the ASV in the surge protection of the
compressor means it is typically controlled by the compressor original
equipment manufacturer (OEM). As such, the ASV is also used in start-
MRKERHWXSTTMRKXLIYRMXXSEWWYVIEHIUYEXI¾S[XSXLIYRMXHYVMRKEF-
normal short duration periods. The cooled recycle valve is instrumental
in controlling operating conditions and matching gas control require-
ments for the pipeline and is controlled by the operator programmable
logic controller (PLC) and station control program.
Figure 33. Typical Two-Unit Compressor Station With ASV And Cooled Recycle Valves
46 gascompressionmagazine.com | APRIL 2023
8LI WGLIQEXMG MR *MKYVI  MHIRXM½IW XLI EW-
sumed locations of the ASV and recycle valves for
a typical multiunit centrifugal compressor station.
ANTI-SURGE VALVES AND A COMMON
STATION RECYCLE VALVE
It may be possible to combine all functions into
a single valve, especially for smaller units (less
than 10,000 hp [7460 kW]). This single valve
would typically be placed upstream of the cooler,
if long-term operation in recycle is not required,
or downstream of the cooler (with compensated
larger valve requirements for surge protection).
However, the following outlined steps should still
FIZIVM½IHJSVWMRKPIZEPZIWIPIGXMSR
Step 1: Check ASV Sizing For Surge Protection
8LI½VWXWXITMRXLITVSNIGX EJXIVHI½RMRKXLI
GSQTVIWWSVWIPIGXMSRERHQENSVIUYMTQIRX MWXS
specify the ASVs, since they are typically long-lead
items due to the fast actuation times required.
These can also be fairly large 8- or 12-in. (203- or
305-mm) valves for larger compressor units. To
Blue = Station Piping For Normal Operation
Red = ASV Critical Discharge Volume
Yellow = Surge Header For ASV Recycle
Green = Cooled Recycle Header
 $FWLRQ16'2I772IÀLQH
(With Check)
(ASV Reroute)
(Current)
Time (Seconds)
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comparison of two units in preferred piping to the right.
determine the necessary relief capacity (percentage open vs.
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region of the compressor map. Using this piping volume (typi-
Time (Seconds)
GEPP]FIX[IIRERHWGJ?ERHQA XLIGSQTVIWWSV
OEM should run a calculation of compressor deceleration in a
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X]TMGEPP]EXJYPP]STIR':[MXLMRXSWIGSRHW 8LI
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Continued on page 48
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Figure 35. Primary Points Of Interest Used To Specify Anti-Surge Valve And Recycle 8LIXLMVHWXITMWXSZIVMJ]XLEXXLIRI[WYVKI
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48 gascompressionmagazine.com | APRIL 2023

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[MPPFIXLI¾S[EXXLIQE\MQYQLIEHSJJXLIWYVKIGSRXVSP
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VIGIMZI¾S[JVSQQSVIXLERSRIYRMXEXXLIWXEXMSRMJSRI
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LSVWITS[IV 8LMW QE\MQYQ ¾S[ TSMRX [SYPH IRWYVI XLI
GSQTVIWWSVGSYPHFIXIWXIHERHJYPP]GSQQMWWMSRIHMRHI
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GSRXVSP¾S[%WWYGLMXMWTVIJIVVIHXSWIPIGXEQE\MQYQ
¾S[ TSMRX JSV XLI GSSPIH VIG]GPI ZEPZI GSVVIWTSRHMRK XS
XLI PEVKIWX YRMX EX XLI WXEXMSR ERH MXW QE\MQYQ ¾S[ EX
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XLI%7:STIRMRKERHTVIZIRXEVXM½GMEPSVYRRIGIWWEV]JEWX
WXSTW0EWXP]XLIWXEXMSRVIG]GPIZEPZIWLSYPHEPWSFITVS
KVEQQIH XS STIR HYVMRK ER] WMRKPI YRMX WXEVXYT SV WLYX
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gascompressionmagazine.com | APRIL 2023 49
 SIMPLIFIED
SAMPLING
ULTIMATE CHEMICALS AND LAB ONE PARTNERSHIP
REINVENTS ENGINE COOLING SYSTEM ANALYSIS

%JXIVXLIGSSPERXMWXIWXIHMRXLIPEFMXJSPPS[WERMJXLIRIPWI¾S[GLEVX&EWIHSRXLIGSRHM-
XMSRSJXLIGSSPERXXLIETTVSTVMEXI¾YWLMWETTPMIHXSQEOIXLIGSSPMRKW]WXIQZMEFPIEKEMR

BY BRENT HAIGHT

U ltimate Chemicals offers cleaning

products that have been developed
WTIGM½GEPP] JSV MRHYWXVMEP IRKMRIW ERH
GSSPMRKW]WXIQW-XTVSZMHIWMRXIVREPERH
external chemical resources and cleaning
services for oil and gas, natural gas pipe-
line compression, natural gas processing
TPERXW GSQTVIWWSV WXEXMSRW VI½RIVMIW
power plants, manufacturing facilities,
machine shops, radiator shops, and other
MRHYWXVMEPETTPMGEXMSRW,IEHUYEVXIVIHMR
1SSVI3OPELSQEXLIGSQTER]LEWHI-
veloped an extensive portfolio of chemi- GEPPWJSVEREP]WMWSJWSPMHWXLEXLEZIFIIRGSPPIGXIHMRXLIGSSPERX±;I
cal cleaners that is the result of formulat- YWI XLEX EREP]WMW XS HIXIVQMRI [LEX ¾YWL MW KSMRK XS GPIER SYX E GYW-
ing a solution to meet customers’ needs XSQIV´WGSSPMRKW]WXIQERHFVMRKMXFEGOXS^IVSLSYV%PSXLMRKIWSR
MRXLI½IPH KIXXMRKETL]WMGEPWEQTPI²WEMH:ERRSWXVER±8LISTIVEXSVLEWXSWGVETI
±;IEVIEFSYXETTP]MRKXLIVMKLXGLIQ- SYXERHKEXLIVIZIV]XLMRKXLI]GERERHLSTIJYPP]VIGSZIVIRSYKLWSPMH
MWXV]ERHYWMRKXLIVMKLXXIGLRSPSK]²WEMH QEXIVMEPXSKIXXIWXIH-X´WRSXEP[E]WERIJ½GMIRXQIXLSH²
David Vannostran, vice president of op- )RXIV0EF3RI,IEHUYEVXIVIHMR4LSIRM\0EF3RIMWERMRHITIRHIRX
IVEXMSRW EX 9PXMQEXI 'LIQMGEPW ±-X EPP XIWXMRKPEFSVEXSV]XLEXWTIGMEPM^IWMRMRHYWXVMEP¾YMHXIWXMRKERHEREP]WMW
WXEVXW[MXLEWEQTPI² A recent partnership between Ultimate Chemicals and Lab One has led
;LIR MX GSQIW XS IRKMRI GSSPMRK W]W- XSERI[ETTVSEGLXSIRKMRIGSSPMRKW]WXIQEREP]WMW°XIWXMRKXLIGSSP-
XIQ EREP]WMW XVEHMXMSREP QIXLSHSPSK] ERXMXWIPJ Continued on page 52

50 gascompressionmagazine.com | APRIL 2023

 Sample Report From Lab One

“Thanks to Lab One and the development of Ultimate

Chemicals’ Enhanced Coolant Analysis Program, a cus-
tomer can send a liquid coolant sample and Lab One
will discern what’s happening in the cooling system,” said
Vannostran. “From there, we can determine what ac-
XMSRWRIIHXSFITIVJSVQIH°ELIEZ]HYX]¾YWLTVI-
ZIRXMZIQEMRXIRERGI¾YWLEVYWXVIQSZEP¾YWLIXG²
“Cooling systems are one of the most neglected sys-
tems in the engine,” said Jason Kronlund, president of
Lab One. “Companies are routinely performing oil test-
ing and analysis to determine the condition of the engine,
but the cooling system is often forgotten. The cooling
system is one of the most detrimental systems for degra-
dation and failure, and it is not being addressed.”
“Vannostran and his team are spearheading a program
where, in conjunction with coolant test analysis, the end
user is informed on the preventive maintenance mea-
sures available,” said Bob Robie, president of Lab One
Consulting, a division of Lab One. “We get a sample of
coolant into the lab, we test it, and then it follows an if-
XLIRIPWI¾S[GLEVX&EWIHSRXLIGSRHMXMSRSJXLIGSSP-
ERX XLI ETTVSTVMEXI ¾YWL MW ETTPMIH XS QEOI XLI GSSP-
ing system viable again for a more stress-free continued
functionality of the coolant.”
A sample kit includes everything Lab One needs to perform testing. Continued on page 54

52 gascompressionmagazine.com | APRIL 2023

 Compressor Elements is a
full product-line provider of
Gas Compressor Component repair
and New Manufactured Parts.

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An inductively coupled plasma (ICP) Spectrometer is among the testing
equipment used by Lab One.
Coolant sampling requires no more than 4 ounces. Coolant
sample kits for the Enhanced Coolant Analysis Program can be
ordered from a portal on Ultimate Chemicals’ website. The kits
include everything required for Lab One to perform testing. “As
WSSR EW XLI VIWYPXW EVI EZEMPEFPI XLI GYWXSQIV MW RSXM½IH ZME
email, and they can access the results online,” said Kronlund.
According to Kronlund, coolant test results are available within
24 to 48 hours of receipt at the lab. Lab One saves results for
EPP XIWXW JSV YT XS ½ZI ]IEVW ±;I PSSO EX XLI GSSPERX QIXEPW
PSSOMRK JSV GSVVSWMSR QIXEPW² WEMH /VSRPYRH ±;I EPWS PSSO EX
coolant additives, phosphates, molybdates, silicates, and borates,
checking to make sure they’re in the appropriate ratio to what
XLI][IVI[LIRXLI][IVIEZMVKMRTVSHYGX;IGLIGOXLIT,SJ
the coolant, the reserve alkalinity of the coolant, which measures
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PIZIPW XLI TL]WMGEP ETTIEVERGI SJ XLI GSSPERX ;I XLIR PSSO EX
the conductivity of the coolant and the total dissolved solids in
the coolant.”
54 gascompressionmagazine.com | APRIL 2023
“
The cooling system
is one of the most
detrimental systems
for degradation and
failure and it is
not being addressed.
”
±;I TVMHI SYVWIPZIW MR FIMRK E SRIWXST
shop for oil, fuel, and coolant testing,” said Ro
bie. “Data are our livelihood. One of the great
strengths of independent analysis is that we
HSR´XWIPP¾YMH[IHSR´XWIPPIUYMTQIRX°[I
provide numbers. That’s the value we bring to
this partnership with Ultimate Chemicals. The
GYWXSQIVKIXWRSRFMEWIHVIWYPXWJVSQYWERH
a suggested action plan from Vannostran. And
that action plan is based on data.”
The partnership between Lab One and Ul
timate Chemicals gives the end user access to
Q]VMEHI\TIVXWMRXLIMVKMZIR½IPH±:ERRSWXVER
and his team have the support of our entire lab
oratory, including a whole consulting arm that
can accommodate any request that their cus
tomers may have,” said Kronlund. “From there,
Ultimate Chemicals is able to recommend what
actions need to be taken, based on the data.
There’s a big difference between receiving data
and understanding the data received.”
“The Ultimate Chemicals’ Enhanced Coolant
Analysis Program improves engine performance
ERH WMQTPM½IW XLI GYWXSQIV I\TIVMIRGI² WEMH
Vannostran. “This partnership allows an end
user the ability to use a liquid sample of their
coolant and receive actionable data, regardless
of the equipment manufacturer.”
±%RH XLMW MW XLMVHTEVX] MRHITIRHIRX XIWX
ing,” said Robie. “The partnership between Ul
timate Chemicals and Lab One empowers the
customer to make the right decision. It is giving
them the facts, the science, and the direction
in which they can proceed to return their en
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Zagreb, Croatia
September 19–21, 2023
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1109 WORDS
Image Courtesy Of Chevron

NEW COMPRESSION AIDES

C hevron has entered into an agreement with

Sembcorp Marine Repairs & Upgrades Pte.
Ltd. (Sembcorp Marine) to reduce the carbon
MRXIRWMX]SJMXWPMUYI½IHREXYVEPKEW 02+ ¾IIX
operations. Sembcorp Marine will provide Chev-
ron with engineering, procurement, installation,
and commissioning services and expects to
complete the work by mid-2025.
Chevron plans to lower the carbon footprint
SJ 02+ XVERWTSVXEXMSR F] MRWXEPPMRK RI[ XIGL-
RSPSKMIWWYGLEWEVIPMUYI½GEXMSRW]WXIQLYPPEMV
lubrication, and a new gas compressor. Together,
these changes are expected to reduce cargo
boil-off, lower fuel consumption, and increase
volumes of cargo delivered. These changes also
align with decarbonization targets set by the In-
ternational Maritime Organization.
DECARBONIZATION OF LNG FLEET

gascompressionmagazine.com | APRIL 2023 57

 IN THE NEWS
EXLINE NAMES
PRODUCTION MANAGER
Exline has named Troy Jacobson as
production manager for the company’s
production machine shop. Jacobson
served six years in the United States
Marine Corps and has been a part of
the manufacturing world since 1992.
Prior to joining Exline, he held several
positions at local companies, including
machinist, shop lead, machine shop
manager, and production manager.
Additionally, he worked for an inter-
national carbide tooling company for
eight years that specialized in machine
shop cutting tools.
BURCKHARDT NAMES NEW
VICE PRESIDENT
Burckhardt Compression (US) Inc.
has named Annie Savarimuthu as vice
president of systems. She will be on
the leadership team of Burckhardt
Compression (US) Inc. Savarimuthu
has more than 22 years of engineer-
ing, project management, opera-
tions, and sales experience in the
energy and oil and gas industries. She
holds a master’s degree in mechani-
cal engineering from The University
of Tulsa, Oklahoma.
TURBODEN/MHI COMPRESSOR
TECHNOLOGY FOR EUROPEAN
DECARBONIZATION PROJECT
Turboden, a Mitsubishi Heavy In-
dustries group company, will provide
a large heat pump (LHP) system to a
European company in the pulp and pa-
per industry that will feed its process
with steam.
LHPs are utility-scale heating plants
that allow the transfer of large quanti-
ties of heat from a colder source to
a higher temperature heat user, like a
district heating network or an indus-
trial process.
The heat upgrade system, based on
the integration of a Turboden LHP
and a mechanical vapor compressor,
will exploit low-grade heat (ranging
between 50°F and 68°F [10°C and
58 gascompressionmagazine.com | APRIL 2023
20°C]) to produce 12 MWth of super-
heated steam at 338°F (170°C), which
is needed in the paper production pro-
cess. The Turboden LHP system uses
a compressor from Mitsubishi Heavy
Industries Compressor Corp. (MCO).
“MCO is very pleased to provide
our compressors to Turboden for the
realization of this innovative LHP,”
said Masahiro Kobayashi, director of
MCO. “Thanks to our long experi-
ence in the market, we will provide
proven technology in order to achieve
outstanding performances with the
highest reliability.”
Headquartered in Italy, Turboden
designs, manufactures, and maintains
organic rankine cycle (ORC) systems.
ORC systems can generate electric
and thermal power exploiting multiple
sources, such as renewables (biomass,
geothermal energy, and solar energy),
traditional fuels, and waste heat from
industrial processes, waste incinera-
tors, engines, or gas turbines.
“This project is an important mile-
stone for establishing Turboden’s lead-
ership in LHP solutions for customers
with high demand of steam or high-
temperature heat in industrial pro-
cesses,” said Paolo Bertuzzi, managing
director and CEO of Turboden.
BAKER HUGHES AND HIF GLOBAL
COLLABORATE ON DIRECT AIR
CAPTURE TECHNOLOGY
Baker Hughes and HIF Global, an
eFuels company, will cooperate on the
development of technology to capture
carbon dioxide (CO2). HIF Global and
Baker Hughes intend to test Baker
Hughes’ Mosaic atmosphere CO2 Di-
rect Air Capture (DAC) technology
pilot units to accelerate DAC deploy-
ment at commercial scale.
Acquired by Baker Hughes in 2022
to enhance its carbon capture, utiliza-
tion, and storage (CCUS) portfolio,
Mosaic Materials is focused on devel-
oping a proprietary direct air capture
technology using metal-organic frame-
work materials that can be used to
separate CO2 from the atmosphere.
HIF Global has two sites where it
anticipates possible deployment of
Baker Hughes’ Mosaic DAC technol-
ogy. In Chile, the HIF Haru Oni eFuels
*EGMPMX] FIKER TVSHYGMRK MXW ½VWX JYIPW
in December 2022 in Magallanes. The
eFuels facility produces green hydro-
gen from wind electricity and water
and combines the hydrogen with re-
cycled CO2 to produce eFuels, syn-
thetic fuels that can be dropped into
I\MWXMRK ZILMGPIW [MXLSYX ER] QSHM½-
cations to their engines. HIF Global
is also completing the engineering for
XLI ½VWX [SVPHWGEPI I*YIPW JEGMPMX] MR
Matagorda County, Texas, and expects
to begin construction in 2024.
“Groundbreaking technologies like
1SWEMG XLEX IREFPI IJ½GMIRX PS[GSWX
CO2 capture from our atmosphere rep-
resent the future of CO2 recycling,” said
Cesar Norton, HIF Global CEO. “Coop-
eration with our partner Baker Hughes
on this important DAC initiative accel-
erates our plan to capture 25 MTPA
of CO2 and combine it with green hy-
drogen to produce 150,000 barrels per
day of eFuels and decarbonize more
than 5 million vehicles in use today.”
Baker Hughes’ portfolio of CCUS
solutions, technologies, and services
includes pre-FEED and FEED con-
sultation, project design, capture
ERH TYVM½GEXMSR ½XJSVTYVTSWI '32
compression technology, well design
and construction for storage, carbon
transportation and injection, and mon-
itoring and site stewardship.
“Collaboration is key to supporting
and accelerating the energy transition
to address climate change, and we are
pleased to work alongside HIF Global
XSWYTTSVXXLIMVWMKRM½GERXIJJSVXWMR
deploying eFuels at scale, leveraging
our Mosaic DAC technology,” said
Lorenzo Simonelli, chair and CEO of
Baker Hughes. “This milestone agree-
ment further illustrates the strength
of Baker Hughes’ extended portfo-
lio of Climate Technology Solutions,
which includes a variety of CCUS
technologies, and validates our strat-
egy and commitment toward decar-
bonization.”
10-13 JULY
 INDEX OF ADVERTISERS
APRIL
ACI Services, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Ariel Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . 15
AXH Air-Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Canadian Hydrogen Convention . . . . . . . . . . . . . . . 61
CECO Compressor Engineering Corp. . . . . . . . . . 11
Compression Dynamics. . . . . . . . . . . . . . . . . . . . . . 23
Compressor Elements . . . . . . . . . . . . . . . . . . . . . . . 53
Cook Compression . . . . . . . . . . . . . . . . Fourth Cover
CPI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
EFRC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
GE Industrial Motors . . . . . . . . . . . . . . . . . . . . . . . . 19
Global Energy Show. . . . . . . . . . . . . . . . . . . . . . . . . 51
HFW Industries, Inc. . . . . . . . . . . . . . . . . . . . . . . . . 41
HOERBIGER Compression Technology . . . . . . .17, 63
ICP Industries, LLC . . . . . . . . . . . . . . . . . . . . . . . . . 27
To advertise in Gas Compression Magazine, contact Sarah Gonzalez at
sgonzalez@thirdcoastpublishing.net or 832.271.7300, ext. 702
CLASSIFIED SECTION
IMES GmbH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
INNIO Waukesha. . . . . . . . . . . . . . . . . . . . . . . . . . . 45
KB Delta
Compressor Valve Parts, Mfg. . . .1, 32 - 33, Third Cover
Kiene Diesel Accessories. . . . . . . . . . . . . . . . . . . . . 29
LNG 2023 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
NEUMAN & ESSER GROUP . . . . . . . . . . . . . . . . . . 13
Patton Divider Block Systems . . . . . . . . Second Cover
Reynolds-French & Co. . . . . . . . . . . . . . . . . . . . . . . 49
Ro-Flo Compressors . . . . . . . . . . . . . . . . . . . . . . . . 25
Samco Enterprises, Inc. . . . . . . . . . . . . . . . . . . . . . . 21
Sloan Lubrication Systems . . . . . . . . . . . . . . . . . . . . 39
Solar Turbines Incorporated . . . . . . . . . . . . . . . . . . 37
Ultimate Chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Zahroof Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
 HAIGHT BRENT HAIGHT, PUBLISHER
bhaight@thirdcoastpublishing.net
REPORT
LNG’S CHANGING
LANDSCAPE
[MPPKSHS[REWXLI]IEVXLEXVIWLETIHXLIKPSFEPPMUYI½IHREXY-
2 ral gas (LNG) market. Russia’s invasion of Ukraine, a contraction in
Chinese gas demand, a drop in South Asian imports, new LNG supply
coming online in the United States … the list goes on. In the near-term,
the outlook for the LNG market remains positive. Demand for LNG in
Europe to displace Russian natural gas continues to grow. Nations are
prioritizing LNG imports to ensure energy security. The result is fast-
tracked infrastructure to supply growing demand for energy.
According to the International Energy Agency (IEA), LNG carrier
orders reached an all-time high of 165 in 2022, representing a 130%
increase from 2021. Strong demand and limited capacity at Korean ship-
yards through 2027 have led to steep price increases for new-build LNG
vessels — surging to more than US$250 million in 2022, compared to
US$200 million at the end of 2021. The result is an uptick in Chinese
yards entering the LNG shipbuilding market. Chinese shipbuilders re-
GIMZIHSVHIVWJSVRI[02+ZIWWIPWMR½ZIXMQIWQSVIXLER
those in 2021, according to the IEA.
LNG demand trends in 2022 were dominated by a surge in LNG
imports into Europe — up 2.3 Tscf (66 × 109 m3), or 63%, com-
pared to 2021. The United States supplied approximately two-thirds
(1.5 Tscf [43 × 109 m3A SJXLIMRGVIQIRXEP02+MR¾S[WMRXS)YVSTI
according to the IEA, thanks to new liquefaction capacity additions in
2022, including the startup of Calcasieu Pass LNG and the sixth train
at Sabine Pass LNG.
While European demand surged in 2022, elsewhere it waned. Asia-
4EGM½GWE[ER HIGPMRIMR02+HIQERH'LMRE´WMQTSVXW[IVIHS[R
by 21%, the largest annual decline since the start of LNG imports in
2006, because of weak demand from industries disrupted by the na-
tion’s pandemic control measures.
62 gascompressionmagazine.com | APRIL 2023
LOOKING AHEAD
The expansion of LNG demand is fueled by
a continuing rise in European imports to an
EPPXMQILMKLSJ8WGJ ð 9 m3) and by a
modest recovery in Asia following the region’s
demand decline in 2022. According to IEA
data, LNG export growth continues at around
4.3% thanks to the return of the 700-Bscf
(20 × 10 9 -m3) Freeport LNG terminal to full
production in March 2023, despite a marked
slowdown in new liquefaction capacity addi-
tions in 2023.
China’s LNG demand is forecast to recover in
2023 as the country emerges from COVID-19.
China’s LNG demand is set to rebound to be-
tween 77 million and 79 million tons (70 million
and 72 million tonnes) in 2023, 9% to 14% high-
er than in 2022, according to analysts at Rystad
Energy, Wood Mackenzie, and ICIS.
Total global trade in LNG reached 437.6 mil-
lion tons (397 million tonnes) in 2022. Indus-
try forecasts expect LNG demand to reach
716 million to 772 million tons (650 million
to 700 million tonnes) per year by 2040. This
is good news for the gas compression mar-
ketplace, as more investment in liquefaction
projects will be necessary to avoid a supply-
demand gap that is expected to emerge by
the late 2020s.
 @GasCompressionM @GasCompressionMagazine

FAVORITE TWEETS INSTAGRAM

L A G N I A P P E
SOUTHERN CHARM
We were at @powergenintl
for Mardi Gras, but we marked
the day rocking these resin
boutonnières by @hribalresin!

IBERDROLA
@IBERDROLA
Hundreds of people from Huesca
participated in the KVER½IWXEHIPHITSVXIin THESE BOOTS
the city: a weekend full of activities, music, WERE MADE FOR
and outdoor exercise. WALKING
We had so much fun
walking the American
LNG Forum last month!

LET’S PLAY SOME

BASKETBALL
Let’s go Bearkats!
#givingback #community

JOHNSON CONTROLS
@JOHNSONCONTROLS
Hey Bay Area! We’re teamed up with
@ChaseCenter to plant a tree for every
fan who attended Sunday’s game. If you’re LAUGHING MATTERS
counting, that means up to 18K trees will
be planted in the area.

ENBRIDGE
@ENBRIDGE
We’re excited to join forces with
@divertinc and develop more facilities
that turn wasted food into renewable
natural gas!
la.gniappe P͖R]͖T
Noun: A little something extra
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