Gas Compression Feb 2021

Also In This Issue: 2020 US COMPRESSOR STARTUP REPORT
UNITED STATES
RACE
LNG
REPORT
No. 5
FEBRUARY 2021
Robt. L. Rowan & Assoc., Inc.
Est. 1953
COMPRESSOR FOUNDATION
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Metallic Plates|Thermoplastics|Springs|Buttons|Poppets|Kits|Center Bolts|Pins|Lift Washers|O-Rings
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www.kbdelta.com • 310-530-1539
FEBRUARY2021
ON THE COVER
LNG Race Report No. 5: United States . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
FEATURES
Proactive Natural Gas Screw Compressor Monitoring

And Preventive Measures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
WORDS
Editorial Chair Hydrogen Report: Canada’s Hydrogen Strategy . . . . . . . . . . . . . . . . . . . . . 20
Joe Kane
Publisher 2020 US Compressor Startup Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Brent Haight
Editor, Latin America

Methods To Effectively Evaluate Modern Journal
Débora Gonzalez de Galdeano Bearing Performance And Achieve High Reliability: Part 4 . . . . . . . . . . . . . 26
Technical Editor
Angela Jarrell A Guide To Machinery Foundations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
+VIIR)J½GMIRG] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Managing Editor
Raeanna Toussaint
Senior Editor
Daniel Foelber
IN EVERY ISSUE
GRAPHICS Contracts & Permits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Art Director
Amanda Ryan Mergers & Markets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ADS Reliable Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
VP, Advertising & Business Development
Sarah Gonzalez What Went Wrong? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Manager, Advertising & Circulation
Kara Kane Index Of Advertisers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
'PEWWM½IHW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
SUBSCRIPTIONS
Manager, Advertising & Circulation Haight Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Kara Kane
Lagniappe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
DIGITAL
&KLHI7HFKQRORJ\2I¼FHU
Jason Bainbridge
Digital Content Manager

Raeanna Toussaint
Evil Genius, Media & Digital Marketing FEBRUARY CONTRIBUTORS:

Amanda Ryan Robert E. Benton, Jr., Daniel Foelber, Brent Haight, Peter Harteveld, B. Henry Henderson,
Angela Jarrell, Joe Kane, Victor K. Obeid, Robert X. Perez, Bob Rowan, Charlie Rowan,
Gas Compression Magazine W. Norm Shade, Patrick J. Smith, Raeanna Toussaint, and John K. Whalen
15814 Champion Forest Drive, Suite 409, Houston, TX 77379
Email: [email protected] Phone: 832.271.7300
www.gascompressionmagazine.com
Gas Compression Magazine (ISSN 2476-0315) Volume 6, No. 2 – Published 12 issues/year by Third Coast Publishing
THIRD
A MEMBER OF 3 R
D
COAST
Group LLC, 15814 Champion Forest Drive, Suite 409, Houston, TX 77379. Copyright 2021 Third Coast Publishing
PUBLISHING GROUP
Group LLC. All Rights Reserved. Materials protected by US and international copyright laws and treaties.
Unauthorized duplication and publication is expressly prohibited. Printed in the USA.
POSTMASTER: Send address changes to:
Circulation Manager, Gas Compression Magazine, 15814 Champion Forest Drive, Suite 409, Houston, TX 77379 USA.
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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 8LI6MS&VEZS4MTIPMRI4VSNIGXEWMRMXMEPP]½PIHGSRWMWXWSJ
NORTHERN LIGHTS 2021 EXPANSION, two interconnected booster compressor stations, each with
NORTHERN NATURAL GAS a metering site; three compressor stations (one at the Rio
Grande LNG Terminal) and other associated utilities, sys-
PLANNED COMPRESSION: tems, and facilities; a 2.4-mile-long, 42-in. (1066-mm) pipe-
Hinckley Compressor Station line, including 0.8 miles (1.2 km) of dual pipeline (referred
to as the header system) in Kleberg and Jim Wells Coun-
STATUS: Favorable Environmental Assessment ties, Texas; 135.5 miles (218.06 km) of parallel 42-in. pipelines
originating in Kleberg County and terminating at Rio Grande
PROJECT DETAILS: 02+ 00'´W 6MS +VERHI 02+ 8IVQMREP MR 'EQIVSR 'SYRX]
FERC has issued a favorable environmental assessment for (referred to as Pipelines 1 and 2); and four metering sites
the Northern Lights 2021 Expansion, allowing it to move along the header system.
forward. The Northern Natural Gas (Northern) project will As part of the project amendment, RB Pipeline proposed
WIVZI XLI ½VQ XVERWTSVXEXMSR VIUYMVIQIRXW SJ 2SVXLIVR´W ZEVMSYWJEGMPMX]QSHM½GEXMSRWXSXLIEYXLSVMÎHTMTIPMRIW]WXIQ
customers associated with increased energy needs, which • Decrease the maximum allowable operating pressure
[IVIMHIRXM½IHXLVSYKLERSTIRWIEWSRLIPHMR (MAOP) of the 2.4-mile-long header system pipeline from
The project will be located in the Minnesota counties of 1480 to 1200 psig (102 to 82 bar)
Dakota, Scott, Carlton, Morrison, and Pine. Northern will • Construct an extension of 0.2 miles (0.3 km) of mainline
construct an extension of its Willmar D. Branch Line and an pipeline of Pipelines 1 and 2 each, for a total of 135.7 miles
interconnect loop; replace the Viking Interconnect Branch (218.3 km) each
Line; construct a new compressor station (Hinckley Com- -RGVIEWIXLIHMEQIXIVSJ4MTIPMRIJVSQXSMR
pressor Station); and modify the Pierz Compressor Station mm) and increase the MAOP of both pipelines from 1480
and interconnect. to 1825 psig (102 to 125 bar)
Hinckley Compressor Station will utilize one 11,153-hp • Increase the transportation capacity of Pipeline 1 from 2.25
O; 7SPEV8EYVYWKEWXYVFMRI1SHM½GEXMSRWXSXLI to 2.6 Bcf/d (63.7 x 106 to 73.6 x 106 m3/d) and decrease the
Pierz Compressor Station and interconnect include the addi- XVERWTSVXEXMSRGETEGMX]SJ4MTIPMRIJVSQXS&GJH
tion of one 1100-hp (820-kW) electric motor-driven recip- (53.8 x 106 m3/d), resulting in the total authorized capacity
rocating compressor unit. of 4.5 Bcf/d (127.4 x 106 m3/d) remaining unchanged
8LI TVSNIGX EQIRHQIRX EPWS MRGPYHIW QSHM½GEXMSRW XS XLI
PROJECT following aboveground facilities that are authorized (but not
RIO BRAVO PIPELINE PROJECT AMENDMENT, ]IXGSRWXVYGXIH EPSRKXLI6MS&VEZS4MTIPMRIVMKLXSJ[E]
RIO BRAVO PIPELINE COMPANY LLC • Eliminate Compressor Station 2 in Kenedy County
• Eliminate Compressor Station 3 within the Rio Grande
PLANNED COMPRESSION: LNG Terminal in Cameron County, except for a meter and
Compressor Station 1 other ancillary facilities within the LNG Terminal
• Eliminate all facilities associated with Booster Stations 1
STATUS: Favorable Environmental Assessment and 2, including related meter stations, in Kenedy County.
As part of the project amendment, the horsepower at Com-
PROJECT DETAILS: pressor Station 1 will increase from 180,000 to 282,000 hp
FERC has issued a favorable environmental assessment (134,280 to 210,372 kW) by switching to four turbine com-
for the Rio Bravo Pipeline Project Amendment, allowing the pressor units and two electric motor compressor units.
project to move forward. Compressor Station 1 will now include four 43,000-hp
The proposed amendment will modify the pipeline system O; 7MIQIRW 7+8 KEW½VIH XYVFMRI GSQTVIW-
JEGMPMXMIW ETTVSZIH MR *)6'´W SVHIV KVERXMRK EYXLSVMÊXMSRW sor units and two 55,000-hp (41,030-kW) Siemens electric
SR2SZIQFIVJSVXLI6MS&VEZS4MTIPMRI4VSNIGX motor-driven centrifugal gas compressor units. The turbines/
When completed, the Rio Bravo Pipeline Company LLC (RB compressors will be installed inside an acoustically insulated
Pipeline) project will transport natural gas to Rio Grande IRGPSWYVI 4VMQEV] EY\MPMEV] IUYMTQIRX JSV XLI GSQTVIWWSV
02+ 00'´W ETTVSZIH FYX RSX ]IX GSRWXVYGXIH PMUYI½IH units will include lube oil coolers, turbine exhaust systems with
natural gas (LNG) terminal in Cameron County, Texas. exhaust stack, turbine air intake system, gas piping, and a unit
blowdown silencer for each compressor unit.
4 gascompressionmagazine.com | FEBRUARY 2021
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MERGERS & MARKETS
BY DANIEL FOELBER
CATERPILLAR SIGNS AGREEMENT

TO BUY WEIR OIL AND GAS
FOR US$405 MILLION
WEIR COMPLETES ITS TRANSITION TO A PURE-PLAY MINING COMPANY,
WHILE CATERPILLAR INVESTS FURTHER INTO GROWING ITS OIL AND GAS PORTFOLIO
WEIR OIL AND GAS: TRANSITION COMPLETE

Weir’s Oil and Gas division is headquartered in Fort Worth, Texas, and oper-
C aterpillar has agreed to buy
the Oil and Gas division
of the Weir Group (Weir), a
ates in over 50 countries. The division has four areas of focus — drilling, well
completion, production, and pipeline transportation.
Drilling brands include Mathena, Novatech, and Weir Wellhead. The Mathena
Scottish engineering company,
product line offers control solutions and services like a mud-gas separator intel-
for US$405 million in cash. In-
ligent system and a vent-gas analyzer intelligent system. Novatech is a general
cluded in the deal are 40 Weir
equipment brand for well service pumps, manufacturing valves, and other prod-
Oil and Gas manufacturing and
ucts. Weir Wellhead is the company’s pressure control equipment brand that sells
services locations, as well as
and rents frac trees and other support equipment for the drilling industry. The
2000 employees. In total, Weir
Weir Wellhead and Novatech brands also support the company’s well service
has approximately 300 loca-
HMZMWMSR741FVERHIHJVEGTYQTWERH¾YMHIRHWJSVQXLIJSYRHEXMSRSJMXW[IPP
tions in more than 70 countries.
service product line.
“When complete, we’ll deliver
Weir manufactures several products for the production industry, including well-
on the transformation of Weir
heads, blowout preventers, packing, environmental control adapters, and several
becoming a premium mining
SXLIVEGGIWWSVMIWYWIHMREVXM½GMEPPMJX-XWTVSHYGXMSRWIKQIRXMRGPYHIWXYVFSQE-
technology pure play. When we
chinery services support. According to Weir, its turbomachinery services team is
announced in February [2020]
capable of handling all makes of centrifugal, axial, and reciprocating compressors.
that we were going to sell [the]
The company’s pipeline transportation group is responsible for supplying cen-
Oil and Gas [division], we had
XVMJYKEPERHTVSGIWWTYQTWTEVXMGYPEVP]XSVI½RMRKERHTIXVSGLIQMGEPGSQTERMIW
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Assuming the sale is cleared by regulators, Weir says that it expects to use the
XS ½RH E KSSH LSQI JSV XLI
TVSGIIHWXSTE]HS[RHIFXXLI½REPTMIGISJMXWXVERWMXMSRE[E]JVSQSMPERHKEW
business, and the second, to
and toward mining. “We are pleased to have reached this agreement that delivers
maximize value for all of our
a great home for the Oil and Gas division and maximizes value for our stakehold-
stakeholders. This deal delivers
ers. Alongside the previous sale of the Flow Control division and the acquisition of
on both objectives,” said Weir
ESCO, it is a major milestone in transforming Weir into a focused, premium mining
CEO Jon Stanton.
XIGLRSPSK]FYWMRIWW²WEMH7XERXSR±-XQIERW;IMVMWMHIEPP]TSWMXMSRIHXSFIRI½X
from long-term structural demographic trends and climate change actions, which
Continued on page 8

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lished pressure pumping and pressure control portfolio with JSVSZIVWIEWJVIMKLX²WEMH'STTMRKIV
Caterpillar’s engines and transmissions enables us to create 0MOIMXWSXLIVWIKQIRXW)RIVK]ERH8VERWTSVXEXMSRXSSOE
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product to support that growth is consistent with Caterpil 1EVOIX'SRWYPXERX&MPP1IVQSYH

2 0 2 0 I S OV E R
It’s time...
to re-ignite
our energy
independence
We can’t predict the future, but we do know what’s
important for our customers today; a reliable, economical,
and safe compressor operation. That’s been the same
since we started, and it will remain the same many years
from now. Forge ahead with Ariel Corporation.
www.arielcorp.com/itstime
RELIABLE COMPRESSION
BY ROBERT X. PEREZ
USE YOUR HISTORICAL RECORDS

TO BETTER MANAGE TIME-DEPENDENT
MACHINERY FAILURE MODES
PART 1
A reliability technician uses an

infrared camera to inspect an
electric motor.
E arly astronomers used their astronomical obser-

vations and analytical powers to earn the favor of
those in power. By being able to use their astronomi-
and repair a machine that’s in distress? When should we schedule a
machine for inspection and repair based on the time since the last
VITEMV#%RIJ½GMIRXQEGLMRIV]VIPMEFMPMX]TVSKVEQYWIWEQSHM½IH
cal data to make predictions about the world around ZIVWMSRSJXLIWGMIRXM½GQIXLSH8SQEOIFIXXIVQEGLMRIV]HIGM-
them, they were believed to see the future. Over the sions, we need to:
centuries, astronomers have been able to predict solar 1EOIHIXEMPIHVITEMVSFWIVZEXMSRWERHXEOIEGGYVEXI½IPHQIE-
eclipses, the start of seasons, and when Halley’s comet surements.
would reappear. Years ago, these predictors seemed to • Store failure and repair data so it can easily be retrieved and
be magicians, but today we know they were using the reviewed. Repair data should include photos, measurements,
WGMIRXM½GQIXLSHXSYRHIVWXERHLS[XLIWSPEVW]WXIQ samples, and detailed observations to assist future investigators.
works. We now know these celestial phenomena were 'ETXYVIERHHMWTPE]½IPHHEXEWSMXGERFIIEWMP]VIXVMIZIHERH
time-based events based on orbital mechanics. To un- analyzed.
derstand their surroundings, scientists have learned 8YVR ½IPH HEXE MRXS YWIJYP MRJSVQEXMSR 8VIRH TPSXW WGEXXIV
they must 1) observe, 2) form hypotheses based on TPSXWERHWTVIEHWLIIXWGEREPPLIPTQEOIWIRWISJ½IPHHEXE
their observations, 3) test their hypotheses, 4) analyze Train reliability technicians so they are current on the latest
their results, and 5) draw conclusions based on their condition monitoring techniques.
best evidence and intuition. • Decide on a path forward, based on the data analysis and re-
-RXLI½IPHSJVSXEXMRKQEGLMRIV]MRWXIEHSJHIZMWMRK view of the historical records. Data should drive decisions.
ERI[WGMIRXM½GXLISV][I[ERXXSQEOIMRJSVQIHHI- • Periodically, review decisions to see if they were right. Data
cisions concerning the condition of our machines. For information is useless unless it is used and evaluated to deter-
example, we want to know: When should we shut down mine its value.

There are several equipment failure distributions that reli-
ability professionals often deal with. However, in this short
column, I will only discuss two common types of failure distri-
butions related to rotating machinery — time-based failures,
also called age-related failures, and random or unpredictable
failures. Time-based failures are those related to corrosion,
erosion, wear, and creep mechanisms, which can be avoided
or mitigated by preemptive maintenance activities. Following
are examples of time-based machinery failures.
A gas turbine loses a hot section blade after a 45,000-hour
run, which results in a catastrophic engine failure. After in-
spection, the blade failure is determined to be due to creep,
which is a time-dependent metallurgical failure mechanism.
Historical records indicate that previously two vibration trips
caused by severe blade rubbing trips related to blade creep
were noted after engine runs of 43,000 and 44,000 hours.
This indicates that creep-related blade failures are strongly
related to the turbine’s service time. Based on the failure
history, we should either refurbish the turbine well before
40,000 hours or redesign the turbine hot section to extend
the service life of the blades.
A rod drop monitor on a reciprocating compressor shows a
gradual downward trend. Historical records show that the rider
bands have been replaced every two years due to wear. Careful
measurement of the rider band and cylinder liner wear during
planned inspections could be helpful in determining their opti-
mum replacement time.
A steam turbine shows an increasing temperature trend on
the active thrust bearing pads. Past records indicate severe
fouling has been seen due to poor steam quality after three
years of operations. Your choices are to either improve the CP Exchange
steam quality, try to clean the rotor online, or replace the ro-
tor on a given interval. High-performance valves for life
The WPII (Weather-Protected II) electric motor stator wind-
ing temperatures have been trending up and reaching alarm levels
during the heat of the day. Records indicate the motor must be Are you looking for a quick and convenient
disassembled and cleaned every four years due to the dirty en- solution that gives you access to CP Valves
ZMVSRQIRX4IVLETWFIXXIVEMV½PXVEXMSRWLSYPHFIGSRWMHIVIHXS
that are guaranteed to work like new?
extend the time between cleaning intervals.
Next time, I will discuss random failure modes in rotating
machinery and possible management strategies to mitigate With CP Exchange you don‘t have to buy
their effects. and stock a complete set of spares
It delivers re-manufactured valves with the
ABOUT THE AUTHOR
Robert X. Perez has more than 35 years of same factory warranty and performance as
rotating equipment experience in the petro- new valves
chemical industry. He earned a BSME degree Never wait for a valve repair, order
from Texas A&M University (College Station), a
replacements ahead of the maintenance
MSME degree from the University of Texas at
Austin, and is a licensed professional engineer in outage
the state of Texas. Perez served as an adjunct Conveniently maximize your compressor
professor at Texas A&M University–Corpus uptime
Christi, where he developed and taught the En-
gineering Technology Rotating Equipment course.
He has written four books and coauthored four books in the
½IPH SJ QEGLMRIV] VIPMEFMPMX] 4IVI^ LEW EPWS [VMXXIR RYQIVSYW
machinery reliability articles for numerous technical conferences
and magazines.
cp-exchange.hoerbiger.com
PROACTIVE NATURAL GAS
SCREW COMPRESSOR MONITORING
AND PREVENTIVE MEASURES
BY PETER HARTEVELD
O il-injected rotary screw compressors compress natural gas but seldom show early warn-
ing signs of failure. Being alert and recognizing signs early provides opportunities to limit
failures, downtime, and repair costs. Knowledge of these potential warning signs, combined
with an expert understanding of machine performance, operating characteristics, and service
requirements can enable the alert maintenance professional to recognize when a machine
requires attention.
%KEWGSQTVIWWSVSTIVEXMRKSYXWMHISJMXWHIWMKRTEVEQIXIVWGERFIMRIJ½GMIRX[LMGLGER
potentially increase the cost of operation and result in damage of the equipment. In this article,
potential warning signs are shared as well as the actions needed to limit failures and reduce
downtime and associated costs.
PREVENTIVE AND PREDICTIVE MEASURES

In an industrial setting, over time a degree WHAT DOES NORMAL LOOK LIKE?
of normal wear and tear should be expected A sometimes-overlooked factor in assessing and predicting the
of the gas compressor. The key is adopting a health of natural gas screw compressors is monitoring the existing
managed process of preventive and predictive operating conditions and establishing what “normal” is for a cer-
measures that help keep compressors function- tain compressor. This is the type of knowledge and understanding
MRKIJJIGXMZIP]ERHIJ½GMIRXP]4VSQTXVITEMVMWSJ a maintenance professional is familiar with but may not have docu-
course important, but consistent monitoring to mented in a procedure for routinely monitoring the health status
identify potential problems before they escalate of the equipment.
is of greater value. The following parameters can help to assess what normal looks
Screw compressors in natural gas compres- like from an operational point of view:
sion can operate in both open and closed sys- • Changes in gas suction and discharge pressures and
tems. In open systems, contaminants have to temperatures
be separated from the gas prior to the gas • Changes in differential temperature between gas discharge
IRXIVMRK XLI GSQTVIWWSV F] YWMRK MRPIX ½PXVE- and oil injection
tion/separation tailored toward the expected 'LERKIWMRKEWHMWGLEVKIXIQTIVEXYVIERHKEW¾S[TVSHYGXMSR
contamination. The gas in closed systems like • Changes in lube oil level
refrigeration applications is clean and therefore 'LERKIWMRPYFISMP¾S[
these systems experience less contaminant-re- • Changes in separator element differential pressure
PEXIHTVSFPIQW3TIRW]WXIQWPMOI½IPHFSSWXIV 'LERKIWMRPYFISMP½PXIVHMJJIVIRXMEPTVIWWYVI
compressors and vapor recovery units (VRUs)
are, by nature, more sensitive than closed sys-
tems. The dynamic conditions of open systems While some of the aforementioned parameters will vary be-
result in faster failure because changes in condi- cause of variations at the gas source, those types of changes will
tions can occur with very little warning. occur within a certain normal range. The changes outside of this
For the purposes of this article, we will focus normal range are the important ones. These provide the mainte-
SR STIR W]WXIQW PMOI ½IPH FSSWXIVW ERH :69 nance professional with an opportunity to prevent a costly, detri-
compressors and problem indicators in this mental failure.
more challenging environment for predicting Changes in any of these parameters can be a sign of a developing
compressor failure. problem and where intervention should be made.

When the gas discharge temperature cannot be con- Typically, used oil analysis involves the following three steps:
XVSPPIHERHKEW¾S[TVSHYGXMSR MWHIGVIEWMRKMXMWER 1. Take a representative sample. This is the most important step
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lead to bearing failure in most cases. GYVEXIMRXIVTVIXEXMSRSJXLIGSRHMXMSRERHTSXIRXMEPIUYMTQIRXJEMPYVI
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related to the operating conditions of the system. A ries. 3RGIXLIWEQTPILEWFIIRXEOIRMXWLSYPHFIWIRXEWWSSR
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minimum is a problem indicator because it reduces GERFIWIRXF]IQEMPSVZMI[IHSRPMRI
XLIVIXIRXMSRXMQISJXLISMPMRXLIVIWIVZSMVERH[MXL 3.,QWHUSUHWXVHGRLODQDO\VLVUHVXOWV8LMWMW[LIRXIGLRMGEPEHZM-
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7PYKW SJ PMUYMHW JVSQ E REXYVEP KEW [IPP IRXIVMRK XLI in the potential of reducing maintenance expense by highlighting mi-
compressor can plug separator elements and lube oil RSVTVSFPIQWFIJSVIXLI]FIGSQIWIVMSYWERHI\TIRWMZIXSVITEMV
½PXIVW VIWYPXMRK MR PYFI SMP WXEVZEXMSR SJ XLI FIEVMRKW 8LIYRWGLIHYPIHWLYXHS[RSJEREXYVEPKEWWGVI[GSQTVIWWSVMW
7QEPPIV WGVI[ GSQTVIWWSVW [MXLSYX E PYFI SMP GMVGYPE- something that can be caused by a mechanical failure. Natural gas
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rely on differential pressure for bearing lube oil supply. JEMPYVIWGERSGGYV[MXLPMXXPI[EVRMRKVIWYPXMRKMRGSWXP]WLYXHS[RW
9RHIV TVIWWYVI XS QE\MQMÎ SYXTYX QEMRXIRERGI TVSJIWWMSREPW
CONDITION MONITORING QYWXTVSXIGXXLIMVIUYMTQIRXWSEZSMHMRKXLMWX]TISJWMXYEXMSRMW
Natural gas compressors typically operate 365 days MQTSVXERX9RTPERRIHQEMRXIRERGIERHFVIEOHS[RSJEGSQTVIW-
TIV]IEV[MXLSYXMRXIVVYTXMSRERHQEMRXEMRELMKLHIKVII WSVMQTEGXWSTIVEXMSREPIJ½GMIRG]ERHTVSHYGXMSR
SJ IJ½GMIRG] %GGMHIRXEP FVIEOHS[RW GER LEZI WIVMSYW
GSRWIUYIRGIW WYGL EW TVSHYGXMSR PSWW ERH I\TIRWMZI ABOUT THE AUTHOR
consequential damages. Using a condition monitoring 4IXIV,EVXIZIPHMWWIRMSVXIGLRMGEPEHZMWSVEX4IXVS'EREHE0YFVMGERXW
ERHHMEKRSWXMGWW]WXIQMWOI]XSTVIZIRXXLMWPIZIPSJMQ-
TEGXJYPFVIEOHS[R
:MFVEXMSREREP]WMWFIEVMRKXIQTIVEXYVIERHSMP¾S[
America’s recycler of natural gas catalysts
monitoring are examples of condition monitoring for
the detection of a potential issue in a compressor.
Continuous real-time capture of this data and oil con-
HMXMSRQSRMXSVMRKMWZMXEPJSVEGGYVEXIEWWIWWQIRXERH
JSVWTSXXMRKIEVP]WXVIWWMRHMGEXSVWSRWGVI[GSQTVIW-
sor operations.
8LIEQFMXMSRWLSYPHFIXSTVSZMHIIEVP]HIXIGXMSRSJ
I\GIWWMZI ZMFVEXMSR SV SMP GSRHMXMSR MWWYIW FYX EGGITX
XLEXEHIKVIISJMQTEGX[MPPSGGYV[MXL[IEVSZIVXMQI • WE BUY SPENT CATALYSTS
8LMWGERFIEGLMIZIH[MXLTVSTIVHIWMKRMRWXEPPEXMSRERH
QEMRXIRERGIEPSRK[MXLWIPIGXMRKEUYEPMX]PYFISMPWYMX- • PRECIOUS METALS RECLAMATION
able for the operating conditions and gas composition and
YWMRKLMKLIJ½GMIRG]PYFISMP½PXVEXMSR • NO MINIMUM LOT SIZES
EFFECTIVE USED OIL ANALYSIS • 15 DAY PAYOUTS

&IJSVIWXEVXMRKEYWIHSMPEREP]WMWTVSKVEQMXMWEHZMW-
EFPIXSWIIOVIGSQQIRHEXMSRWJVSQXLISVMKMREPIUYMT- • WE ORGANIZE & PAY SHIPPING
QIRX QERYJEGXYVIV 3)1 QERYEP EW [IPP EW EHZMGI
JVSQXIGLRMGEPPYFVMGEXMSRI\TIVXW%R]HIZMEXMSRJVSQ • ACCEPT PARTS IN ALL CONDITIONS
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age and result in operational issues and high repair costs.
;LMPIYWIHSMPEREP]WMWMWRSXRIGIWWEVMP]ETVIHMGXMZI Get quotes and set up shipping right from our website.
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IRZMVSRQIRXMWGVMXMGEPXSMHIRXMJ]ER]GLERKIWXLEXVI- • Truck & Bus Catalysts • Power Generation Catalysts • Natural Gas Compression Catalysts
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gascompressionmagazine.com | FEBRUARY 2021 13

LNG 92-8)(
RACE REPORT N0. 5: 78%8)7
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growth for Kinder Morgan. The company 3. CALCASIEU PASS
is one of the largest transporters of natu- Venture Global’s Calcasieu Pass is one of the largest projects that’s expected
ral gas out of the Permian to facilities along to be completed within the next few years. With an initial FERC order received
the Gulf Coast. Tapping into the LNG busi- in February 2019, the project is well underway toward meeting its expected
ness opens doors for pipeline companies in completion date in late 2022.
search of new markets. The Calcasieu Pass project is unique for a number of reasons. Unlike Cheniere’s
2. CAMERON LNG large-scale projects, the facility will implement mid-scale liquefaction technology
Formed in 2014, Cameron LNG is the F]VYRRMRKIPIGXVMGEPP]HVMZIR184%PMUYI½GEXMSRXVEMRWMRRMRIFPSGOW
result of a US$10 billion vision to build a Before entering the trains, the gas will undergo acid gas removal and dehydra-
liquefaction facility. Jointly owned by Sem- tion through three 50% capacity pretreatment trains. Attached to the facility
pra, Mitsui, Mitsubishi, Total, and NYK [MPPFIE1;GSQFMRIHG]GPIKEW½VIHTS[IVTPERX[MXLE1;KEW½VIH
Line, Cameron commenced its commercial aeroderivative turbine as backup. Two 7,062,933-ft3 (200,000-m3) storage tanks
operations for Train 1 in August 2019, Train will help the facility maximize output. Continued on page 16
2 in March 2020, and Train 3 in August
2020 for a total of 12 MTPA of capacity.
In 2016, Cameron received regulatory ap-
proval for an expansion project that would
add two trains for 9.97 MTPA of additional
capacity and two storage tanks. Having just
completed its third train, Cameron hasn’t
QEHIE½REPHIGMWMSRSR[LIXLIVSVRSXXS
pursue its expansion project. If undertak-
en, the expansion would bring the facility’s
total capacity to 24.92 MTPA, which would
make it the second largest LNG export
facility in the United States (behind Che-
niere’s Sabine Pass).
3. FREEPORT LNG
In November 2020, Freeport LNG
shipped its 100th cargo since going into
service in September 2019. The US$13.5
billion facility has three trains and around
15 MTPA of LNG capacity.
PROJECTS TO WATCH
1. CORPUS CHRISTI TRAIN 3
The third train at Cheniere Energy’s
Corpus Christi liquefaction facility is now
96% complete. It will join Trains 1 and 2, for
a total capacity of 13.5 MTPA. In Novem-
ber 2019, Cheniere received Federal En-
ergy Regulatory Commission (FERC) ap-
proval for up to seven additional midscale
trains, which will add roughly 10 MTPA of
capacity.
2. SABINE PASS LNG TRAIN 6
Cheniere Energy’s Sabine Pass is expected
XSGSQTPIXIMXWWM\XLERH½REPXVEMRMR
7MRGI WLMTTMRK XLI ½VWX 97 02+ I\TSVX MR
2016, Cheniere has retained its position as
the largest US LNG exporter. Sabine Pass
LEW½ZIEGXMZIXVEMRWJSVEXSXEPTVSNIGXGE-
pacity of 22.5 MTPA. Including the Corpus
Christi expansion project, Cheniere would
have a total capacity of over 50 MTPA,
which is nearly enough LNG to supply all of
India’s existing and planned capacity.

STATU
CAPACITY STARTUP
TYPE
PROJECT NAME (MTPA) DATE
S
Kenai (Alaska) 1.50 Export 1969
Everett (Massachusetts) 5.40 Import 1971
Cove Point (Maryland) 0.00 Import 1978
Elba Island (Georgia) 0.00 Import 1978
Lake Charles (Louisiana) 0.00 Import 1982
Northeast Gateway Deepwater Port (Massachusetts) 3.00 Import 2007
Sabine Pass LNG (Texas) 0.00 Import 2008
EXISTIN
Freeport LNG (Texas) 0.00 Import 2008
Cameron LNG (Louisiana) 0.00 Import 2009
G
Golden Pass (Texas) 0.00 Import 2010
Gulf LNG Clean Energy Project (Mississippi) 0.00 Import 2011
Sabine Pass LNG Trains 1 And 2 (Texas) 9.00 Export 2016
Sabine Pass LNG Trains 3 And 4 (Texas) 9.00 Export 2017
Cove Point (Maryland) 5.25 Export 2018
Sabine Pass LNG Train 5 (Texas) 4.50 Export 2019
Cameron LNG Train 1 (Louisiana) 4.00 Export 2019
Corpus Christi LNG Trains 1 And 2 (Texas) 9.00 Export 2019
Freeport LNG Expansion, LP (Texas) 15.00 Export 2019
Elba Liquefaction Project (Georgia) 2.50 Export 2020
Cameron LNG Trains 2 And 3 (Louisiana) 8.00 Export 2020
Corpus Christi LNG Train 3 (Texas) 4.50 Export 2021
U.C.
Sabine Pass LNG Train 6 (Texas) 4.50 Export 2022
Calcasieu Pass (Louisiana) 10.80 Export 2022
*
UNITED
Golden Pass (Texas) 15.60 Export 2024

STATES
Delfin FLNG (Louisiana) 6.67 Export 2023

Driftwood LNG (Louisiana) 27.60 Export 2023
Gulf LNG Liquefaction (Mississippi) 10.00 Export 2023
Magnolia LNG (Louisiana) 8.80 Export 2023
Plaquemines LNG (Mississippi) 20.00 Export 2023
Rio Grande LNG (Texas) 27.00 Export 2023
Monkey Island LNG (Louisiana) 15.75 Export 2023
PLANNED
Texas LNG (Texas) 2.00 Export 2023

Fourchon LNG (Louisiana) 2.00 Export 2023
West Delta LNG Deepwater Port (Louisiana) 4.20 Export 2023
G2 LNG (Louisiana) 14.00 Export 2023
Corpus Christi LNG (Phase III) (Texas) 9.50 Export 2023
Port Arthur (Texas) 13.50 Export 2023
Annova LNG (Texas) 6.00 Export 2024
Alaska LNG (Alaska) 20.00 Export 2025
Jordan Cove Energy Project (Oregon) 7.80 Export 2025
Lake Charles (Louisiana) 16.45 Export 2025
CE FLNG (Louisiana) 8.00 Export 2026
* U.C. = Under Construction
OPERATOR LNG STORAGE SHAREHOLDERS
LOCATION
TRAINS (m3)
Andeavor Onshore 1 105,000 Andeavor
Exelon Generation Onshore 0 154,000 Exelon Generation
Dominion Energy Onshore 0 695,000 Dominion Energy
Southern LNG Onshore 0 550,000 Southern LNG
Energy Transfer Equity Onshore 0 425,000 Energy Transfer Equity
Excelerate Energy Offshore 0 0 Excelerate Energy
Sabine Pass LNG Onshore 0 800,000 Cheniere Energy
Freeport LNG Development LP Onshore 0 320,000 Freeport LNG Invements, Global Infrastructure Partners, Osaka Gas
Cameron LNG Onshore 0 480,000 Sempra Energy
Golden Pass LNG Onshore 0 800,000 ExxonMobil, Qatar Petroleum
Gulf LNG Energy Onshore 0 320,000 El Paso, Crest Group, Sonangol USA
Sabine Pass Liquefaction Onshore 2 0 Cheniere Energy
Dominion Energy Onshore 2 0 Dominion Energy, Brookfield Super-Core Infrastructure Partners
Cameron LNG Onshore 1 0 Sempra Energy, Total, Mitsubishi, Mitsui, NYK Line
Corpus Christi LNG Onshore 2 480,000 Cheniere Energy
Freeport LNG Development LP Onshore 3 320,000 Freeport LNG Investments, Global Infrastructure Partners, Osaka Gas
Elba Liquefaction Co. Onshore 1 0 Kinder Morgan
Cameron LNG Onshore 2 0 Sempra Energy, Total, Mitsubishi, Mitsui, NYK Line
Corpus Christi LNG Onshore 1 0 Cheniere Energy
Venture Global LNG Onshore 9 400,000 Venture Global LNG
ExxonMobil Onshore 3 0 Qatar Petroleum, ExxonMobil
Delfin LNG Offshore 0 0 Delfin LNG
Driftwood LNG Onshore 20 705,000 Tellurian Investments
Gulf LNG Liquefaction Onshore 2 0 Kinder Morgan, General Electric
Magnolia LNG Onshore 4 320,000 LNG Ltd.
Venture Global LNG Onshore 20 800,000 Venture Global LNG
NextDecade Onshore 6 720,000 NextDecade
SCT&E LNG Onshore 3 360,000 SCT&E LNG
Texas LNG Brownsville LLC Onshore 1 0 Texas LNG Brownsville LLC
Fourchon LNG Onshore 4 0 Fourchon LNG
LNG 21 Offshore 0 300,000 LNG 21
G2 LNG Onshore 2 0 G2 LNG
Corpus Christi LNG Onshore 7 240,000 Cheniere Energy
Sempra Energy Onshore 2 0 Sempra Energy
Annova LNG Onshore 6 320,000 Exelon Generation
Alaska LNG Onshore 3 480,000 Alaska Gasline Development Corp
Jordan Cove Energy Onshore 2 320,000 Pembina Pipeline Corporation
Lake Charles LNG Export Co. Onshore 3 0 Shell, Energy Transfer Partners LP, Energy Transfer Equity LP
Cambridge Energy Offshore 0 0 Cambridge Energy
LNG RACE REPORT – TOP COUNTRIES

LH
LH2 2
HYDROGEN
H 2 CANADA’S
REPORT
BRENT HAIGHT HYDROGEN STRATEGY
A ROADMAP TO 2050
Image Source: Government Of Canada
C anada’s federal government released its Hydrogen Strat-

egy For Canada, a 141-page report that outlines a plan
to make hydrogen a key part of Canada’s path to net-zero
Canada’s short-term goal is to lay the foundation for the
L]HVSKIR IGSRSQ] SZIV XLI RI\X ½ZI ]IEVW 8LMW MRGPYHIW
developing new hydrogen supply and distribution infrastruc-
carbon emissions by 2050 and make Canada a global leader in ture to support early deployment hubs in mature applica-
hydrogen technologies. tions while supporting emerging applications. According to
“As we rebuild our economy from the impacts of CO- the report, regulations such as Canada’s Clean Fuel Standard
:-(ERH½KLXXLII\MWXIRXMEPXLVIEXSJGPMQEXIGLERKIXLI will be fundamental to driving near-term investment in the
development of low-carbon hydrogen is a strategic priority sector, in addition to introducing new policy and regulatory
for Canada. The time to act is now,” said Canada’s Minis- measures that will advance Canada to achieve net-zero emis-
ter of Natural Resources Seamus O’Regan. “The Hydrogen sions by 2050.
Strategy For Canada lays out an ambitious framework for The report states that emerging hydrogen use in the
actions that will cement hydrogen as a tool to achieve our near-term will be dominated by mature market applications
goal of net-zero emissions.” at or near commercial market readiness, including oil and

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2020 US COMPRESSOR STARTUP REPORT
PROJECT PRIME MOVER COMPRESSOR
Project Name Facility Operator State Type (Gas Turbine, OEM Model Number hp (kW) OEM Model
Recip Engine, Number
Electric Motor)
Sabal Trail Project Phase II Albany Compressor Station Sabal Trail Transmission Georgia Gas Turbine Solar Turbines Inc. Titan 130 20,500 (15,293)
Sabal Trail Project Phase II Dunnellon Compressor Station Sabal Trail Transmission Florida Gas Turbine Solar Turbines Inc. Titan 130 20,500 (15,293)
Elba Liquefaction Project: Phase 1 MMLS Unit 2 Elba Liquefaction Company Georgia Electric Motor Siemens 10,455 (7800)
Freeport LNG Liquefaction Project LNG Train 2 Freeport LNG Texas Electric Motor GE 10,053 (7500) GE
Freeport LNG Liquefaction Project Mixed Refrigeration Compression Freeport LNG Texas Electric Motor GE 10,053 (7500) GE
Cameron Liquefaction Project Train 2 Cameron LNG Louisiana Gas Turbine GE Frame 7 EA Elliott
Information in this report is gathered from US Federal Energy Regulatory Commission (FERC) records and shows the units that received FERC approval to be placed into service in 2020.
South Mainline Expansion Project Red Mountain Compressor Station El Paso Natural Gas Company New Mexico Gas Turbine Solar Turbines Inc. Mars 90 13,220 (9862)
South Mainline Expansion Project Dragoon Compressor Station El Paso Natural Gas Company Arizona Gas Turbine Solar Turbines Inc. Mars 90 13,220 (9862)
Sierrita Compressor Expansion Project Sierrita Compressor Station Sierra Gas Pipeline LLC Arizona Gas Turbine Solar Turbines Inc. Mars 100 15,900 (11,861) Solar C45
Hillabee Expansion Project Phase II Compressor Station 95 Transcontinental Gas Pipline Company Alabama Gas Turbine Solar Turbines Inc. Mars 100-1600S 16,000 (11,936)
Midcontinent Supply Header Interstate
Calumet Compressor Station Midship Pipeline Company Oklahoma Gas Turbine Solar Turbines Inc. Centaur 50 6130 (4572) Solar C45
Pipeline Project
Calumet Compressor Station Midship Pipeline Company Oklahoma Gas Turbine Solar Turbines Inc. Centaur 50 6130 (4572) Solar C45
Pipeline Project
Calumet Compressor Station Midship Pipeline Company Oklahoma Gas Turbine Solar Turbines Inc. Mars 100 15,900 (11,861) Solar C65
Pipeline Project
Tatums Compressor Station Midship Pipeline Company Oklahoma Gas Turbine Solar Turbines Inc. Taurus 70 10,915 (8142) Solar C45
Pipeline Project
Tatums Compressor Station Midship Pipeline Company Oklahoma Gas Turbine Solar Turbines Inc. Taurus 70 10,915 (8142) Solar C45
Pipeline Project
Tatums Compressor Station Midship Pipeline Company Oklahoma Gas Turbine Solar Turbines Inc. Titan 130 22,400 (16,710) Solar C75
Pipeline Project
Bennington Compressor Station Midship Pipeline Company Oklahoma Gas Turbine Solar Turbines Inc. Centaur 50 6130 (4572) Solar C45
Pipeline Project
Bennington Compressor Station Midship Pipeline Company Oklahoma Gas Turbine Solar Turbines Inc. Centaur 50 6130 (4572) Solar C45
Pipeline Project
Bennington Compressor Station Midship Pipeline Company Oklahoma Gas Turbine Solar Turbines Inc. Titan 250 30,000 (22,380) Solar C85
Pipeline Project
numbers, manufacturer information, and other information is not available in the public record.
Willis Lateral Project Goodrich Compressor Station Gulf South Pipeline Company Texas Gas Turbine Solar Turbines Inc. Mars 100 15,876 (11,843)
Petal III Compression Project Petal III Compressor Station Gulf South Pipeline Company Mississippi Electric Motor 5000 (3730)
Petal III Compression Project Petal III Compressor Station Gulf South Pipeline Company Mississippi Electric Motor 5000 (3730)
Cheyenne Hub Enhancement Project Cheyenne Compressor Station Rockies Express Pipeline LLC Colorado Recip Engine Caterpillar G3616 5350 (3991)
Empire North Project Jackson Compressor Station Empire Pipeline, Inc. Pennsylvania Gas Turbine Solar Turbines Inc. Taurus 70 10,534 (7858)
Empire North Project Jackson Compressor Station Empire Pipeline, Inc. Pennsylvania Gas Turbine Solar Turbines Inc. Taurus 70 10,534 (7858)
Empire North Project Farmington Compressor Station Empire Pipeline, Inc. New York Electric Motor 16,000 (11,936)
Empire North Project Farmington Compressor Station Empire Pipeline, Inc. New York Electric Motor 16,000 (11,936)
Southeastern Trail Project Compressor Station 175 Transcontinental Gas Pipline Company Virginia Gas Turbine Solar Turbines Inc. Titan 130 22,490 (16,777)
Portland XPress Project- Phase III Eliot Compressor Station Portland Natural Gas Transmission System Maine Gas Turbine Solar Turbines Inc. Centaur 50 6300 (4699)
Sabine Pass Compression Project Compressor Station No. 348 Natural Gas Pipeline Company Louisiana Gas Turbine Solar Turbines Inc. Titan 130 22,490 (16,777) Solar C65-2
Bushton To Clifton A-Line
Tescot Compressor Station Northern Natural Gas Company Kansas Gas Turbine Solar Turbines Inc. Mars 11,152 (8319)
Abandonment Project
Gulf Coast Southbound Project Compressor Station 300 Natural Gas Pipeline Company Texas Electric Motor 10,000 (7460)
Gulf Coast Southbound Project Compressor Station 301 Natural Gas Pipeline Company Texas Gas Turbine Solar Turbines Inc. Mars 100 15,900 (11,861) Solar C65
Unit 1 Expansion Sinton Compressor Station Cheniere Corpus Christi Pipeline Texas Gas Turbine Solar Turbines Inc. Titan 130E 22,000 (16,412)
Unit 1 Expansion Sinton Compressor Station Cheniere Corpus Christi Pipeline Texas Gas Turbine Solar Turbines Inc. Titan 130E 22,000 (16,412)
Every effort is made to ensure the completeness and accuracy of the data presented. However, this report is limited to the level of detail included in FERC documents. In some cases, model
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7
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METHODS TO EFFECTIVELY EVALUATE
MODERN JOURNAL BEARING PERFORMANCE
AND ACHIEVE HIGH RELIABILITY
PART 4
BY PATRICK J. SMITH, VICTOR K. OBEID, ROBERT E. BENTON, JR., AND JOHN K. WHALEN
EDITOR’S NOTE
This article is based on a paper presented at the 48th Turbomachinery and 35th Pump Symposia,
September 10 – 12, 2019, Houston. Part 1 was published in the July 2020 issue of Gas Compression
Magazine, p. 16. Part 2 was published in the September 2020 issue of Gas Compression Magazine,
p. 10. Part 3 was published in the January 2021 issue of Gas Compression Magazine, p. 38. Figures,
tables, equations, and references follow consecutively from Parts 1, 2, and 3.
CASE STUDY C
This case study pertains to a three-pinion, integral gear cen- However, not all the bearing information is available.
trifugal compressor that is driven by a 3500-hp (2610-kW), ;LEX MW ORS[R MW XLEX XLMW FIEVMRK MW E ½ZITEH XMPXMRK
3000-rpm induction motor. There are two pinions in the low- pad type with nonaligned, cylindrical, center pivot pads.
er half of the gearbox with impellers mounted on both ends The nominal bearing journal is 1.875 in. (47.6 mm), the
of both pinions. These rotors are used to compress dry air. length-to-diameter ratio is 1, and the diametral clear-
There is a single pinion in the gear case cover with impellers ance is 0.005 to 0.008 in. (0.127 to 0.203 mm). The pin-
mounted on both ends of the pinion. This rotor is used to ion speed is 35,060 rpm and calculated load at design
compress nitrogen. There are thrust collars on all the pinions conditions is 780 lb f (3.48 kN). To perform the analyses,
that transmit pinion axial load to the bullgear. assumptions of the preload, pad angle, and pivot angle
The gearbox utilizes tilting pad journal bearings for all three were made. All the data used for the analyses are sum-
pinions with single, noncontacting, proximity-type shaft vibra- marized in Table 4.
tion probes adjacent to each bearing. There are no bearing %TPSXSJQMRMQYQSMP½PQXLMGORIWWEKEMRWXHMEQIXVEP
temperature probes. GPIEVERGIMWWLS[RMR*MKYVI%WWLS[RXLI½PQXLMGO-
The nitrogen section of this compressor was operated at ness is more than 0.001 in. (0.025 mm) down to a diam-
VIHYGIH¾S[ERHTS[IVPIZIPWJSVWIZIVEP]IEVW[MXLSYXER] etral clearance of about 0.0043 in. (0.109 mm). This is
TVSFPIQW ,S[IZIV EFSYX E ]IEV EJXIV XLI ¾S[ ERH TS[IV below the minimum design clearance of 0.005 in. Also
were increased, the pinion radial vibrations increased. The
compressor was shut down to investigate, and heavy deposits
were discovered on both bearings. The shaft journals were
cleaned, and both pinion bearings were replaced. The com-
pressor ran for approximately one more year and the prob-
lem repeated itself.
At the time this problem occurred, a comprehensive bear-
ing analysis was not performed. It was decided to change from
the original equipment manufacturer (OEM) bearing design to a
higher-tech bearing that incorporated chromium copper pads,
spherical seats, offset pivots, hot oil carryover blockers, bypass
cooling, and directed lubrication. A picture of this bearing is
shown in Figure 22. Note that this bearing design was run in an
evacuated condition (no end seals).17
There were no bearing problems after these bearings
[IVIVIXVS½XXIH8SYRHIVWXERHXLIMRMXMEPTVSFPIQEFIEV-
ing analysis of the original bearing design was performed. Figure 22. Replacement Bearing

Bearing Geometry
Journal Diameter &IEVMRK%\MEP (MEQIXVEP%WWIQFPIH 'PIEVERGI Preload Pad Angle Pivot Angle Pad Orientation
MRQQ Length 2SQMREP(IWMKR'PIEVERGI Ratio degrees degrees 9RHIV3TIVEXMRK
MRQQ MRQQ mil/in. 0SEH
8S Load On Pad
Bearing Operating Parameters

Pinion Speed Journal Load Journal Speed &IEVMRK9RMX 0YFVMGERX 3MP7YTTP] 'EPGYPEXIH3MP
rpm Lb JO2 JXWQW Load 8IQTIVEXYVI *PS[8S&IEVMRK
TWM1TE *' KTQ0QMR
-73:+
Table 4. Study 3 Design Data – Original Bearing
note that both the original bear-

ing and the upgraded bearing have
WMQMPEV QMRMQYQ SMP ½PQ XLMGORIWW
values through the range. For sim-
TPMGMX] E MR QQ
GPIEVERGI[MPPFIYWIHJSVGSQTEVM-
son purposes.
% TPSX SJ QE\MQYQ TEH XIQ-
perature versus radial diametral
GPIEVERGIMWWLS[RMR*MKYVI%W
WLS[RXLIQE\MQYQTEHXIQTIVE-
XYVIMWUYMXIPS[EXXLIHIWMKRGPIEV-
ERGI ERH HSIW RSX I\GIIH *
' YRXMP XLI HMEQIXVEP GPIEV-
ERGIMWEFSYXMRQQ
Figure 23. Calculated Minimum Oil Film Thickness Versus Diametral Clearance For Case Study C
Continued on page 28
Bearing Geometry
.SYVREP(MEQIXIV &IEVMRK%\MEP (MEQIXVEP%WWIQFPIH 'PIEVERGI 4VIPSEH Pad Angle 4MZSX%RKPI 4EH3VMIRXEXMSR
MRQQ Length 2SQMREP(IWMKR'PIEVERGI 6EXMS (IKVIIW (IKVIIW (Under Operating
MRQQ MRQQ mil/in. 0SEH
2.7 29 0SEH3R4EH
Bearing Operating Parameters

4MRMSR7TIIH .SYVREP0SEH .SYVREP7TIIH Bearing Unit 0YFVMGERX 3MP7YTTP] 'EPGYPEXIH3MP
rpm Lb JO2 JXWQW 0SEH 8IQTIVEXYVI *PS[8S&IEVMRK
TWM1TE *' KTQ0QMR
-73:+
Table 5. Bearing Data For New Application
The bearing clearance was checked in

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XYVIMRWXVYQIRXEXMSRMXMWRSXTSWWMFPI
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Figure 24. Calculated Maximum Pad Temperature Versus Diametral Clearance For Case Study C 3RITSWWMFMPMX]MWXLEXXLIVI[EWER
MWWYI[MXLSMPWYTTP]XSXLIWIFIEVMRKW
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GIWWJYPP] MR QER] SXLIV QEGLMRIW EX
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MR XLMW QEGLMRI [IVI MR XLI KIEVFS\
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XLIVI [IVI RS MWWYIW [MXL I\GIWWMZI
GPEQTMRK SV QMWEPMKRQIRX 7S FEWIH
SRI\TIVMIRGIERHMRWTIGXMSRWXLIVI
HMHRSXETTIEVXSFIER]MWWYIW[MXL
Figure 25. Maximum Pad Temperature And Minimum Oil Film Thickness Versus Diametral XLI FIEVMRK WIPIGXMSR SV ETTPMGEXMSR
Clearance For New Application 8LMWKMZIWWSQIGVIHMFMPMX]XSERMWWYI
[MXLSMP¾S[7SXLIFIEVMRKEREP]WMW
[EWVIVYREWWYQMRKEPS[IVSMP¾S[

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JSV XLI SVMKMREP FIEVMRK HIWMKR ERH FIPS[ KTQ
0TQ JSVXLIQSHM½IHFIEVMRK'SQTEVIHXSEHIWMKR
SJKTQ0TQ MXHSIWR´XETTIEVPMOIP]XLEXLMKL
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SMP ½PQ XLMGORIWW [EW RSX PIWW XLER MR YRXMP XLI Double Deck Valve
HMEQIXVEPGPIEVERGI[EWFIPS[MRQQ %X
QMPQMRMQYQ½PQXLMGORIWWXLITVIHMGXIHTEHXIQ- The efficient and reliable modular design
TIVEXYVI[EW*' WSSTIVEXMSR[MXLGPIEVERG- of StraightFlo™ valves is now available as
IWFIPS[MRQQ WLSYPHFIEZSMHIH%P-
XLSYKLXLINSYVREPWTIIH[EWEFMXIPIZEXIHXLIPSEH[EW a drop in replacement for poppet valves
ZIV] PS[ [LMGL VIWYPXIH MR KSSH FIEVMRK TIVJSVQERGI
%PWSXLIVIMWEPSXSJMRXIVREPLMWXSV][MXLXLMWFIEVMRK in Pipeline applications.
HIWMKRMRWMQMPEVETTPMGEXMSRW&EWIHSRXLMWXLIFIEVMRK
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19RM-
ZIVWMX]8YVFSQEGLMRIV]0EF
WWW.ZAHROOFVALVES.COM
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A GUIDE TO MACHINERY
FOUNDATIONS
REPAIRING CRACKS IN EPOXY GROUTS
&=',%60-)63;%2%2(&3&63;%2
C racks in epoxy grouts used in machine foundations are the re-

sult of stress that develops in the grout during curing or from
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MR*MKYVI Continued on page 32
Figure 2

Optimize Your Compressor
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At HOERBIGER, service is not about just repairing our customers’ components. It’s about meeting all of
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UHOLDELOLW\HĴFLHQF\DQGHQYLURQPHQWDOVRXQGQHVVRI\RXUFRPSUHVVRU2XUKLJKO\VNLOOHGWHFKQLFLDQVDQG
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8=4)3*7)%0%28
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and application. Masking tape along both sides of the pre-
pared crack will help achieve a neat, straight sealant applica-
Figure 3 tion and aid in clean up.
%08)62%8):)68-'%0'6%'/6)4%-61)8,3(
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point, such as an anchor bolt, a square corner, or jackscrew 8LI EJSVIQIRXMSRIH QIXLSH [SVOW [IPP TEVXMGYPEVP]
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IV ¾YMH JVSQ TIRIXVEXMRK XLI KVSYX ERH GSRXEQMREXMRK XLI sion joints. Often, though, particularly when a foundation
concrete below. With this precaution, cracks outside the MWMRWMHIEFYMPHMRKWLEHIHJVSQXLIWYRERHRSXWYFNIGXXS
QEGLMRISVWSPITPEXIQE]RSXEJJIGXXLIEFMPMX]SJXLIKVSYX I\XVIQI XIQTIVEXYVI ZEVMEXMSRW ER ITS\] MRNIGXMSR KVSYX
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below the grout, in the concrete. While not considered as ZMFVEXMSRW WIXXPIQIRX IXG XS XLI VITEMVIH ITS\] KVSYX
serious as vertical cracks, they nevertheless cause concern ERSXLIVGVEGOEHNEGIRXXSXLI½VWX[MPPPMOIP]VIWYPX
since they give the appearance that the whole grout cap has Vee or rout out the top of the crack or leave it unchipped
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,3;836)4%-6:)68-'%0'6%'/7 with a putty knife before it hardens. Masking tape applied
Good results in providing an oil-tight seal in cracks in the EPSRKXLIGVEGOELIEHSJXMQIGEREPWSLIPTMRGPIERYT
grout shoulder have been obtained by veeing out the crack, -J WIEPMRK ZIVXMGEP GVEGOW MW MR GSRRIGXMSR [MXL ER IHKI
MR[MHIJVSQXLIWLSYPHIVIHKIXSXLIQEGLMRIJVEQI PMJXMRKVITEMVXLIRXLIITS\]PMUYMHVITEMVSVMRNIGXMSRKVSYX
8LMWZIIPSGEXIHEXXLIXSTSJXLIGVEGOMWXLIR½PPIH[MXL can be forced into the vertical cracks through drilled holes
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-J XLIVI MW [EXIV MR XLI GVEGOW HV]MRK GER FI LEWXIRIH appear as wavy lines near or at the grout/concrete inter-
by pouring a fast-evaporating solvent such as acetone or face. Quite often, this type of crack will be present if there
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potentially hazardous so follow good, safe application prac- TSWI WMRGI XLIVI EVI RS IUYMTQIRX PSEHW XLIVI -R WYGL
XMGIW ERH XLI QERYJEGXYVIV´W MRWXVYGXMSRW 8LI GVEGOW SV cases, besides seeing the wavy lines on the vertical side,
ER]EVIEXSFIKVSYXIHQYWXFIHV]JSVXLVIIXS½ZIHE]W EGXYEP HMWFSRHQIRX SJ XLI KVSYX GET [MPP FI RSXMGIH

either visually or by tapping. As you the life of the grout and the machinery tential for cracking, than a grout that
get closer to the equipment base, it supports. When it comes to preci- MWXSS¾I\MFPI'VEGOWGERFIVITEMVIH
the grout bond will be intact since sion machinery grouting, it is best to but a grout that compresses under
grout held in compression by the have a more rigid grout that has better load to the point where alignment is
weight of the equipment and proper support properties, even with the po- lost will have to be replaced.
preload of the anchor bolts usu-
ally will not disbond. Disbondment
of the grout shoulder is sometimes ABOUT THE AUTHORS
more pronounced in the vicinity of a Charlie Rowan is president and CEO of Robt. L. Rowan & Assoc. He has
vertical crack, even if the shoulder is more than 30 years of experience in rotating and reciprocating machinery
more narrow than 6 in. JSYRHEXMSR HIWMKR ERH VITEMV GLIQMGEP GSEXMRK WTIGM½GEXMSRW ERH MRWXEPPE-
Preventing edgelifting is easier than tions, concrete repair and applications, and technical support for multina-
repairing it. When forming for the tional oil and gas foundation repairs. He has developed and patented numer-
grout pour, install expansion joints ev- ous mounting systems for compressors and turbines.
ery 3 to 4 ft. and limit the width of the Bob Rowan is a professional engineer with over 50 years of experience
grout shoulder. repairing large concrete structures and heavy machinery foundations, in-
cluding the precision grouting of turbomachinery trains, gas compressors,
HOW TO REPAIR electric generators, and mining equipment. Along with his father, Robert
EDGELIFTING CRACKS 6S[ER7V&SF6S[ERHIZIPSTIHXLI½VWXITS\]QEGLMRIV]KVSYX[LMGL
-JXLIIHKIPMJXMRKMWSRP]E½RI[EZ] later became Ceilcote grout.
line without severe disbondment or Headquartered in Houston, Robt L. Rowan & Assoc. specializes in repair
movement, sealing the vertical cracks designs and anchoring materials for large equipment foundations such as
and doing nothing about the horizon- reciprocating compressors, pumps, fans, blowers, mills, crushers, and skid-
tal cracks on the sides of the founda- mounted equipment.
tion is acceptable.
If disbondment is severe, the best
cure is to remove the disbonded sec-
tion and repour that area. A vertical
saw cut with a masonry blade is used VANEC Industrial Silencers
XS HI½RI XLI FEH EVIE ERH EWWMWX MR Engineering And Manufacturing Industrial Silencers
removing the loose cap. Repouring Since 1969.
the area will result in a sound cap. In
some cases, an expansion joint could
even be added at the saw cut as fur-
ther insurance or to break up a long
run, which should have had expansion
NSMRXWMRXLI½VWXTPEGI
A second method is to vertically
drill 3/8- to 1/2-in. holes with ma-
sonry drills through the loose grout
cap and force an epoxy injection grout
SVYR½PPIHKVSYXPMUYMHQM\XYVI MRXS
the separation. A grease gun with a
rubber lab bottle stopper is used to More Than 150 Years Combined Experience In Solving Noise And Emissions Control Problems
½X MRXS XLI HVMPPIH LSPI SV E GSTTIV
tubing standpipe with a funnel is used.
The holes can be on 12- to 14-in. ABSORBTIVE TYPE SILENCERS / CATALYST EXHAUST SILENCERS / CENTRIFICAL COMPRESSOR
XSQQ GIRXIVW%W]SY SILCENCERS / ENGINE SILENCERS / GAS TURBINE EXHAUST SILENCERS / INTAKE FILTER SILENCERS /
approach the edge, look for a show of
the epoxy liquid at the wavy line hori- RECIPROCATING COMPRESSOR SILENCERS / ROTARY POSITIVE BLOWER SILENCERS /
zontal crack. Use “duct seal” or tape VACUUM PUMP SEPERATOR-SILENCERS / VENT & BLOWDOWN SILENCERS
to retain the epoxy liquid until it sets.
All of the abovementioned meth- (716) 827-4959 / [email protected] / WWW.VANEC.COM
ods for repairing both vertical and Contact your Local Representative:
horizontal cracks have been used for (832) 314-8255 / [email protected]
years. The results have been good,
Our dedicated, wholly owned, primary manufacturing facility is located in Gainesville, TX
oil-tight repairs that have extended

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S cania Argentina, a South American branch of one of Swe-
den’s largest commercial vehicle and engine manufacturers,
LEWPEYRGLIHMXW+VIIR)J½GMIRG]PMRI8LI+VIIR)J½GMIRG]
SJVIRI[EFPIHMIWIPMRMXW)YVSIRKMRIPMRIMRRSXMRK
that use of renewable diesel can result in a 90% reduction in
line is a concept that applies to the entire Scania product carbon dioxide (CO 2 IQMWWMSRW YRHIV STXMQEP GSRHMXMSRW
TPEXJSVQJSVYVFERWYFYVFERERHPSRKHMWXERGIXVERWTSVX-X 7GERMEMWGYVVIRXP]SRMXWXLMVHKIRIVEXMSRSJ)YVSIRKMRIW
includes three solutions — compressed natural gas (CNG), EPP SJ [LMGL YWI WIPIGXMZI GEXEP]XMG VIHYGXMSR 7'6 JSV I\-
PMUYI½IHREXYVEPKEW02+ ERHFMSKEW°XLEXGERFIYWIHXS LEYWX EJXIVXVIEXQIRX 8LI IZSPYXMSR SJ 7GERME KEW IRKMRIW
TS[IVXVYGOWFYWIWERHIRKMRIW ERHFMSKEWTVSHYGIHYRHIVXLI)YVSWXERHEVHQEREKIH
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BACKGROUND -R7GERMEMRXVSHYGIHERI[XVYGOPMRIXLEXGSRWYQIWSR
7GERMELEWFIIRHIZIPSTMRKMXWEPXIVREXMZIIRIVK]ERHVI- EZIVEKI PIWWHMIWIPJYIP-X[EWXLIVIWYPXSJ]IEVWSJVI-
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( [MXLERIWXMQEXIHGSWXSJ97
IXLERSPJYIPIHXVYGOPMRIMRXLIW8SHE]XLIGSQTER] FMPPMSR%XXLIXMQIMX[EWXLIGSQTER]´WFMKKIWXMRZIWXQIRXMR
boasts the largest portfolio of alternative engines on the MXW]IEVLMWXSV]8LIXVYGOPMRIJIEXYVIWERI[GEFXIGLRSPS-
QEVOIX [LMGL GER VYR SR JYIPW WYGL EW PMUYI½IH SV GSQ- gies, services, insights, and an “ingenious toolbox of sustainable
TVIWWIH FMSKEW IXLERSP ERH QSVI %GGSVHMRK XS XLI GSQ- solutions in the form of products and services in which Scania is
TER]EPPSJMXW)YVSERH)YVSIRKMRIWGERVYRSRL]HVS- ½VWXMRXLIMRHYWXV]XSHIPMZIV°ERH-JIIP-GERGPEMQXLMW[MXL
KIREXIH ZIKIXEFPI SMP ERH RIEVP] EPP SJ MXW ZILMGPIW GER VYR GSR½HIRGI²WEMH7GERME')3,IRVMO,IRVMOWWSR

GREEN EFFICIENCY
SCANIA ARGENTINA’S GREEN EFFICIENCY
LINE MARKS THE COMPANY’S LATEST
DEVELOPMENT TOWARD ACHIEVING
FOSSIL-FREE COMMERCIAL TRANSPORT BY 2050
EMISSION REDUCTION GOALS

Scania has announced two major goals to reduce emis-
sions, a short-term goal for 2025 and a long-term goal for
2050. By 2025, the company expects to cut CO 2 emissions
from its operations by 50% and from its products by 20%
compared to 2015. Scania acknowledges that, in order to
meet the targets of the Paris Agreement, it will need to
GSQTPIXIP]HIGEVFSRMÎMXWIRXMVIGSQQIVGMEPXVYGOMRK¾IIX
by 2050, meaning phasing out the use of fossil fuels. “We are
seeing a rapid development in which many customers are
focusing all their attention on reducing CO2 emissions,” says
Magnus Höglund, director of sustainable transport at Scania
Trucks. “Development toward sustainable transportation
is now being driven by a number of factors, with greater
awareness of climate challenges being perhaps the single big-
gest driving force.”
Scania presents the cab Scania’s aggressive goals and adherence to the Paris Agree-
of its LNG-fueled truck ment are based on the Pathways Study. Released in May 2018
at ExpoAgro 2020. and initiated by Scania, the Pathways Study details the ways
in which the company could achieve fossil-free commercial
transport by 2050. The study notes that “achieving a fossil-
free commercial transport system in the timeframe of the
4EVMW%KVIIQIRXXEVKIXMWRSXSRP]TSWWMFPIFYXEPWS½RER-
cially attractive from a societal perspective. This is the key
conclusion of the Pathways Study initiated by Scania.” The
study goes on to note that “CO2 emissions can be reduced
by over 20% simply by optimizing transport systems, for
example, through improved routing and better load man-
agement. Moreover, there are several fuel and powertrain
“CO emissions can
2 pathways to a fossil-free future. Biofuels offer the highest
CO 2IQMWWMSRWVIHYGXMSRTEXL[E]ERHIPIGXVM½GEXMSRMWXLI
be reduced by over 20%
most cost-effective solution. Other technologies, such as hy-
simply by optimizing drogen fuel cells and e-highways, have important use cases
to consider and may be critical for select geographies and
transport systems.
” applications. To reach this goal, the industry must begin to
change rapidly and immediately. New technologies can take
a long time to achieve wide adoption as the existing stock
of vehicles turns over slowly. This means that for 2050 to
be fossil-free, changes at scale are required already by 2025,
including not just new technologies but also new infrastruc-
ture, behaviors, and partnerships.”

A closer look at
the fuel tank of
Scania’s CNG-
fueled truck
from its Green
)J½GMIRG]PMRI
INTRODUCING THE GREEN

EFFICIENCY LINE
0EYRGLIHMRXLI+VIIR)J½GMIR-
cy line is the next step for Scania to-
ward achieving its 2025 and 2050 goals.
7YWXEMREFMPMX] ERH TVS½XEFMPMX] EVI XLI
key drivers for developing the new line.
From a sustainability standpoint, Sca-
nia’s new natural gas and biogas engines
result in 50% less fuel consumption
compared to the company’s already
low-diesel Euro 6-compliant version.
According to Scania, 12% of the green-
house effect is caused by commercial
transportation. Natural gas, although
derived from oil, pollutes 20% less than
diesel, resulting in lower emissions.
Biogas is even better, polluting 90% less
than diesel engines. Better yet, natural
gas has greater availability across the
world, allowing for lower costs and a
broader reach for Scania’s vehicles. A
cleaner operation, easier maintenance,
a better quality of life for users and citi- compared to diesel, is 40% cheaper. This is mostly due to the sheer size and scale
zens, and a reduction of gaseous and of natural gas-related infrastructure projects. Scania believes that oil and coal are
noise emissions are some of the other on the way out, and gas and renewables are on the way in. However, Scania has
key reasons why Scania chose natural HIXIVQMRIHXLEX[MHIWTVIEHIPIGXVM½GEXMSRMWRSXEZMEFPISTXMSRMRXLIWLSVXXIVQ
gas as the alternative energy fuel of due to the following reasons:
GLSMGI JSV XLI +VIIR )J½GMIRG] PMRI • It requires high investment.
The company notes that passenger bus- • Batteries have a short useful life.
es that run on gas in the form of CNG, • There aren’t enough ways to recharge vehicles.
LNG, or biogas offer a very low noise • Autonomy is still in its infancy.
level compared to diesel, equivalent to • There isn’t enough infrastructure, especially compared to gas.
standing 328 feet (100 m) away from a • There has yet to be a viable system to recycle batteries.
diesel-powered bus. Alternatively, Scania sees a 1.6% annual increase in global gas consumption
*VSQ E TVS½XEFMPMX] WXERHTSMRX XLI SZIV XLI RI\X ½ZI ]IEVW SJ [LMGL [MPP FI HVMZIR F] XLI 9RMXIH 7XEXIW
cost of operating Scania’s CNG buses, China, and the Middle East.

LOWER YOUR TOTAL
COST OF OWNERSHIP
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Waukesha Magnetic Bearings introduces

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For more than 30 years, Waukesha has
a
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provided life-cycle cost savings
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eliminating auxiliary equipment,
ent, lowering energy consumption,
minimizing maintenance, and d maximizing reliability.
Our Automated Commissioningi ffunction

ti and
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Now, our continued technological advances are increasing the scalability

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Waukesha Magnetic Bearings is a proud part of Dover Precision Components

LATIN AMERICA’S CNG OPPORTUNITY
7GERME %VKIRXMRE´W +VIIR )J½GMIRG] PMRI MW PIERMRK MRXS 0EXMR
%QIVMGE´W HIRWI RIX[SVO SJ KEW TVSHYGXMSR ERH MQTSVXW 0EXMR
%QIVMGEERHXLI'EVMFFIERTVSHYGIETTVS\MQEXIP]FGJH
\6 m3H SJREXYVEPKEWVITVIWIRXMRK SJKPSFEPTVSHYGXMSR
8LIGSRXMRIRXGSRWYQIWEFSYXFGJH\6 m3H ERHLEW
MXWHI½GMXGSZIVIHF]1I\MGERMQTSVXWJVSQXLI9RMXIH7XEXIWZME
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-RXLIVIKMSR&VE^MP1I\MGSERH%VKIRXMREEVIGEXIKSVMÎHEW
PEVKITVSHYGIVWERHMQTSVXIVWSJREXYVEPKEWFYXXLI][MPPPMOIP]
GSRXMRYIXSHITIRHSRMQTSVXWMRXLIGSQMRK]IEVWXSQIIXHS-
QIWXMGHIQERH
8LIVIEVIWIZIVEPQENSVREXYVEPKEWTVSNIGXWMRHIZIPSTQIRXMR
Lucas Woinilowicz, Business Development Manager At 0EXMR%QIVMGE2SXEFPITVSNIGXWYRHIVHIZIPSTQIRXMRXLIVIKMSR
Scania Argentina, In Front Of A Scania Truck EVIXLI+2)%XLI+EWSHYGXS7YV4IVYERS+74 XLIMRHYWXVMEP-
MÊXMSRSJREXYVEPKEWMR&SPMZMEXLIMRGVIEWISJVIKEWM½GEXMSRGETEG-
MX]MR'LMPIERH'SPSQFMEERHXLIHIZIPSTQIRXSJ:EGE1YIVXE
ARGENTINA: THE PIONEER OF CNG
-2*6%7869'896)%2(():)0341)28
8LIVI EVI QER] VIEWSRW [L] 7GERME %VKIRXMRE A bus hooks up to a CNG fueling station. Argentina, as a
GSYRXV]LEWSRISJXLIPEVKIWX'2+¾IIXWMRXLI[SVPH[MXL
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800.TRY.CECO
What Went Wrong? CASE No 2
BY W. NORM SHADE After decades of successful
compressor operation, what caused
a serious piston rod failure?
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
XLI VIEHIVW -R IEGL GEWI E JEMPYVI SV
Figure 1. The piston rod fail-
incident is described and the question is
ure occurred in one of two
asked, “What went wrong?²-RIEGLGEWI 600-rpm, 7-in.- (178-mm-)
the answer (or at least the best specula- stroke, 2-throw vee-type
tion) and the solution that was applied compressors that had oper-
to the problem will be explained. ated reliably for more than
two decades.
B roken piston rods are not unheard of in reciprocating com-

pressors. By design, they tend to be the weakest link in most
compressor throws. Such failures usually can be traced to extenu-
Maintenance records showed that experienced person-
nel had completed the rod replacement and that all the
boxes were checked verifying proper torque and run-out
ating circumstances such as improper assembly, misalignment of checks. A review of the procurement records showed that
the compressor cylinder with the frame, liquid ingestion into the QEXIVMEP GIVXM½GEXMSRW LEH FIIR TVSZMHIH F] XLI WYTTPMIV
cylinder, or operation outside rated conditions. However, the fail- MRHMGEXMRK XLEX XLI VSH QEXIVMEP [EW %-7- EPPS] WXIIP
YVISJETMWXSRVSHMRXLI½VWXWXEKISJERSRPYFIGEVFSRHMS\MHI 8LI GSQTER]´W QEMRXIRERGI IRKMRIIV EPWS WIRX XLI JEMPIH
(CO2) compressor in a processing facility operated by a multi- piston rod and piston to an outside lab for examination and
REXMSREPJSSHTVSHYGXWGSQTER]FEJ¾IHXLIGSQTER]´WQEREKI- XIWXMRK8LIPEF´WVITSVXGSRGPYHIHXLEXXLIVSHJEMPIH½VWX
ment and maintenance staff. The failure occurred in one of two but it could not identify any obvious defects at the point of
600-rpm, 7-in.- (178-mm-) stroke, 2-throw vee-type compressors failure (the fracture surface was beaten up after the failure).
(Figure 1) that had operated reliably for more than two decades. 8LIPEF´WQIXEPPYVKMGEPEREP]WMWGSRGPYHIHXLEXXLIQEXIVMEP
%PXLSYKLSRP]SRISJXLIGSQTVIWWSVW[EWRIIHIHJSVXLITPERX´W [EWGSRWMWXIRX[MXL%-7-EWMRHMGEXIHMRXLIQEXIVMEP
operation, the failure caused the plant to have no backup or cov- GIVXM½GEXMSRW ERH XLIMV XIRWMPI XIWX SJ E WTIGMQIR XEOIR
erage for downtime required for routine maintenance. Moreover, from another part of the rod showed an ultimate tensile
XLIGSQTER]´WQEREKIQIRX[EWGSRGIVRIHXLEXXLIGSQTVIWWSVW strength of 116,800 psi (80,530 bar), also consistent with
were worn out and nearing the end of their useful life. heat-treated 4140.
The 1.625-in.- (41.3-mm-) diameter piston rod was threaded This left the end user wondering, “What went wrong?” Un-
into the crosshead and locked with a hex-shaped crosshead nut WEXMW½IH[MXLXLIPEGOSJEHI½RMXMZII\TPEREXMSRSJXLIJEMPYVI
to prevent loosening, similar to the sketch in Figure 2. The pis- the plant management sought a further expert assessment.
XSRVSHJEMPIHEXXLI½VWXXLVIEHFI]SRHXLIGVSWWLIEHRYX%W This review included modeling the compressor performance
shown in Figure 3, which is the end of the broken rod removed and comparing the calculated rod loads with the nameplate
from the crosshead, the fracture face was beaten up by con- rating. Although the rod load was approximately 88% of the
tact with the other piece of broken rod before the compressor GSQTVIWWSV´W REQITPEXI VEXMRK XLMW VIZMI[ MRMXMEPP] SJJIVIH
stopped. Unfortunately, the broken rod also led to a broken no better explanation of the failure. However, concerned
8-in.- (203-mm-) diameter piston and scoring of the cylinder the metallurgical lab could not tell much about the material
bore. Since the compressor cylinders were non-lube, piston condition at the point of the failure, the lab was requested to
rods were routinely replaced at least once a year as part of the carefully examine a section of the threaded area immediately
TPERX´WTVIZIRXMZIQEMRXIRERGITVSKVEQ-RXLMWGEWIXLIJEMPIH adjacent to the failure. This investigation revealed the smok-
rod had been replaced only 10 days earlier. ing gun and answered the question, “What went wrong?”!

Figure 2. The 1.625-in.- (41.3-mm-) diameter piston
rod was threaded into the crosshead and locked
with a hex-shaped crosshead nut to prevent loos-
ening, similar to this sketch. The piston rod failed at
XLI½VWXXLVIEHFI]SRHXLIGVSWWLIEHRYX
A microscopic examination of the threads showed that the *MKYVI 8LMW MW XLI IRH SJ XLI FVSOIR
QEXIVMEPKVEMR¾S[[EWMRXIVVYTXIHF]XLIXLVIEHWGSRWMWXIRX rod removed from the crosshead, show-
with machine cut threads. Piston rods, which are among the MRKXLEXXLIJVEGXYVIJEGI[EWFIEXIRYT
most highly stressed components in a reciprocating compres- F]GSRXEGX[MXLXLISXLIVTMIGISJFVS-
sor, must be designed so they can operate without failure under OIRVSHFIJSVIXLIGSQTVIWWSVWXSTTIH
cyclic fatigue and buckling modes when the rods are subjected
to anticipated loads. The loads on piston rods result from the
superposition of the gas pressures acting on both sides of the The stresses produced by the alternating tensile and com-
piston and from the inertia loads that result from the accelera- pressive loads in the piston rod with each stroke are exacer-
tion and deceleration of the mass of the piston and rod assem- bated by any bending caused by misalignment or inadequate
bly. The combined net load varies with every degree of rotation preload on the threaded attachments to the crosshead and
of the compressor crankshaft. There are both alternating ten- piston. Therefore, piston rods are susceptible to fatigue fail-
sile and compressive rod loads (Figure 4). Every reciprocating ure, and modern reciprocating compressors almost always re-
compressor has a rated tensile and a rated compressive rod quire rolled threads, instead of cut threads on piston rods. In
load, which should not be exceeded during operation. Continued on page 42

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Compressor designers evaluate the an existing rod and produce a sketch
fatigue margin of piston rods by cal- of the geometric features. The new
culating the operating stresses over maintenance engineer approved the
the full compression cycle. Then, tak- drawing after adding a material speci-
ing the maximum and minimum stress ½GEXMSR JSV %-7- ERH E VIUYMVI-
extremes, a factor of safety can be ment for hardening the rod in the
calculated. The safety factor calcula- packing area. The sketch also speci-
tion includes a stress concentration ½IH XLI XLVIEH HMEQIXIV TMXGL ERH
factor applied to the alternating, or length, but it lacked any instructions
cyclic, stress in the rod. Higher stress for thread rolling, something of which
concentration factors result in lower neither the maintenance staff nor the
Figure 4. The loads on piston rods result from
the superposition of the gas pressures acting
safety factors, meaning less margin engineer had knowledge. The new
on both sides of the piston and from the iner- from fatigue failure. Generally ac- consolidated supplier used the sketch
tia loads that result from the acceleration and cepted stress concentration factors XS ½RH E PS[GSWX WSYVGI JSV TMWXSR
deceleration of the mass of the piston and rod for cut threads are approximately rods. Many shops have the lathes and
assembly. The combined net load varies with 32% higher than for rolled threads grinders needed for manufacturing
every degree of rotation of the compressor of the same diameter and pitch. This piston rods, but very few have facili-
crankshaft to produce both alternating tensile can be interpreted to mean that ties for rolling threads. Most lathes
and compressive rod loads. rolled threads are 32% less likely to can be programmed or set up to cut
fail from fatigue than the same size threads, so shops inexperienced in
threads formed by machine cutting. the duty required for piston rods can
8LMWMWEZIV]WMKRM½GERXHMJJIVIRGI produce a nice-looking product with-
fact, API 618, 5th Edition, requires that 7SJSVXLIGEWIHIWGVMFIHLIVI[MXL out rolling the threads. The smok-
piston rods have rolled threads with a the compressor throw operating near ing gun, however, is the loss of the
polished thread relief area. the rated rod load limit, and observing fatigue resistance provided by rolled
*MKYVI WLS[W XLI WMKRM½GERX HMJ- that this vee-type compressor is gen- threads. Eventually, all the original
JIVIRGIW MR XLI KVEMR ¾S[ TVSHYGIH erally a lighter-duty design than most rolled thread rods were consumed
by thread cutting and thread rolling horizontally opposed compressors, it JVSQ MRZIRXSV] ERH XLI ½VWX SJ XLI
processes. The lower image, which is is apparent that the 32% higher fatigue cut thread rods was installed with the
the result of the machine cutting the margin of rolled threads was a critical
threads, shows that the inherent grain factor that led to the rapid failure of
¾S[ SJ XLI VE[ QEXIVMEP MW MRXIVVYTX- the piston rod.
ed by each thread. The upper image 9TSRPIEVRMRKEFSYXXLIWI½RHMRKW
WLS[W XLI KVEMR ¾S[ JVSQ XLI XLVIEH the plant maintenance personnel felt
rolling process. Unlike thread cutting, vindicated and shared some inside
which severs the grain structure in the information that explained how they
steel, thread rolling reforms the grain ended up with piston rods with cut
structure in a continuous line along the threads. The plant’s highly experi-
thread form (Figure 6). Historic testing enced maintenance engineer had
has proven that thread rolling improves retired three years earlier, and the
fatigue resistance (Figure 7), which is a replacement he had groomed soon
plot of threaded stud fatigue research moved on to another division. Dur-
conducted well over half a century ing a period when a second replace-
ago. Rolled threads also have increased ment was still coming up to speed,
resistance to stripping under heavy the sourcing department implement-
stresses as the material is “closed-up” ed a program to consolidate the
from work hardening along the root, plant’s suppliers. This resulted in the
¾EROWERHGVIWX6SPPIHXLVIEHWGSQ- sourcing of compressor components
pel failures to take place across the from a large distribution company
KVEMR ¾S[ VEXLIV XLER [MXL XLI KVEMR that sold everything from conveyor
¾S[ MR [IEOIV GYX XLVIEHW 8LI VSPP- FIPXWXSTVIWWYVIW[MXGLIW7MRGITMW-
Figure 5. Unlike thread cutting, which
ing process also results in “burnished” ton rods from the original compres-
severs the grain structure in the steel as
VSSXWERH¾EROW[MXLEGSRWMWXIRXWYV- sor manufacturer were expensive, shown in the lower image, thread rolling
JEGI½RMWL7YVJEGIMQTIVJIGXMSRWJVSQ especially when ordered through a reforms the grain structure in a continu-
thread cutting can become the starting distributor, sourcing requested the ous line along the thread form (upper).
points for fatigue failure. maintenance department measure

Stress At Minor Thread Area, psi
Machine Cut Screw Threads
Cold Rolled Screw Threads
Cycles To Failure
Figure 6. This micrograph shows the continuous grain structure Figure 7. Historic testing has proven that thread rolling improves
reformed by thread rolling. Image Source: SPS Technologies fatigue resistance.
result explained at the beginning of this story. Fortunately, piston rods having cut threads. Second, reverse engineering
the maintenance engineer added a requirement for rolled of compressor components should only be done by expe-
threads on the drawing, and subsequent replacement rods rienced compressor engineers, because there are usually
experienced no similar failures. important material and processing requirements that may
Several lessons can be learned from this experience. not be evident by simply measuring the geometry and sur-
First, in all but very light-duty applications, rolled threads face hardness of the component. This is a trap that can
are a paramount requirement for reciprocating compres- be tripped when replacement piston rods and other com-
sor piston rods and other threaded components that expe- ponents are manufactured by suppliers who lack the en-
VMIRGI G]GPMG PSEHMRK 2SXEFP] XLMW WTIGM½G MRGMHIRX MW FYX gineering design skills and experience to fully assess the
one of several failures the author has encountered with application requirements.
Experience, Reliability, Integrity

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INDEX OF ADVERTISERS
FEBRUARY
Ariel Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 GEA Systems North America LLC . . . . . . . . . . . . . . . . . 15
AXH Air-Coolers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 HOERBIGER Compression Technology . . . . . . . . . . 11, 31
Blue Industrial Partners, LLC . . . . . . . . . . . . . . . . . . . . . . 33 KB Delta

Compressor Valve Parts, Mfg. . . . . 1, 24 - 25, Third Cover
Burckhardt Compression. . . . . . . . . . . . . . . . . . . . . . . . . . 3
NEUMAN & ESSER GROUP . . . . . . . . . . . . . . . . . . 18 - 19
CECO Compressor Engineering Corp. . . . . . . . . . . . . . 39
Red Fox Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Compressor Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Robt. L. Rowan & Assocs., Inc. . . . . . . . . . . . Second Cover
Cook Compression . . . . . . . . . . . . . . . . . . . . Fourth Cover
Samco Enterprises, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . 41
CPI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Waukesha Magnetic Bearings. . . . . . . . . . . . . . . . . . . . . . 37
Elliott Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Zahroof Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
To advertise in Gas Compression Magazine, contact Sarah Gonzalez at

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EQUI PMENT & TECHNOLOGY 2
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HAIGHT
REPORT BRENT HAIGHT, PUBLISHER
[email protected]
THE RISE OF RENEWABLE

NATURAL GAS
8LI PERH½PP TVSNIGXW EVI FIMRK YWIH QSWXP] JSV FMSKEW
A report commissioned by the US Department of Energy’s
Argonne National Laboratory shows the promise of re-
newable natural gas (RNG) and its growing presence in the
production, but increasingly to produce RNG. The EPA esti-
mates another 478 candidate projects could be used for bio-
green energy landscape. KEWSV62+1SWXPERH½PPTVSNIGXWEVIJSYRHXSFIIGSRSQMGEP
The joint assessment, released by Argonne National Lab- at US$10/MMBtu or less.
oratory and NGO Energy Vision, an independent research As US energy companies look to diversify, RNG is gaining trac-
organization, consists of a database of current and projected tion. California is leading the charge. As of December 31, 2020,
RNG projects. The assessment reveals rapid growth in RNG XLI +SPHIR 7XEXI LEH 62+WTIGM½G TVSNIGXW MR STIVEXMSR
capacity and production nationwide. It found that the total (Rounding out the top three states are Wisconsin with 17 RNG
number of RNG production facilities in the United States that projects in operation and Texas with 15.) Southern California
are operational, under construction, or planned increased by Gas Co. (SoCal Gas) announced an agreement between SoCal
42% — from 219 in early 2019 to 312 by the end of 2020. That Gas, the San Diego Gas & Electric Company, consumer advocate
includes 157 RNG production facilities now operating (up 78% groups, and industry groups to bring increased volumes of RNG
from 2019); 76 projects under construction (up 100%); and 79 to California customers. The program will be made available to
projects in planning stages. both residential and nonresidential customers, with the latter
The 157 operational projects now producing RNG repre- having a purchase percentage option to choose how much of
sent a total production capacity of over 59 million MMBtu their natural gas is RNG, ranging from 25% to 100%.
— a 30% increase in production capacity since 2019. And with SoCal Gas, serving 21.8 million people in more than 500
155 new RNG projects under construction or being planned, communities, is the nation’s largest natural gas distribution
rapid capacity growth should continue in the years ahead. utility. A study commissioned by SoCal Gas found that by re-
Potential domestic RNG production is estimated to be be- placing 16% of California’s natural gas supply with RNG would
tween 10 and 20 times greater than actual current produc- cut GHG emissions as much as converting all buildings to
XMSR6IEGLMRKXLEXTSXIRXMEP[SYPHLEZIEWMKRM½GERXMQTEGX electric-only energy by 2030.
on overall US greenhouse gas (GHG) emissions. California passed legislation in 2018 that requires regulators to
The main source of RNG — also known as biomethane, consider adopting a renewable gas mandate. If implemented by
biogas, or renewable methane — is the decomposition of or- the state utility commission, gas utilities would have to buy 32 Bcf
KERMGQEXIVMEPWMRPERH½PPWWI[EKIXVIEXQIRXTPERXWERHFMS- (906.1 x 106 m3 SJ62+F]XLI½VWXWYGLQERHEXIMRXLI
digesters. As organic material breaks down without oxygen, United States. In addition, the California Public Utility Commis-
it produces methane. sion is pursuing multiple rulemaking phases to increase renew-
62+GEREPWSFIGVIEXIHJVSQKEWM½GEXMSR[LIVIFMSQEWW able gas, serving the state’s energy needs and reducing methane
is heated under pressure until it gives off volatile gases. In emissions. Legislation from 2018 (SB 1440) calls for renewable
addition, methane can be created by using electricity to split gas procurement targets for utilities. The bill primarily focuses
hydrogen away from water and combine it with carbon. on biomethane, but renewable hydrogen blending is an option
8LI TSXIRXMEP 62+ JVSQ EPP 97 PERH½PPW I\GIIHW &GJH under the umbrella of “renewable gas.” It is estimated that Cali-
(28.3 x 106 m3/d) of gas equivalent, according to the US En- fornia has upward of ~250 MMcfd (~7.07 x 106 m3/d) in RNG,
vironmental Protection Agency (EPA) — assuming all land- which has been deemed as technically producible.
½PPWRSXGYVVIRXP]FIMRKYWIHXSTVSHYGI62+EVIIZIRXYEPP] Final compression of the RNG depends on how the gas will
brought online to capture and upgrade biogas into RNG. This be used, for example, CNG for vehicles, transported via tank-
makes up two-thirds of the total estimated US RNG potential. er, or pipeline injection. Regardless, as RNG usage increases,
&EWIHSRXLI)4%´WI\MWXMRKPERH½PPQIXLERISYXVIEGLTVS- so does opportunity for companies operating within the gas
KVEQPERH½PPTVSNIGXW[IVIMRSTIVEXMSREWSJ(IGIQFIV compression industry.

Precision Performance
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The World Turns to Elliott.

C O M P R E S S O R S | T U R B I N E S | C R Y O D Y N A M I C S® | G L O B A L S E R V I C E
@GasCompressionM @GasCompressionMagazine
FAVORITE TWEETS INSTAGRAM
L A G N I A P P E
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VIRTUAL WEBINARS
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PERMIAN HIGHWAY PIPELINE Electric Partnership’s latest
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Recently, Kinder Morgan was pleased to
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Blanco, Texas, an organization that provides #kindermorgan
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LAUGHING MATTERS
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Watch the video at cookcompression.com/rdv
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Also In This Issue: 2020 US COMPRESSOR STARTUP REPORT

ROWAN REPAIR SOLUTIONS SOLVE:

Your wallet can.

LNG Race Report No. 5: United States . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Proactive Natural Gas Screw Compressor Monitoring

Publisher 2020 US Compressor Startup Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Editor, Latin America

Digital Content Manager

Evil Genius, Media & Digital Marketing FEBRUARY CONTRIBUTORS:

USA NEW ZEALAND

40K 2,285% 16,000 FROM TO

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CATERPILLAR SIGNS AGREEMENT

WEIR OIL AND GAS: TRANSITION COMPLETE

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BRING WORN OUT CYLINDERS BACK TO LIFE …

WITH OUR STATE-OF-THE-ART

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E arly astronomers used their astronomical obser-

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Golden Pass (Texas) 15.60 Export 2024

Delfin FLNG (Louisiana) 6.67 Export 2023

Texas LNG (Texas) 2.00 Export 2023

Andeavor Onshore 1 105,000 Andeavor

Exelon Generation Onshore 0 154,000 Exelon Generation

Dominion Energy Onshore 0 695,000 Dominion Energy

Southern LNG Onshore 0 550,000 Southern LNG

Energy Transfer Equity Onshore 0 425,000 Energy Transfer Equity

Excelerate Energy Offshore 0 0 Excelerate Energy

Sabine Pass LNG Onshore 0 800,000 Cheniere Energy

Cameron LNG Onshore 0 480,000 Sempra Energy

Golden Pass LNG Onshore 0 800,000 ExxonMobil, Qatar Petroleum

Sabine Pass Liquefaction Onshore 2 0 Cheniere Energy

Sabine Pass Liquefaction Onshore 2 0 Cheniere Energy

Dominion Energy Onshore 2 0 Dominion Energy, Brookfield Super-Core Infrastructure Partners

Sabine Pass Liquefaction Onshore 1 0 Cheniere Energy

Corpus Christi LNG Onshore 2 480,000 Cheniere Energy

Elba Liquefaction Co. Onshore 1 0 Kinder Morgan

Corpus Christi LNG Onshore 1 0 Cheniere Energy

Sabine Pass Liquefaction Onshore 1 0 Cheniere Energy

Venture Global LNG Onshore 9 400,000 Venture Global LNG

ExxonMobil Onshore 3 0 Qatar Petroleum, ExxonMobil

Delfin LNG Offshore 0 0 Delfin LNG

Driftwood LNG Onshore 20 705,000 Tellurian Investments

Gulf LNG Liquefaction Onshore 2 0 Kinder Morgan, General Electric

Magnolia LNG Onshore 4 320,000 LNG Ltd.

Venture Global LNG Onshore 20 800,000 Venture Global LNG

NextDecade Onshore 6 720,000 NextDecade

SCT&E LNG Onshore 3 360,000 SCT&E LNG

Texas LNG Brownsville LLC Onshore 1 0 Texas LNG Brownsville LLC

Fourchon LNG Onshore 4 0 Fourchon LNG

LNG 21 Offshore 0 300,000 LNG 21

SRJEXX]EGMHQIXL]PIWXIV*%1) 7GERMEETTVSZIHXLIYWI

)HMXSVMEP-W%0;%=7*6)) GAS COMPRESSION INDUSTRY

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