Insights v10.1 - Dresser-Rand | DATUM Compressors
Transcription
Insights v10.1 - Dresser-Rand | DATUM Compressors
insights A PUBLICATION OF DRESSER-RAND Editorial Statement: ® “insights” is a periodical publication of Dresser-Rand. Its editorial mission is to inform our readership in the areas of energy industries, as well as business and world affairs that have an impact on our mutual concerns. Comments, inquiries and suggestions should be directed to: Janet Ofano Communications Coordinator DRESSER-RAND insights Editorial Office Paul Clark Drive Olean, New York 14760 USA Phone: (716) 375-3000 FAX: (716) 375-3178 insights VOLUME 10, NO. 1 Featured in this issue of insights: Candid Visions: Safety – The Goal Is Zero Dresser-Rand Introduces Integrated Compression SystemTM For Onshore And Offshore Projects, Including Sub-Sea D-R Succeeds With Applied DATUM Technology For Major U.S. Refinery In Record Time © Copyright 2007 Dresser-Rand insights VOLUME 10, NO. 1 CONTENTS 1 Candid Visions: Safety – The Goal Is Zero Dresser-Rand’s Peter Taschner details the company’s commitment to safety. 4 Dresser-Rand Introduces Integrated Compression System For Onshore And Offshore Projects, Including Sub-Sea The new concept provides a complete compression system solution in a compact package. 6 Dresser-Rand Test Capabilities Prepared For Every Challenge Dresser-Rand continues to expand and enhance its global equipment test capabilities. 9 CIRS Continues To Improve Client Relations Around the World The rapid response system is designed to continually increase client satisfaction. behaviors are identified and steps are taken to eliminate those behaviors. By using behavioral auditing techniques, many unsafe behaviors that could result in injuries and accidents have been eliminated by D-R employees. 10 Dresser-Rand Keeping It Cool – And Safe D-R’s complete line of COPPUS portable ventilators helps clients keep their operations safe. 12 Engineer’s Notebook: Curtis Stage Nozzle/Rotor Aerodynamic Interaction and the Effect on Stage Performance Presented at IGTI Turbo Expo 2006 in Barcelona, Spain. 16 Dresser-Rand Succeeds With Applied DATUM® Technology For Major U.S. Refinery In Record Time Rapid upgrade solution to another OEM’s equipment provides increased performance. 19 Global Visions: Dresser-Rand Equipment Powers Australia’s BassGas Project D-R Training Programs Address Global Need COVER PHOTO: Sydney, Australia -- Australia's southeastern States receive vital, clean energy from Origin Energy's BassGas Project offshore platform. (See article on page 19.) This document may contain forward-looking statements within the meaning of U.S. securities laws. All statements other than statements of historical fact are statements that could be deemed forward-looking statements, including but not limited to statements relating to the Company's plans, objectives, goals, strategies and future events and financial performance. The words "anticipates," "believes," "expects," "intends," and similar expressions identify such forward-looking statements. Although the Company believes such statements are based on reasonable assumptions, these forward-looking statements are subject to numerous factors, risks and uncertainties that could cause actual results, performance or achievements to differ materially from those stated, and no assurance can be given with respect thereto. These and other risks are discussed in greater detail in the Company's filings with the Securities and Exchange Commission at www.sec.gov. The Company undertakes no obligation to update forwardlooking statements. Peter Taschner Safety: The Goal is Zero Editor’s Note: This installment of Candid Visions is an interview with Peter Taschner, Dresser-Rand’s former chief safety officer for company operations worldwide. Taschner accepted the position of director of operations for Olean Operations in October, 2006 but maintained his role as chief safety officer until March, 2007 when Joseph (Joe) Megginson was named chief safety officer, worldwide for Dresser-Rand. Megginson is located in D-R's Houston, Texas offices. Many of us may take safety for granted when we go to work each day. But Peter Taschner, Dresser-Rand’s former chief safety officer, does not take safety lightly. He recognizes that safety is something every employee needs to focus on every day. Taschner’s goal for incidents and injuries among employees at Dresser-Rand locations and on clients’ sites is zero. “The secret to operating injury- and incident-free is to eliminate unsafe behaviors,” Taschner emphasizes. Using many short behavioral audits, risk At the core of the company’s safety program is the D-R Health, Safety and Environment (HSE) Management System. The system comprises four principles: (1) all injuries and incidents are preventable; (2) staying injury free is the responsibility of all employees; (3) employees must be thoroughly trained and involved in safety matters; and (4) “good safety is good business.” Research shows that, for the most part, injuries result from unsafe behaviors. Because most safety programs focus on conditions to improve safety, they struggle to see results. At Dresser-Rand, the focus is on eliminating unsafe behaviors. HSE improvement is a continuous process. Based on annual safety assessments made at various sites, objectives are set and plans to achieve them are established. Employees are then trained, and the plans are implemented. Sustained improvements are intended to be achieved as a result of these efforts. Dresser-Rand manages the HSE system the same way it manages other aspects of its business. The HSE system is given the same priority as cost, quality, productivity, on-time delivery and employee relations. Potential safety problems are viewed as opportunities for improvement. Good safety communications result in all employees understanding the goals, objectives, plans, performances and current safety issues. The editor of insights spoke to Taschner about his role as Dresser-Rand’s chief safety officer and how the position contributes to the success of the company. insights: Why is DresserRand's safety program so important to D-R clients? Taschner: Dresser-Rand’s safety program shows our Continued on page 3 For information about Dresser-Rand, visit our website at www.dresser-rand.com. 1 insights VOLUME 10, NO. 1 CONTENTS 1 Candid Visions: Safety – The Goal Is Zero Dresser-Rand’s Peter Taschner details the company’s commitment to safety. 4 Dresser-Rand Introduces Integrated Compression System For Onshore And Offshore Projects, Including Sub-Sea The new concept provides a complete compression system solution in a compact package. 6 Dresser-Rand Test Capabilities Prepared For Every Challenge Dresser-Rand continues to expand and enhance its global equipment test capabilities. 9 CIRS Continues To Improve Client Relations Around the World The rapid response system is designed to continually increase client satisfaction. behaviors are identified and steps are taken to eliminate those behaviors. By using behavioral auditing techniques, many unsafe behaviors that could result in injuries and accidents have been eliminated by D-R employees. 10 Dresser-Rand Keeping It Cool – And Safe D-R’s complete line of COPPUS portable ventilators helps clients keep their operations safe. 12 Engineer’s Notebook: Curtis Stage Nozzle/Rotor Aerodynamic Interaction and the Effect on Stage Performance Presented at IGTI Turbo Expo 2006 in Barcelona, Spain. 16 Dresser-Rand Succeeds With Applied DATUM® Technology For Major U.S. Refinery In Record Time Rapid upgrade solution to another OEM’s equipment provides increased performance. 19 Global Visions: Dresser-Rand Equipment Powers Australia’s BassGas Project D-R Training Programs Address Global Need COVER PHOTO: Sydney, Australia -- Australia's southeastern States receive vital, clean energy from Origin Energy's BassGas Project offshore platform. (See article on page 19.) This document may contain forward-looking statements within the meaning of U.S. securities laws. All statements other than statements of historical fact are statements that could be deemed forward-looking statements, including but not limited to statements relating to the Company's plans, objectives, goals, strategies and future events and financial performance. The words "anticipates," "believes," "expects," "intends," and similar expressions identify such forward-looking statements. Although the Company believes such statements are based on reasonable assumptions, these forward-looking statements are subject to numerous factors, risks and uncertainties that could cause actual results, performance or achievements to differ materially from those stated, and no assurance can be given with respect thereto. These and other risks are discussed in greater detail in the Company's filings with the Securities and Exchange Commission at www.sec.gov. The Company undertakes no obligation to update forwardlooking statements. Peter Taschner Safety: The Goal is Zero Editor’s Note: This installment of Candid Visions is an interview with Peter Taschner, Dresser-Rand’s former chief safety officer for company operations worldwide. Taschner accepted the position of director of operations for Olean Operations in October, 2006 but maintained his role as chief safety officer until March, 2007 when Joseph (Joe) Megginson was named chief safety officer, worldwide for Dresser-Rand. Megginson is located in D-R's Houston, Texas offices. Many of us may take safety for granted when we go to work each day. But Peter Taschner, Dresser-Rand’s former chief safety officer, does not take safety lightly. He recognizes that safety is something every employee needs to focus on every day. Taschner’s goal for incidents and injuries among employees at Dresser-Rand locations and on clients’ sites is zero. “The secret to operating injury- and incident-free is to eliminate unsafe behaviors,” Taschner emphasizes. Using many short behavioral audits, risk At the core of the company’s safety program is the D-R Health, Safety and Environment (HSE) Management System. The system comprises four principles: (1) all injuries and incidents are preventable; (2) staying injury free is the responsibility of all employees; (3) employees must be thoroughly trained and involved in safety matters; and (4) “good safety is good business.” Research shows that, for the most part, injuries result from unsafe behaviors. Because most safety programs focus on conditions to improve safety, they struggle to see results. At Dresser-Rand, the focus is on eliminating unsafe behaviors. HSE improvement is a continuous process. Based on annual safety assessments made at various sites, objectives are set and plans to achieve them are established. Employees are then trained, and the plans are implemented. Sustained improvements are intended to be achieved as a result of these efforts. Dresser-Rand manages the HSE system the same way it manages other aspects of its business. The HSE system is given the same priority as cost, quality, productivity, on-time delivery and employee relations. Potential safety problems are viewed as opportunities for improvement. Good safety communications result in all employees understanding the goals, objectives, plans, performances and current safety issues. The editor of insights spoke to Taschner about his role as Dresser-Rand’s chief safety officer and how the position contributes to the success of the company. insights: Why is DresserRand's safety program so important to D-R clients? Taschner: Dresser-Rand’s safety program shows our Continued on page 3 For information about Dresser-Rand, visit our website at www.dresser-rand.com. 1 Safety: The Goal is Zero Continued from page 1 Meet Peter Taschner Peter Taschner is Dresser-Rand’s former chief safety officer for company operations worldwide. He joined the company in January 2005 after spending more than 20 years with DuPont in a variety of positions. Taschner has a Bachelor of Science degree in electrical engineering and an MBA from Lehigh University in Bethlehem, Pennsylvania. He and his wife, Terri, are parents of five children ranging in age from eight to 17. Taschner recognizes that the biggest challenge in this position is convincing co-workers that zero injuries and incidents is an achievable goal. “Safety improves as individuals realize that all injuries and incidents can be prevented. Watching as my co-workers gain an understanding of how they can achieve greatness in their safety performance is the most rewarding part of my job.” clients that a company that has the operating discipline to have a great safety record will have that same operating discipline in all other aspects of its business, for example quality, on-time delivery, costs, etc. Clients want to see a good corporate safety record, because they use it to measure the overall abilities of a company. We also directly affect the client's own safety performance when we are working at their sites. insights: How does the Dresser-Rand safety program work in unison with D-R clients? Taschner: We participate with client safety programs while working within the structure of our own HSE management system. If we come upon other effective safety programs – at a client’s site, for example – we can integrate them into our own HSE management system. insights: What actions has D-R taken to improve safety? Taschner: We have instituted a comprehensive safety management system that comprises 12 essential 2 elements. Line managers are accountable and responsible for the safety of their employees, and a safety committee structure is in place to support those managers. A behavioral auditing element empowers all supervisors and managers to look for unsafe behaviors and seek employees’ cooperation in eliminating them. By gaining employees’ commitment to change one or two things they are doing that may lead to an injury, we make the workplace safer with each audit. Since it is likely that the employee performs the same behavior several times each workday, we eliminate hundreds or thousands of unsafe behaviors with each audit. The incident investigation element forces us to determine the root cause of each incident and put corrective measures in place to ensure that similar incidents will not happen again. insights: Are the objectives of this program being realized? Taschner: Absolutely. Significant improvement has been achieved at the Olean, New York and Le Havre, France facilities, for example. The Olean facility had 22 injuries in the first 10 months of 2005 for a total recordable rate of 2.9. The Olean facility started a program focused on eliminating unsafe behavior in 2005. Since October 2005 Olean has achieved a total recordable rate of 1.1. The same effort was undertaken in Le Havre, where employees had 14 injuries in the first nine months of 2005 for a total recordable rate of 3.0. Since September 2005, the Le Havre facility has achieved a total recordable rate of 1.1. insights: What are D-R’s target goals for safety and what challenges lie ahead in reaching these goals? Taschner: The goal is zero incidents. A single incident can be as minor as coffee spilled on the floor of a work area. This is a longrange goal that will not be reached immediately. But it can be achieved as we continuously improve in all 12 elements of the safety management system. The total recordable case rate (TRCR) objective for 2007 is to achieve 0.8 or better. This means that to achieve our goal, we can have a maximum of one injury for every 125 employees during the course of the year. In 2006, our TRCR was 1.6. insights: How does safety fit into D-R’s long-term company goals? Taschner: Safety is critical to the long-term success of Dresser-Rand for two reasons. First and foremost, our employees are our most valuable resource and we want them to return home safely in the same condition they came to work. Secondly, our clients demand outstanding safety performance. A good company safety record is a competitive advantage. Companies that do not take safety seriously or do not work to improve their safety performance will lose their competitive advantage and will not stand the test of time. ■ "Companies that do not take safety seriously or do not work to improve their safety performance will lose their competitive advantage and will not stand the test of time." — Peter Taschner 3 Safety: The Goal is Zero Continued from page 1 Meet Peter Taschner Peter Taschner is Dresser-Rand’s former chief safety officer for company operations worldwide. He joined the company in January 2005 after spending more than 20 years with DuPont in a variety of positions. Taschner has a Bachelor of Science degree in electrical engineering and an MBA from Lehigh University in Bethlehem, Pennsylvania. He and his wife, Terri, are parents of five children ranging in age from eight to 17. Taschner recognizes that the biggest challenge in this position is convincing co-workers that zero injuries and incidents is an achievable goal. “Safety improves as individuals realize that all injuries and incidents can be prevented. Watching as my co-workers gain an understanding of how they can achieve greatness in their safety performance is the most rewarding part of my job.” clients that a company that has the operating discipline to have a great safety record will have that same operating discipline in all other aspects of its business, for example quality, on-time delivery, costs, etc. Clients want to see a good corporate safety record, because they use it to measure the overall abilities of a company. We also directly affect the client's own safety performance when we are working at their sites. insights: How does the Dresser-Rand safety program work in unison with D-R clients? Taschner: We participate with client safety programs while working within the structure of our own HSE management system. If we come upon other effective safety programs – at a client’s site, for example – we can integrate them into our own HSE management system. insights: What actions has D-R taken to improve safety? Taschner: We have instituted a comprehensive safety management system that comprises 12 essential 2 elements. Line managers are accountable and responsible for the safety of their employees, and a safety committee structure is in place to support those managers. A behavioral auditing element empowers all supervisors and managers to look for unsafe behaviors and seek employees’ cooperation in eliminating them. By gaining employees’ commitment to change one or two things they are doing that may lead to an injury, we make the workplace safer with each audit. Since it is likely that the employee performs the same behavior several times each workday, we eliminate hundreds or thousands of unsafe behaviors with each audit. The incident investigation element forces us to determine the root cause of each incident and put corrective measures in place to ensure that similar incidents will not happen again. insights: Are the objectives of this program being realized? Taschner: Absolutely. Significant improvement has been achieved at the Olean, New York and Le Havre, France facilities, for example. The Olean facility had 22 injuries in the first 10 months of 2005 for a total recordable rate of 2.9. The Olean facility started a program focused on eliminating unsafe behavior in 2005. Since October 2005 Olean has achieved a total recordable rate of 1.1. The same effort was undertaken in Le Havre, where employees had 14 injuries in the first nine months of 2005 for a total recordable rate of 3.0. Since September 2005, the Le Havre facility has achieved a total recordable rate of 1.1. insights: What are D-R’s target goals for safety and what challenges lie ahead in reaching these goals? Taschner: The goal is zero incidents. A single incident can be as minor as coffee spilled on the floor of a work area. This is a longrange goal that will not be reached immediately. But it can be achieved as we continuously improve in all 12 elements of the safety management system. The total recordable case rate (TRCR) objective for 2007 is to achieve 0.8 or better. This means that to achieve our goal, we can have a maximum of one injury for every 125 employees during the course of the year. In 2006, our TRCR was 1.6. insights: How does safety fit into D-R’s long-term company goals? Taschner: Safety is critical to the long-term success of Dresser-Rand for two reasons. First and foremost, our employees are our most valuable resource and we want them to return home safely in the same condition they came to work. Secondly, our clients demand outstanding safety performance. A good company safety record is a competitive advantage. Companies that do not take safety seriously or do not work to improve their safety performance will lose their competitive advantage and will not stand the test of time. ■ "Companies that do not take safety seriously or do not work to improve their safety performance will lose their competitive advantage and will not stand the test of time." — Peter Taschner 3 Dresser-Rand Introduces Integrated Compression SystemTM for Onshore and Offshore Projects, including Sub-Sea In a major advance in centrifugal compressor technology, Dresser-Rand Company has announced it is developing a fully Integrated Compression System (ICSTM) engineered to provide an efficient, compact solution to compression system design. The Dresser-Rand ICS uses as a platform high-efficiency DATUM‚ centrifugal compressor technology driven by a high-speed, close-coupled motor, with an integrated rotary gas-liquid separation unit, packaged with process gas coolers in a single module. It provides a complete compression system that can be applied to all markets – upstream, midstream and downstream with the smallest footprint, reduced weight and at the lowest total installed cost. “Traditional compression modules typically are very large and heavy structures, require lengthy production time, and are expensive,” said Jesus Pacheco, vice president of Client Services at Dresser-Rand. “With this integrated approach, the total footprint of a conventional module can be reduced by up to 65 percent while its weight can be halved by a Dresser-Rand ICS compression module. It’s smaller, it’s lighter, and it can be produced in less 4 time. The performance of D-R’s ICS, incorporating DATUM compressor and rotary separation technologies will be competitive to the overall performance of traditional systems when the suction scrubber and inlet piping losses are taken into account. This translates into a cost-effective solution that can add real value to our clients’ capital projects and operations throughout the life of the equipment.” Dresser-Rand’s DATUM centrifugal compressor technology was first introduced to the industry in September 1995 at the 24th Turbomachinery Symposium. Dresser-Rand’s DATUM line of centrifugal compressors sets the standard for modular design and highefficiency performance. DATUM units dramatically improved the serviceability of centrifugal compressors, resulting in reduced down time and lower life-cycle costs. To date, more than 500 DATUM units have been sold to clients in more than 40 countries for virtually every type of critical gas compression application. Driving the DATUM compressor line with a highspeed, close-coupled motor ensures a compact design that is environmentally friendly and cost-effective. Completely Integrated Separator Technology The ICS’ ability to effectively handle any dry or wet gas application is made possible by the integration of advanced rotary separation technology within the compressor. This technology was developed by Multiphase Power and Technologies, a joint venture company created in 1998 between Dresser-Rand and Aker Kvaerner. The joint venture brought together D-R's experience in designing and manufacturing durable and reliable rotating machinery with Kvaerner Process Systems' expertise in separation technology. In 2005, Dresser-Rand acquired full ownership in Multiphase Power and Technologies. Following the acquisition, Vincent R. Volpe, Jr., Dresser-Rand’s president and CEO, stated that the move “…reinforces DresserRand’s ‘Total Solutions’ approach, designed to offer clients significant value, and complements our existing technologies in the global oil and gas industries.” That statement has proved itself with the development of Dresser-Rand’s ICS system, according to Pacheco. Dresser-Rand’s rotary separation technologies (RST) provide an efficient and compact method of gasliquid separation that uses centrifugal forces to separate gas, oil and water and remove solids from the flow. The separation process protects down-line machinery from potential damage by reducing oil content in a single process at the wellhead manifold “With this integrated approach, the total footprint of a conventional module can be reduced by up to 65 percent while its weight can be halved by a Dresser-Rand ICS compression module.” — Jesus Pacheco, vice president of Client Services at Dresser-Rand allowing produced water to be disposed in an environmentally sound manner. An in-line, rotary separator (IRIS®) has also been developed for and successfully applied in applications that require the separation of liquids from a gas stream. This separation technology achieves equal or better efficiencies than gravitybased systems while being significantly more compact. “Oil and gas producers are able to take advantage of these advances in technology to effectively reduce the overall size of production facilities, platforms and sub-sea modules,” said Julian Smith, director of Business Development at Dresser-Rand, who heads up the company’s Separator Strategic Business Unit. "Downtime and potential production losses are reduced because the equipment is protected from liquids and particles in the pipelines by the separators.” Uniquely Suited for Subsea Applications A key attribute of DresserRand’s ICS is that it turns “compressors” into compact “compression systems.” We believe this attribute would make it uniquely suited for the developing sub-sea applications. Because the compressor, motor, separa- tion system and gas coolers are contained within the same process module, it can be installed as a single, compact unit and eliminates the need for large, stand-alone separators. The reduced weight and smaller footprint make it very attractive when compared to traditional compressor-only technologies as well as being easier to transport, install and retrieve. "DATUM compression technology has proved it can provide high efficiency with maximum reliability thereby reducing life-cycle costs,” Pacheco stated. “Combined with other Dresser-Rand technologies, such as the RST, we can offer much more than just a compressor. ICS is a complete compression system in a compact, costeffective package. As opportunities for sub-sea compression emerge, we expect the Dresser-Rand ICS system to offer the best solutions and provide real value to our clients operating in seabed production.■ The Dresser-Rand ICS uses as a platform high-efficiency DATUM‚ centrifugal compressor technology driven by a high-speed, close-coupled motor, with an integrated rotary gas-liquid separation unit, packaged with process gas coolers in a single module. 5 Dresser-Rand Introduces Integrated Compression SystemTM for Onshore and Offshore Projects, including Sub-Sea In a major advance in centrifugal compressor technology, Dresser-Rand Company has announced it is developing a fully Integrated Compression System (ICSTM) engineered to provide an efficient, compact solution to compression system design. The Dresser-Rand ICS uses as a platform high-efficiency DATUM‚ centrifugal compressor technology driven by a high-speed, close-coupled motor, with an integrated rotary gas-liquid separation unit, packaged with process gas coolers in a single module. It provides a complete compression system that can be applied to all markets – upstream, midstream and downstream with the smallest footprint, reduced weight and at the lowest total installed cost. “Traditional compression modules typically are very large and heavy structures, require lengthy production time, and are expensive,” said Jesus Pacheco, vice president of Client Services at Dresser-Rand. “With this integrated approach, the total footprint of a conventional module can be reduced by up to 65 percent while its weight can be halved by a Dresser-Rand ICS compression module. It’s smaller, it’s lighter, and it can be produced in less 4 time. The performance of D-R’s ICS, incorporating DATUM compressor and rotary separation technologies will be competitive to the overall performance of traditional systems when the suction scrubber and inlet piping losses are taken into account. This translates into a cost-effective solution that can add real value to our clients’ capital projects and operations throughout the life of the equipment.” Dresser-Rand’s DATUM centrifugal compressor technology was first introduced to the industry in September 1995 at the 24th Turbomachinery Symposium. Dresser-Rand’s DATUM line of centrifugal compressors sets the standard for modular design and highefficiency performance. DATUM units dramatically improved the serviceability of centrifugal compressors, resulting in reduced down time and lower life-cycle costs. To date, more than 500 DATUM units have been sold to clients in more than 40 countries for virtually every type of critical gas compression application. Driving the DATUM compressor line with a highspeed, close-coupled motor ensures a compact design that is environmentally friendly and cost-effective. Completely Integrated Separator Technology The ICS’ ability to effectively handle any dry or wet gas application is made possible by the integration of advanced rotary separation technology within the compressor. This technology was developed by Multiphase Power and Technologies, a joint venture company created in 1998 between Dresser-Rand and Aker Kvaerner. The joint venture brought together D-R's experience in designing and manufacturing durable and reliable rotating machinery with Kvaerner Process Systems' expertise in separation technology. In 2005, Dresser-Rand acquired full ownership in Multiphase Power and Technologies. Following the acquisition, Vincent R. Volpe, Jr., Dresser-Rand’s president and CEO, stated that the move “…reinforces DresserRand’s ‘Total Solutions’ approach, designed to offer clients significant value, and complements our existing technologies in the global oil and gas industries.” That statement has proved itself with the development of Dresser-Rand’s ICS system, according to Pacheco. Dresser-Rand’s rotary separation technologies (RST) provide an efficient and compact method of gasliquid separation that uses centrifugal forces to separate gas, oil and water and remove solids from the flow. The separation process protects down-line machinery from potential damage by reducing oil content in a single process at the wellhead manifold “With this integrated approach, the total footprint of a conventional module can be reduced by up to 65 percent while its weight can be halved by a Dresser-Rand ICS compression module.” — Jesus Pacheco, vice president of Client Services at Dresser-Rand allowing produced water to be disposed in an environmentally sound manner. An in-line, rotary separator (IRIS®) has also been developed for and successfully applied in applications that require the separation of liquids from a gas stream. This separation technology achieves equal or better efficiencies than gravitybased systems while being significantly more compact. “Oil and gas producers are able to take advantage of these advances in technology to effectively reduce the overall size of production facilities, platforms and sub-sea modules,” said Julian Smith, director of Business Development at Dresser-Rand, who heads up the company’s Separator Strategic Business Unit. "Downtime and potential production losses are reduced because the equipment is protected from liquids and particles in the pipelines by the separators.” Uniquely Suited for Subsea Applications A key attribute of DresserRand’s ICS is that it turns “compressors” into compact “compression systems.” We believe this attribute would make it uniquely suited for the developing sub-sea applications. Because the compressor, motor, separa- tion system and gas coolers are contained within the same process module, it can be installed as a single, compact unit and eliminates the need for large, stand-alone separators. The reduced weight and smaller footprint make it very attractive when compared to traditional compressor-only technologies as well as being easier to transport, install and retrieve. "DATUM compression technology has proved it can provide high efficiency with maximum reliability thereby reducing life-cycle costs,” Pacheco stated. “Combined with other Dresser-Rand technologies, such as the RST, we can offer much more than just a compressor. ICS is a complete compression system in a compact, costeffective package. As opportunities for sub-sea compression emerge, we expect the Dresser-Rand ICS system to offer the best solutions and provide real value to our clients operating in seabed production.■ The Dresser-Rand ICS uses as a platform high-efficiency DATUM‚ centrifugal compressor technology driven by a high-speed, close-coupled motor, with an integrated rotary gas-liquid separation unit, packaged with process gas coolers in a single module. 5 D-R Test Capabilities Prepared for Every Challenge During the past decade, continuous advancements in computer capabilities have enabled Dresser-Rand to accelerate the innovations in the performance of rotating equipment. The development of sophisticated three-dimensional solid modeling design systems, as well as computational fluid dynamic analysis software, have translated into more efficient compressors and turbines, uniquely engineered for specific applications. The corollary to this expanding knowledge and capability is an ongoing effort to employ the most advanced processes for testing and data analysis to measure and verify the performance of the equipment. At its world-class test facilities in Le Havre, France, and Olean, New York, Dresser-Rand has invested in the most advanced testing capabilities in the industry, and cultivated the knowledge of experienced test engineers. Both D-R facilities are proficient at performing not only full mechanical testing, but also full-load, full- pressure ASME PTC10 Type I performance string testing. “Testing represents the final, critical quality check on all manufactured equipment,” explained Don Wehlage, manager of testing at Dresser-Rand in Olean. “It represents the verification of the design and manufacturing process.” D-R’s test facility in Olean comprises 36,000 square feet (3345 sq./m) with 20 test stands that allow maximum flexibility to run multiple tests concurrently. “All units are mechanically tested for API 617 compliance,” Wehlage said. “Performance testing per ASME PTC 10 Type 1 and/or Type 2 tests is based on client requirements. More than 16,000 square feet (1485 sq./m) of the Olean facility are dedicated to testing small units, while more than 20,000 square feet (1860 sq./m) are used for hydrocarbon tests and larger machines. “Of the 20 test stands, most have permanent drives in place,” Wehlage said. “We’ve performed as many as three tests at once. But we may have up to a dozen stands occupied at any given time depending on the complexity of the tests and the setup time required for each. Some tests can be set up in a week or so, while a full-load hydrocarbon test or full-load inert test for LNG equipment may take months to prepare.” The D-R Olean test facility was specifically designed to conduct large string fullload, full-pressure Type I tests exceeding 115,000 hp (85 MW) with hydrocarbon gas. The facility has 23 steam turbines, one operating up to 30,000 hp (22 MW) to accommodate various tests. The company also has two dual-rotation, variable speed electric motors operating up to 2,500 hp (1.9 MW). In Le Havre, France, Dresser-Rand operates its second world-class test facility for centrifugal compressors and turbine equipment. A total of 12 test stands are available for both API 617 mechanical testing as well as ASME PTC Class I hydrocarbon tests. Each test area is equipped with a full range of instrumentation and quick connections to accommodate the wide range of equipment and test requirements. “Increasingly, our clients are requesting more sophisticated, thorough testing of their equipment, and they rely on our expertise,” said Yann Peignet, manager of the D-R test facility in Le Havre. “This has led to a tremendous effort in the past 10 years to fully develop our capabilities.” Dresser-Rand DJ 160 power turbine powered by a RollsRoyce Avon gas generator capable of 6000 kW/5300 rpm. Electric motor-driven packages can be subject to no load or full load string tests, using an auxiliary power supplied from diesel generators for 20kV at 50Hz or 60Hz. Twenty gearboxes are used as required for API compressor testing. High- pressure gas coolers are permanently installed to facilitate and shorten the installation of compressor for type I testing with heat dissipation capabilities from 8000 to 16,000 kW. Two cooling tower systems are used -- an 8000 kW system for the mechanical test stands (allowing 6500 kW gas power on test stand), and a 32,000 kW system for full load test stands (allowing 26,000 kW gas power on test stand). The two steam turbine API 612 test stands can accommodate both back-pressure and condensing steam turbine application equipment. The maximum test power is 1800 kW with steam flows of up to 15 T/Hr to condensor and 10 T/Hr to exhaust. Steam pressures of 10 to 38 barG with temperatures up to 716 degrees Fahrenheit (380° Celsius) can be obtained. Turbines with ratings of up to 50MW can be tested. “All units are mechanically tested,” said Peignet. “We also are prepared to run up to six full compression train string tests a year depending Continued on page 8 Both facilities maintain an intricate infrastructure to support the respective test operations. The Le Havre plant maintains four electrical variable-speed DC motors capable of 1500 kW/1500 rpm, as well as a The Dresser-Rand facility in Olean, New York, includes 20 test stands in 36,000 square feet (3345 sq./m), which allow multiple tests to run concurrently. 6 7 D-R Test Capabilities Prepared for Every Challenge During the past decade, continuous advancements in computer capabilities have enabled Dresser-Rand to accelerate the innovations in the performance of rotating equipment. The development of sophisticated three-dimensional solid modeling design systems, as well as computational fluid dynamic analysis software, have translated into more efficient compressors and turbines, uniquely engineered for specific applications. The corollary to this expanding knowledge and capability is an ongoing effort to employ the most advanced processes for testing and data analysis to measure and verify the performance of the equipment. At its world-class test facilities in Le Havre, France, and Olean, New York, Dresser-Rand has invested in the most advanced testing capabilities in the industry, and cultivated the knowledge of experienced test engineers. Both D-R facilities are proficient at performing not only full mechanical testing, but also full-load, full- pressure ASME PTC10 Type I performance string testing. “Testing represents the final, critical quality check on all manufactured equipment,” explained Don Wehlage, manager of testing at Dresser-Rand in Olean. “It represents the verification of the design and manufacturing process.” D-R’s test facility in Olean comprises 36,000 square feet (3345 sq./m) with 20 test stands that allow maximum flexibility to run multiple tests concurrently. “All units are mechanically tested for API 617 compliance,” Wehlage said. “Performance testing per ASME PTC 10 Type 1 and/or Type 2 tests is based on client requirements. More than 16,000 square feet (1485 sq./m) of the Olean facility are dedicated to testing small units, while more than 20,000 square feet (1860 sq./m) are used for hydrocarbon tests and larger machines. “Of the 20 test stands, most have permanent drives in place,” Wehlage said. “We’ve performed as many as three tests at once. But we may have up to a dozen stands occupied at any given time depending on the complexity of the tests and the setup time required for each. Some tests can be set up in a week or so, while a full-load hydrocarbon test or full-load inert test for LNG equipment may take months to prepare.” The D-R Olean test facility was specifically designed to conduct large string fullload, full-pressure Type I tests exceeding 115,000 hp (85 MW) with hydrocarbon gas. The facility has 23 steam turbines, one operating up to 30,000 hp (22 MW) to accommodate various tests. The company also has two dual-rotation, variable speed electric motors operating up to 2,500 hp (1.9 MW). In Le Havre, France, Dresser-Rand operates its second world-class test facility for centrifugal compressors and turbine equipment. A total of 12 test stands are available for both API 617 mechanical testing as well as ASME PTC Class I hydrocarbon tests. Each test area is equipped with a full range of instrumentation and quick connections to accommodate the wide range of equipment and test requirements. “Increasingly, our clients are requesting more sophisticated, thorough testing of their equipment, and they rely on our expertise,” said Yann Peignet, manager of the D-R test facility in Le Havre. “This has led to a tremendous effort in the past 10 years to fully develop our capabilities.” Dresser-Rand DJ 160 power turbine powered by a RollsRoyce Avon gas generator capable of 6000 kW/5300 rpm. Electric motor-driven packages can be subject to no load or full load string tests, using an auxiliary power supplied from diesel generators for 20kV at 50Hz or 60Hz. Twenty gearboxes are used as required for API compressor testing. High- pressure gas coolers are permanently installed to facilitate and shorten the installation of compressor for type I testing with heat dissipation capabilities from 8000 to 16,000 kW. Two cooling tower systems are used -- an 8000 kW system for the mechanical test stands (allowing 6500 kW gas power on test stand), and a 32,000 kW system for full load test stands (allowing 26,000 kW gas power on test stand). The two steam turbine API 612 test stands can accommodate both back-pressure and condensing steam turbine application equipment. The maximum test power is 1800 kW with steam flows of up to 15 T/Hr to condensor and 10 T/Hr to exhaust. Steam pressures of 10 to 38 barG with temperatures up to 716 degrees Fahrenheit (380° Celsius) can be obtained. Turbines with ratings of up to 50MW can be tested. “All units are mechanically tested,” said Peignet. “We also are prepared to run up to six full compression train string tests a year depending Continued on page 8 Both facilities maintain an intricate infrastructure to support the respective test operations. The Le Havre plant maintains four electrical variable-speed DC motors capable of 1500 kW/1500 rpm, as well as a The Dresser-Rand facility in Olean, New York, includes 20 test stands in 36,000 square feet (3345 sq./m), which allow multiple tests to run concurrently. 6 7 CIRS Continues to Improve Client Relations Around the World D-R Test Capabilities .... Continued from page 7 on the complexity of the tests. Safety is always the first priority for our employees and clients for any test we conduct.” In Olean, a dedicated steam plant with four automatic boilers provides up 360,000 pounds of steam an hour, with a maximum primary steam pressure of 600 psi and 750 degrees F (400° degrees C). Three cooling towers can accommodate up to 35,000 gallons of cooling water a minute and a heat rejection rate of 450 million btus an hour. Natural gas compression boost systems up to 600 psi are available for gas turbine fuel gas. More than 250,000 hp of installed power has been on the test stand at one time. In mid-2005, a significant test took place at D-R’s Olean facility involving the first aero-derivative mechanical drive Rolls-Royce TRENT 60 Dry Low Emission (DLE) gas turbine matched to drive a Dresser-Rand DATUM Model D14 centrifugal compressor. The ASME PTC10 Type I performance test was the culmination of efforts by Dresser-Rand and RollsRoyce to design and produce equipment for six export gas compressor trains as part of Dolphin 8 Energy’s Dolphin Gas Project in the Middle East. Six mechanical drive RollsRoyce TRENT 60 DLE gas turbines will drive six Dresser-Rand DATUM centrifugal compressors. The project represents the first application of the aeroderivative industrial TRENT 60 engine as a compressor driver. The test included fullpressure testing at over 2000 psi (140 Bar) and 53,600 hp (40,000 KW) to simulate site conditions. While computer technology has made a tremendous impact on equipment design, it has had an equally important impact on data collection and analysis. D-R’s data acquisition systems include state-of-theart computing capability, and meet strict API and client specifications. D-R’s test facility control rooms at both plants use the latest computer-based vibration recording and analysis software, as well as online performance calculation systems. “During the past four years we greatly enhanced our data acquisition systems and improved all of our related processes for all range of tests. We collect massive amounts of data, all of which are time stamped. If anything significant occurs during the test, we can quickly analyze it and work with the product engineering group with in-depth data to determine the problem,” noted Peignet. According to Peignet, all test parameters can be displayed online and recorded in the control room, with no hand-written records on test stand instruments. Test data displays for vibration, temperature and pressure performance can be transmitted from D-R Olean to client offices via the Internet for live monitoring of test activity. Simulation of the aerodynamic properties of a client’s gas is achieved through a complex, closed loop system. “As with any fullload hydrocarbon string test, the ability to mix different gases to simulate the client’s actual on-site gas is critical,” Wehlage stated. “With our online gas blend system, we are able to mix the inert test gases of nitrogen and carbon dioxide with propane and natural gas in the proper percentages to match the on-site conditions.” Gas compositions are blended to match the inlet density and “K” value at the test inlet temperature. “Every contract is unique, and all present their own test challenges,” Wehlage said. “At D-R, our test capabilities and personnel are second to none.”■ "Safety is always the first priority for our employees and clients for any test we conduct." —Yann Peignet, manager of Dresser-Rand's Le Havre test facility In 2003, Dresser-Rand Company introduced its innovative Client Interface and Response System (CIRS), an interactive tool that enables clients to use the Internet to bring an issue, technical question or problem on an existing piece of equipment to the company’s attention. In fact, CIRS has become a vital D-R initiative on the company’s annual business plan, with high-level focus aimed at improving client relations globally. In just three years, CIRS has grown from 200 to more than 4,000 users. Ron Allen, Dresser-Rand’s project leader for CIRS, attributes much of this growth to the rapid responses clients are getting to their inquiries. “It’s no secret that the frustration with continually being put on hold or never getting a response to an email request ranks as one of the most irritating events in today’s fast-paced, timecrunched world,” Allen says. With the CIRS, the DresserRand employee assigned to the inquiry responds directly to the client within two working days to let the client know that the inquiry has been received and is being processed. This issue owner is actually just the tip of the resource iceberg; the resolution of CIRS issues and the implementation of best practices and corrective actions involve a multitude of D-R individuals and departments. Depending on the issue, the client may have the problem solved in less than a day, but the goal is to never exceed 20 days. The success of CIRS is due to all these groups’ commitment to making this tool as effective as possible. CIRS creates a tracking system from start to finish of a client’s query - it’s a “living case history.” Clients must first register in the CIRS program prior to being able to submit issues into the system. A number is assigned to each “case,” and once registered a client can access the system at any time to submit new issues and check the status of issues that were entered into the system. Although at first North and South American clients seemed to be leading the way in using the system, clients in Europe and around the world are increasingly using the CIRS. The adage, “If it ain’t broke, don’t fix it,” isn’t followed by the CIRS team. Allen is continually looking at ways to upgrade and enhance the program based on user feedback. According to Allen, approximately 40 percent of the issues are technical questions while the balance of the issues relates to parts and equipment. D-R clients, such as Chevron Corporation have used the program successfully for some time. “I have used the CIRS system on several occasions and have been satisfied with the response,” said Tommy Hinkel, project machinery representative at the Chevron Corporation refinery in Pascagoula, Mississippi. “My questions have always been directed to a well qualified person. I have also acquired several new Dresser-Rand contacts in the process.” Since its inception three years ago, CIRS has become almost completely automated. When a query is made, the system directs the request to the proper, pre-programmed DresserRand location. Also, changes made in the field, as well as new modules that will improve response capabilities, are continually being added to the CIRS database. This upgrading has significantly improved the program. “CIRS has become a key component in DresserRand's continued growth. By helping solve problems quickly, we keep our clients satisfied. And a satisfied client becomes a repeat client,” says Allen. ■ 9 CIRS Continues to Improve Client Relations Around the World D-R Test Capabilities .... Continued from page 7 on the complexity of the tests. Safety is always the first priority for our employees and clients for any test we conduct.” In Olean, a dedicated steam plant with four automatic boilers provides up 360,000 pounds of steam an hour, with a maximum primary steam pressure of 600 psi and 750 degrees F (400° degrees C). Three cooling towers can accommodate up to 35,000 gallons of cooling water a minute and a heat rejection rate of 450 million btus an hour. Natural gas compression boost systems up to 600 psi are available for gas turbine fuel gas. More than 250,000 hp of installed power has been on the test stand at one time. In mid-2005, a significant test took place at D-R’s Olean facility involving the first aero-derivative mechanical drive Rolls-Royce TRENT 60 Dry Low Emission (DLE) gas turbine matched to drive a Dresser-Rand DATUM Model D14 centrifugal compressor. The ASME PTC10 Type I performance test was the culmination of efforts by Dresser-Rand and RollsRoyce to design and produce equipment for six export gas compressor trains as part of Dolphin 8 Energy’s Dolphin Gas Project in the Middle East. Six mechanical drive RollsRoyce TRENT 60 DLE gas turbines will drive six Dresser-Rand DATUM centrifugal compressors. The project represents the first application of the aeroderivative industrial TRENT 60 engine as a compressor driver. The test included fullpressure testing at over 2000 psi (140 Bar) and 53,600 hp (40,000 KW) to simulate site conditions. While computer technology has made a tremendous impact on equipment design, it has had an equally important impact on data collection and analysis. D-R’s data acquisition systems include state-of-theart computing capability, and meet strict API and client specifications. D-R’s test facility control rooms at both plants use the latest computer-based vibration recording and analysis software, as well as online performance calculation systems. “During the past four years we greatly enhanced our data acquisition systems and improved all of our related processes for all range of tests. We collect massive amounts of data, all of which are time stamped. If anything significant occurs during the test, we can quickly analyze it and work with the product engineering group with in-depth data to determine the problem,” noted Peignet. According to Peignet, all test parameters can be displayed online and recorded in the control room, with no hand-written records on test stand instruments. Test data displays for vibration, temperature and pressure performance can be transmitted from D-R Olean to client offices via the Internet for live monitoring of test activity. Simulation of the aerodynamic properties of a client’s gas is achieved through a complex, closed loop system. “As with any fullload hydrocarbon string test, the ability to mix different gases to simulate the client’s actual on-site gas is critical,” Wehlage stated. “With our online gas blend system, we are able to mix the inert test gases of nitrogen and carbon dioxide with propane and natural gas in the proper percentages to match the on-site conditions.” Gas compositions are blended to match the inlet density and “K” value at the test inlet temperature. “Every contract is unique, and all present their own test challenges,” Wehlage said. “At D-R, our test capabilities and personnel are second to none.”■ "Safety is always the first priority for our employees and clients for any test we conduct." —Yann Peignet, manager of Dresser-Rand's Le Havre test facility In 2003, Dresser-Rand Company introduced its innovative Client Interface and Response System (CIRS), an interactive tool that enables clients to use the Internet to bring an issue, technical question or problem on an existing piece of equipment to the company’s attention. In fact, CIRS has become a vital D-R initiative on the company’s annual business plan, with high-level focus aimed at improving client relations globally. In just three years, CIRS has grown from 200 to more than 4,000 users. Ron Allen, Dresser-Rand’s project leader for CIRS, attributes much of this growth to the rapid responses clients are getting to their inquiries. “It’s no secret that the frustration with continually being put on hold or never getting a response to an email request ranks as one of the most irritating events in today’s fast-paced, timecrunched world,” Allen says. With the CIRS, the DresserRand employee assigned to the inquiry responds directly to the client within two working days to let the client know that the inquiry has been received and is being processed. This issue owner is actually just the tip of the resource iceberg; the resolution of CIRS issues and the implementation of best practices and corrective actions involve a multitude of D-R individuals and departments. Depending on the issue, the client may have the problem solved in less than a day, but the goal is to never exceed 20 days. The success of CIRS is due to all these groups’ commitment to making this tool as effective as possible. CIRS creates a tracking system from start to finish of a client’s query - it’s a “living case history.” Clients must first register in the CIRS program prior to being able to submit issues into the system. A number is assigned to each “case,” and once registered a client can access the system at any time to submit new issues and check the status of issues that were entered into the system. Although at first North and South American clients seemed to be leading the way in using the system, clients in Europe and around the world are increasingly using the CIRS. The adage, “If it ain’t broke, don’t fix it,” isn’t followed by the CIRS team. Allen is continually looking at ways to upgrade and enhance the program based on user feedback. According to Allen, approximately 40 percent of the issues are technical questions while the balance of the issues relates to parts and equipment. D-R clients, such as Chevron Corporation have used the program successfully for some time. “I have used the CIRS system on several occasions and have been satisfied with the response,” said Tommy Hinkel, project machinery representative at the Chevron Corporation refinery in Pascagoula, Mississippi. “My questions have always been directed to a well qualified person. I have also acquired several new Dresser-Rand contacts in the process.” Since its inception three years ago, CIRS has become almost completely automated. When a query is made, the system directs the request to the proper, pre-programmed DresserRand location. Also, changes made in the field, as well as new modules that will improve response capabilities, are continually being added to the CIRS database. This upgrading has significantly improved the program. “CIRS has become a key component in DresserRand's continued growth. By helping solve problems quickly, we keep our clients satisfied. And a satisfied client becomes a repeat client,” says Allen. ■ 9 Dresser-Rand Keeping It Cool – And Safe In 2005, Dresser-Rand acquired certain assets of Tuthill Energy Systems that included the COPPUS® ventilator product lines. For nearly a century, these portable ventilators have proved themselves powerful, reliable industrial air movers that can help companies meet their safety and maintenance demands around the world. “Our clients are refineries, utilities, chemical plants, shipyards, steel mills and a variety of other industries whose employees face ventilation hazards every day,” said John Barkley, business development manager, portable ventilation team. “Consequently, this new line of ventilators was a nice complement to our traditional product line. Dresser-Rand can now offer a large selection to meet virtually any portable ventilation or cooling need a client might have.” Operations involving high air temperatures, radiant heat sources, high humidity, or strenuous physical activities have high potential for inducing heat stress in employees. Use of ventilation and spot cooling at points of high heat to avoid heat stress is only one benefit of the COPPUS ventilator line. Ventilators also are used in confined spaces to facilitate 10 the supply of fresh air or to remove fumes. Efficient air curing and drying of paints and coatings also are benefits of a good ventilation system. There are basically three types of air movers: axial (where the air flow is straight through the unit), centrifugal (where the discharge is tangential from the inlet), and flow amplifier (where air flow is pneumatically enhanced with no moving parts). Axial models are the most common because of the widespread availability of 115-volt electrical service. The D-R COPPUS ventilator models provide a choice of drives -- electric, pneumatic, steam, water or gasoline. Also, specific construction materials and certified electrical components combine to create sparkresistant products, designed for long-lasting performance, durability, and ease of use. For example, they are made to accommodate any flexible ductwork and offer an abundance of accessories. The lightweight, deckmounted, compressed air-drive ventilator is an easyto-transport, rugged and maintenance-free shipboard ventilator for degassing or delivering a fresh air supply to cargo tanks and other onboard confined spaces. The COPPUS Cadet ventilator is ideal for use underground and light industrial confined space ventilation. These versatile, economic ventilators deliver exceptional airflow in a compact, lightweight design, and their non-corrosive, injection-molded housing is nearly indestructible. “Their design, performance and versatility make them ideal for many applications and help enable us to help our clients meet their top priority of maintaining a healthy and safe environment.” — John Barkley, business development manager, COPPUS portable ventilation team The industrial COPPUS COLDFRONT misting systems transform highvelocity fans into “super coolers” capable of reducing high ambient temperatures up to 40 degrees Fahrenheit (4.4 degrees Celsius) in low relative humidity applications. They add moisture in dry manufacturing environments to improve the process and reduce the potential for hazardous static electrical charges.■ 2007 Catalog Information on the entire line of COPPUS® portable ventilators from Dresser-Rand is available in a new comprehensive product catalog. For a copy of the catalog, or for product support, contact PV Customer Services toll free at: 1-888-268-8726 or by email at [email protected]. 11 Dresser-Rand Keeping It Cool – And Safe In 2005, Dresser-Rand acquired certain assets of Tuthill Energy Systems that included the COPPUS® ventilator product lines. For nearly a century, these portable ventilators have proved themselves powerful, reliable industrial air movers that can help companies meet their safety and maintenance demands around the world. “Our clients are refineries, utilities, chemical plants, shipyards, steel mills and a variety of other industries whose employees face ventilation hazards every day,” said John Barkley, business development manager, portable ventilation team. “Consequently, this new line of ventilators was a nice complement to our traditional product line. Dresser-Rand can now offer a large selection to meet virtually any portable ventilation or cooling need a client might have.” Operations involving high air temperatures, radiant heat sources, high humidity, or strenuous physical activities have high potential for inducing heat stress in employees. Use of ventilation and spot cooling at points of high heat to avoid heat stress is only one benefit of the COPPUS ventilator line. Ventilators also are used in confined spaces to facilitate 10 the supply of fresh air or to remove fumes. Efficient air curing and drying of paints and coatings also are benefits of a good ventilation system. There are basically three types of air movers: axial (where the air flow is straight through the unit), centrifugal (where the discharge is tangential from the inlet), and flow amplifier (where air flow is pneumatically enhanced with no moving parts). Axial models are the most common because of the widespread availability of 115-volt electrical service. The D-R COPPUS ventilator models provide a choice of drives -- electric, pneumatic, steam, water or gasoline. Also, specific construction materials and certified electrical components combine to create sparkresistant products, designed for long-lasting performance, durability, and ease of use. For example, they are made to accommodate any flexible ductwork and offer an abundance of accessories. The lightweight, deckmounted, compressed air-drive ventilator is an easyto-transport, rugged and maintenance-free shipboard ventilator for degassing or delivering a fresh air supply to cargo tanks and other onboard confined spaces. The COPPUS Cadet ventilator is ideal for use underground and light industrial confined space ventilation. These versatile, economic ventilators deliver exceptional airflow in a compact, lightweight design, and their non-corrosive, injection-molded housing is nearly indestructible. “Their design, performance and versatility make them ideal for many applications and help enable us to help our clients meet their top priority of maintaining a healthy and safe environment.” — John Barkley, business development manager, COPPUS portable ventilation team The industrial COPPUS COLDFRONT misting systems transform highvelocity fans into “super coolers” capable of reducing high ambient temperatures up to 40 degrees Fahrenheit (4.4 degrees Celsius) in low relative humidity applications. They add moisture in dry manufacturing environments to improve the process and reduce the potential for hazardous static electrical charges.■ 2007 Catalog Information on the entire line of COPPUS® portable ventilators from Dresser-Rand is available in a new comprehensive product catalog. For a copy of the catalog, or for product support, contact PV Customer Services toll free at: 1-888-268-8726 or by email at [email protected]. 11 Curtis Stage Nozzle/Rotor Aerodynamic Interaction and the Effect on Stage Performance By: Stephen Rashid Chief Aerodynamicist Advanced Turbomachine, LLC 261 N. Main St. Wellsville, NY 14895 Matthew Tremmel ProAero Technology 641 Nightingale Dr. Indialantic, FL 32903 review of Curtis stage design practices, field wear, and dirt patterns, in conjunction with performance testing and CFD modeling, determined that the nozzle/rotor aerodynamic interaction is far more complex than typical design and performance calculations assume. Understanding this nozzle/rotor interaction is key to obtaining improved performance, a more accurate performance prediction, or both. This paper discusses the nature of this interaction and its implications to Curtis stage performance prediction. INTRODUCTION John Waggott Independent Consultant 1933 Riverview Dr. Wellsville, NY 14895 Randall Moll, P.E. Manager, Steam Advanced Engineering Dresser-Rand 37 Coats St. Wellsville, NY 14895 Editor’s Note: The following paper was presented at the IGTI Turbo Expo 2006, May 8-11, in Barcelona, Spain. This edited version is reprinted here with the permission of IGTI. Curtis, or velocity compounded, stages are a sub-group of impulse turbine stages. They are typically applied when wheel speeds are low compared to the overall expansion energy. The low relative wheel speed means not all of the fluid energy can be extracted in the initial rotor row, thus, Curtis stages have at least one additional stator row, or reversing ring, combined with a second rotor row. A typical flowpath layout for a two row Curtis stage is provided in Figure 1. stage machines where low cost and raw power are the key requirements. Curtis stage design practices reflect their utilitarian application, and are based on empirical data gathered over many years. Performance predictions for Curtis stages are an order of magnitude less precise than that commonly achieved on Rateau or reaction stages. The test data presented in the following sections are the result of performance tests conducted by the authors at Dresser-Rand. CURTIS STAGE PERFORMANCE VARIABILITY Curtis stages are not generally used where efficiency is a design requirement. Typical Curtis stage efficiencies range between 40% and 50%, and can be as low as 25%. However, being able to predict efficiency with some degree of accuracy is necessary, even in low efficiency applications. Curtis stage builders have expended effort to understand the variability in Curtis stage performance. This variability is shown in Figure 2A, along with Rateau stage designs for comparison. Figure 2B presents the efficiency differential between measured test and predicted efficiency versus predicted efficiency. Predicted efficiencies were obtained using the same design/performance calculation tools used to design the turbines in question. The primary design tool used to predict efficiency is a meanline calculation with a calibrated loss model. 14 12 Curtis stages are usually used in applications where very high work levels are required from a single stage. The typical efficiency of a Curtis stage is 40% to 50%, so they tend to be applied in single Figure 2A: Test versus predicted efficiency comparison As can be seen in Figures 2A and 2B, the variation in final tested efficiency relative to the predicted design value is significantly greater for Curtis stages than it is for Rateau stages. Typically 80% of the stage power is provided by the first row of a two-row Curtis stage. While the nozzles and rotor blades are typically not aerodynamically challenging to design, it is assumed that the interaction between the nozzle and first rotor row is the key to understanding Curtis stage performance variability. ABSTRACT Curtis, or velocity compounded, stages commonly don’t achieve the same accuracy of performance prediction expected of most other turbine stages. A supersonic. As with other turbine rows, this supersonic exit condition results in Prandtl-Meyer expansion on the uncovered portion of the nozzle, with the accompanying supersonic flow angle deviation. The inlet relative flow angle to the first rotor row will be a function of the nozzle geometry, the nozzle pressure ratio, and the wheel speed. Figure 1: Typical two-row Curtis stage flowpath layout Figure 2B: Dh (test-predicted) versus predicted efficiency for Curtis and Rateau machines VELOCITY TRIANGLES The basic nozzle/rotor interaction issue can be seen in a typical Curtis stage nozzle exit/rotor inlet velocity triangle. Curtis stages have low wheel speed, generally they operate in this regime as a result of the high stage energies at which they are applied. This results in a rotor inlet Mach number, which is nearly as high as the Mach number leaving the nozzle. Figure 4 provides a graphical representation of the nozzle to rotor velocity triangle, with the nozzle absolute exit velocity shown in green (V), and variations in the rotor relative inlet velocity (W) depicted in red (Curtis) and blue (Rateau). For Rateau stages, the wheel speed (U), is large enough to drop the relative velocity to subsonic levels. This is not the case for the Curtis stage. UNIQUE ROTOR INCIDENCE The velocity triangle for the first rotor row of a Curtis stage is very likely to result in a supersonic relative velocity. This condition is only encountered occasionally in turbines. The significance of the supersonic inlet condition to the first rotor row is the accompanying unique incidence. A turbomachinery row with a supersonic inlet velocity can only accept flow at a specific flow angle. In order to establish a periodic flow field, the bow shock and the succeeding expansion fans must exactly counteract each other so that each blade will see the same conditions as the adjacent blade. Methods for determining the unique inlet angle of a supersonic blade row depend on the leading edge geometry of the airfoil in question. The flow area at the rotor inlet must be correct, not only with respect to the flow angle, but in terms of the overall flow area as well, for the supersonic rotor inlet condition to exist. Simple continuity and 2-D potential flow calculations verify that the streamtube required to satisfy the overall rotor inlet flow area is significantly less than the full leading edge height. If this is not the case, the entire flowfield must shock down to a subsonic solution at the rotor leading edge. The resulting static pressure increase at the rotor leading edge would represent significant stage reaction. CURTIS STAGE PERFORMANCE TESTING There is an apparent effect of the ratio of wheel velocity over steam velocity on the performance of a Curtis stage which is not accounted for in the performance models. In order to ascertain the basis of this velocity ratio effect, a series of performance tests were carried out. These tests sought to verify the apparent trend in performance prediction accuracy with velocity ratio. Thus, Curtis stages have an aerodynamic constraint, a supersonic rotor inlet, which is not common to other impulse turbine stages, simply due to the low velocity ratio regime in which they operate and the high nozzle exit Mach number associated with high stage energy. SUPERSONIC NOZZLE EXIT CONDITION The nozzle exit condition for a Curtis stage is nearly always Figure 4: Nozzle/rotor velocity triangle comparison between Curtis and Rateau stages Continued on page 14 15 13 Curtis Stage Nozzle/Rotor Aerodynamic Interaction and the Effect on Stage Performance By: Stephen Rashid Chief Aerodynamicist Advanced Turbomachine, LLC 261 N. Main St. Wellsville, NY 14895 Matthew Tremmel ProAero Technology 641 Nightingale Dr. Indialantic, FL 32903 review of Curtis stage design practices, field wear, and dirt patterns, in conjunction with performance testing and CFD modeling, determined that the nozzle/rotor aerodynamic interaction is far more complex than typical design and performance calculations assume. Understanding this nozzle/rotor interaction is key to obtaining improved performance, a more accurate performance prediction, or both. This paper discusses the nature of this interaction and its implications to Curtis stage performance prediction. INTRODUCTION John Waggott Independent Consultant 1933 Riverview Dr. Wellsville, NY 14895 Randall Moll, P.E. Manager, Steam Advanced Engineering Dresser-Rand 37 Coats St. Wellsville, NY 14895 Editor’s Note: The following paper was presented at the IGTI Turbo Expo 2006, May 8-11, in Barcelona, Spain. This edited version is reprinted here with the permission of IGTI. Curtis, or velocity compounded, stages are a sub-group of impulse turbine stages. They are typically applied when wheel speeds are low compared to the overall expansion energy. The low relative wheel speed means not all of the fluid energy can be extracted in the initial rotor row, thus, Curtis stages have at least one additional stator row, or reversing ring, combined with a second rotor row. A typical flowpath layout for a two row Curtis stage is provided in Figure 1. stage machines where low cost and raw power are the key requirements. Curtis stage design practices reflect their utilitarian application, and are based on empirical data gathered over many years. Performance predictions for Curtis stages are an order of magnitude less precise than that commonly achieved on Rateau or reaction stages. The test data presented in the following sections are the result of performance tests conducted by the authors at Dresser-Rand. CURTIS STAGE PERFORMANCE VARIABILITY Curtis stages are not generally used where efficiency is a design requirement. Typical Curtis stage efficiencies range between 40% and 50%, and can be as low as 25%. However, being able to predict efficiency with some degree of accuracy is necessary, even in low efficiency applications. Curtis stage builders have expended effort to understand the variability in Curtis stage performance. This variability is shown in Figure 2A, along with Rateau stage designs for comparison. Figure 2B presents the efficiency differential between measured test and predicted efficiency versus predicted efficiency. Predicted efficiencies were obtained using the same design/performance calculation tools used to design the turbines in question. The primary design tool used to predict efficiency is a meanline calculation with a calibrated loss model. 14 12 Curtis stages are usually used in applications where very high work levels are required from a single stage. The typical efficiency of a Curtis stage is 40% to 50%, so they tend to be applied in single Figure 2A: Test versus predicted efficiency comparison As can be seen in Figures 2A and 2B, the variation in final tested efficiency relative to the predicted design value is significantly greater for Curtis stages than it is for Rateau stages. Typically 80% of the stage power is provided by the first row of a two-row Curtis stage. While the nozzles and rotor blades are typically not aerodynamically challenging to design, it is assumed that the interaction between the nozzle and first rotor row is the key to understanding Curtis stage performance variability. ABSTRACT Curtis, or velocity compounded, stages commonly don’t achieve the same accuracy of performance prediction expected of most other turbine stages. A supersonic. As with other turbine rows, this supersonic exit condition results in Prandtl-Meyer expansion on the uncovered portion of the nozzle, with the accompanying supersonic flow angle deviation. The inlet relative flow angle to the first rotor row will be a function of the nozzle geometry, the nozzle pressure ratio, and the wheel speed. Figure 1: Typical two-row Curtis stage flowpath layout Figure 2B: Dh (test-predicted) versus predicted efficiency for Curtis and Rateau machines VELOCITY TRIANGLES The basic nozzle/rotor interaction issue can be seen in a typical Curtis stage nozzle exit/rotor inlet velocity triangle. Curtis stages have low wheel speed, generally they operate in this regime as a result of the high stage energies at which they are applied. This results in a rotor inlet Mach number, which is nearly as high as the Mach number leaving the nozzle. Figure 4 provides a graphical representation of the nozzle to rotor velocity triangle, with the nozzle absolute exit velocity shown in green (V), and variations in the rotor relative inlet velocity (W) depicted in red (Curtis) and blue (Rateau). For Rateau stages, the wheel speed (U), is large enough to drop the relative velocity to subsonic levels. This is not the case for the Curtis stage. UNIQUE ROTOR INCIDENCE The velocity triangle for the first rotor row of a Curtis stage is very likely to result in a supersonic relative velocity. This condition is only encountered occasionally in turbines. The significance of the supersonic inlet condition to the first rotor row is the accompanying unique incidence. A turbomachinery row with a supersonic inlet velocity can only accept flow at a specific flow angle. In order to establish a periodic flow field, the bow shock and the succeeding expansion fans must exactly counteract each other so that each blade will see the same conditions as the adjacent blade. Methods for determining the unique inlet angle of a supersonic blade row depend on the leading edge geometry of the airfoil in question. The flow area at the rotor inlet must be correct, not only with respect to the flow angle, but in terms of the overall flow area as well, for the supersonic rotor inlet condition to exist. Simple continuity and 2-D potential flow calculations verify that the streamtube required to satisfy the overall rotor inlet flow area is significantly less than the full leading edge height. If this is not the case, the entire flowfield must shock down to a subsonic solution at the rotor leading edge. The resulting static pressure increase at the rotor leading edge would represent significant stage reaction. CURTIS STAGE PERFORMANCE TESTING There is an apparent effect of the ratio of wheel velocity over steam velocity on the performance of a Curtis stage which is not accounted for in the performance models. In order to ascertain the basis of this velocity ratio effect, a series of performance tests were carried out. These tests sought to verify the apparent trend in performance prediction accuracy with velocity ratio. Thus, Curtis stages have an aerodynamic constraint, a supersonic rotor inlet, which is not common to other impulse turbine stages, simply due to the low velocity ratio regime in which they operate and the high nozzle exit Mach number associated with high stage energy. SUPERSONIC NOZZLE EXIT CONDITION The nozzle exit condition for a Curtis stage is nearly always Figure 4: Nozzle/rotor velocity triangle comparison between Curtis and Rateau stages Continued on page 14 15 13 Curtis Stage Nozzle/Rotor .... Continued from page 13 Test instrumentation consisted of three inlet flange pressures and temperatures, one nozzle bowl pressure, four nozzle exit pressures, and three exhaust flange pressures and temperatures. In addition, speed, flow rate, and torque were also measured. Pressure transducers of appropriate range were used at each measurement location. Data was obtained from numerous individual tests. Test uncertainty varies slightly from test to test, but the typical test uncertainty is approximately ±3%, with the largest component of this uncertainty being spatial. Finally, repeat test points were taken after each test program, and entire test programs re-run, to verify the repeatability of the data. This series of tests consisted of running a single Curtis stage unit, at constant pressures and temperatures, over a range of velocity ratios by varying the turbine speed. In addition to overall performance instrumentation, this test series also included static pressure taps at various locations around the nozzle exit. This added nozzle instrumentation was intended to assist in the determination of stage reaction, and how the pressure just inside the nozzle compared to the pressure between the nozzle and rotor. Studies on a supersonic Rateau stage note that reaction varies with velocity ratio, with the reaction being negative at the lower velocity ratios. Data from the Curtis stage testing confirmed the trend toward negative reaction in this regime. The nozzle static pressure taps reveal significant variation in pressure with changes in 14 Finally, a comparison of the axial nozzle breakout area to an annular streamtube of the same area was made, and is depicted in Figure 16A. When the height of the respective areas are compared to the noted clean area on the first rotor row suction surface, it is found that the exposed nozzle height of 11.84 mm is significantly larger than the apparent 7.95 mm height of the stream entering the rotor. wheel speed. The short side pressure has almost no variation relative to the face pressure. Since the short side pressure represents the last point at which the nozzle is a full passage, it demonstrates a well behaved relationship with the face pressure. The mid and long side pressures, however, vary considerably relative to the face pressure. These pressures, in the “uncovered” portion of the nozzle are subject to the after expansion as flow leaves the “covered” portion of the passage, showing the effects of flow angle variation, streamtube height variation, or both, with wheel speed. This angle/streamtube height variation occurs even though the overall nozzle pressure ratio remains essentially constant. abruptly at the point where the suction surface became covered by the adjacent blade. Figure 14 provides dimensions taken at the time of the inspection of the radial extent and location of the clean area. DIRT AND WEAR PATTERNS Figure 13: First rotor dirt patterns observed during a field inspection (mapped on a new blade for clarity) The supersonic flowfield of the first rotor inlet dictates that the leading edge flow area be significantly less than the full leading edge span would provide. While this conclusion appears to be difficult to substantiate, there is evidence in field units that this is indeed the case. Figure 13 presents a mapping of first rotor row dirt patterns observed by the authors during a field inspection of a single stage Curtis unit. These are superimposed on a clean, single blade for clarity. There was a nearly uniform coating of deposits over the entire flowpath portion of the first row blades. However, the most striking feature of the observed deposits is the virtually clean area on the midspan region of the suction surface leading edge. This clean portion stopped When these dirt patterns are compared to typical first rotor row blade wear on long running units, as diagrammed in Figure 15, there is a clear correspondence between the areas of highest blade wear, and the cleanest portions of the dirt patterns. value. This leads to the conclusion that the flow is indeed coalescing from discrete nozzle streams into a coherent uniform stream, and at the time it enters the rotor, it has virtually completely made the transition. The actual streamtube entering the rotor is probably not perfectly annular, but similar to the shaded area shown in Figure 16A. CFD MODELING NUMERICAL METHOD Simulation of the flowfield through the nozzle and first rotor was performed with the parallel code TURBO, a compressible flow code that solves the unsteady RANS equations within the rotating reference frame. The code uses an implicit finite volume scheme with a NASA/CMOTT- The calculated annular streamtube height of 8.13 mm is very close to the 7.95 mm disrupted and it takes several more time steps before the flow reestablishes itself. • Interaction of the bow wake with the edge of the separation region. Rather than a shock pattern being set up between the blade surfaces, it is established between the separation edge and the rotor pressure surface. Figure 24 depicts a series of oblique shocks and expansions reflecting off of the edge of the separation layer. There is also a shock set up on the pressure side just downstream of the leading edge that intersects with the bow shock. CONCLUSIONS Figure 16A: Comparison of axial nozzle breakout area to equivalent annular height Figure 14: Radial location and extent of clean suction surface leading edge With an axial spacing between the nozzle exit and the first rotor row leading edge on the order of 1.27 mm, it doesn’t seem likely that the flow could make the transition. However, the data indicate that the transition actually begins in the nozzle. The constant Mach number, combined with the requirement for unique rotor incidence, implies that the axial flow area and absolute flow angle must compensate to achieve these conditions. For the test unit, operating at the design condition the resulting streamtube height is 9.98 mm. This height is much closer to the 7.95 mm height noted in the dirt patterns than the full nozzle exit height of 11.84 mm. Thus, the transition to the 7.95 mm flow height begins at the last “covered” portion of the nozzle. developed two-equation k-e turbulence model. For efficient use of computing resources, a phase-lag approximation is available to enable use of only one blade passage per blade row in the simulation. Modeling indicates for the design conditions of this turbine, the suction side leading “flat” to circular arc occurs too early and, for this solidity, results in the flow separating from the suction surface. Some additional interesting features include: • Disruption of the bow shock of the rotor by the nozzle wake. The bow shock is near the leading edge of the rotor at a time where the nozzle has not yet passed by and subsequently, when the nozzle wake just starts to influence the rotor. The bow shock system is completely The high error band in Curtis stage performance prediction is due mainly to the complexity of the interaction between the nozzle and the first rotor row. The first rotor row of a Curtis stage has a supersonic inlet, and resulting unique incidence, due to low velocity ratio and high stage energy. In order to maintain the supersonic inlet, the rotor leading edge streamtube must be considerably smaller in height than the blade trailing edge (and thus, the provided blade leading edge height), or the flowfield will shock down to a subsonic inlet, with the attending high positive stage reaction. Dirt and wear patterns confirm the streamtube contraction into the first rotor row. Maintaining the rotor’s unique incidence requires that the nozzle angle, and/or streamtube height, must adjust as wheel speed changes, and this was noted in the behavior of nozzle static pressure taps during Curtis stage testing. Figure 24: Mach Contours interaction with separation region Stage reactions, measured on these Curtis stage tests confirm the low, actually negative, reaction noted on other supersonic rotor tests. The nozzle to rotor streamtube contraction and geometric expansion is very aggressive, and the drilled-hole nozzle type was challenging to model in CFD. However, CFD did confirm the separation of flow off the leading edge suction surface (as seen in the dirt patterns), and the resulting impingement of that high energy flow stream on the pressure surface of the adjacent blade (observed in both dirt, and wear, patterns). The unsteady flow behavior caused by the thick “trailing edge” of the nozzle was also shown to significantly influence the behavior of the rotor flow well past what traditional Curtis-stage design methodologies account for. ■ For additional technical papers, visit our website at: www.dresser-rand.com Figure 15: Typical areas of first rotor blade wear for long service units 15 Curtis Stage Nozzle/Rotor .... Continued from page 13 Test instrumentation consisted of three inlet flange pressures and temperatures, one nozzle bowl pressure, four nozzle exit pressures, and three exhaust flange pressures and temperatures. In addition, speed, flow rate, and torque were also measured. Pressure transducers of appropriate range were used at each measurement location. Data was obtained from numerous individual tests. Test uncertainty varies slightly from test to test, but the typical test uncertainty is approximately ±3%, with the largest component of this uncertainty being spatial. Finally, repeat test points were taken after each test program, and entire test programs re-run, to verify the repeatability of the data. This series of tests consisted of running a single Curtis stage unit, at constant pressures and temperatures, over a range of velocity ratios by varying the turbine speed. In addition to overall performance instrumentation, this test series also included static pressure taps at various locations around the nozzle exit. This added nozzle instrumentation was intended to assist in the determination of stage reaction, and how the pressure just inside the nozzle compared to the pressure between the nozzle and rotor. Studies on a supersonic Rateau stage note that reaction varies with velocity ratio, with the reaction being negative at the lower velocity ratios. Data from the Curtis stage testing confirmed the trend toward negative reaction in this regime. The nozzle static pressure taps reveal significant variation in pressure with changes in 14 Finally, a comparison of the axial nozzle breakout area to an annular streamtube of the same area was made, and is depicted in Figure 16A. When the height of the respective areas are compared to the noted clean area on the first rotor row suction surface, it is found that the exposed nozzle height of 11.84 mm is significantly larger than the apparent 7.95 mm height of the stream entering the rotor. wheel speed. The short side pressure has almost no variation relative to the face pressure. Since the short side pressure represents the last point at which the nozzle is a full passage, it demonstrates a well behaved relationship with the face pressure. The mid and long side pressures, however, vary considerably relative to the face pressure. These pressures, in the “uncovered” portion of the nozzle are subject to the after expansion as flow leaves the “covered” portion of the passage, showing the effects of flow angle variation, streamtube height variation, or both, with wheel speed. This angle/streamtube height variation occurs even though the overall nozzle pressure ratio remains essentially constant. abruptly at the point where the suction surface became covered by the adjacent blade. Figure 14 provides dimensions taken at the time of the inspection of the radial extent and location of the clean area. DIRT AND WEAR PATTERNS Figure 13: First rotor dirt patterns observed during a field inspection (mapped on a new blade for clarity) The supersonic flowfield of the first rotor inlet dictates that the leading edge flow area be significantly less than the full leading edge span would provide. While this conclusion appears to be difficult to substantiate, there is evidence in field units that this is indeed the case. Figure 13 presents a mapping of first rotor row dirt patterns observed by the authors during a field inspection of a single stage Curtis unit. These are superimposed on a clean, single blade for clarity. There was a nearly uniform coating of deposits over the entire flowpath portion of the first row blades. However, the most striking feature of the observed deposits is the virtually clean area on the midspan region of the suction surface leading edge. This clean portion stopped When these dirt patterns are compared to typical first rotor row blade wear on long running units, as diagrammed in Figure 15, there is a clear correspondence between the areas of highest blade wear, and the cleanest portions of the dirt patterns. value. This leads to the conclusion that the flow is indeed coalescing from discrete nozzle streams into a coherent uniform stream, and at the time it enters the rotor, it has virtually completely made the transition. The actual streamtube entering the rotor is probably not perfectly annular, but similar to the shaded area shown in Figure 16A. CFD MODELING NUMERICAL METHOD Simulation of the flowfield through the nozzle and first rotor was performed with the parallel code TURBO, a compressible flow code that solves the unsteady RANS equations within the rotating reference frame. The code uses an implicit finite volume scheme with a NASA/CMOTT- The calculated annular streamtube height of 8.13 mm is very close to the 7.95 mm disrupted and it takes several more time steps before the flow reestablishes itself. • Interaction of the bow wake with the edge of the separation region. Rather than a shock pattern being set up between the blade surfaces, it is established between the separation edge and the rotor pressure surface. Figure 24 depicts a series of oblique shocks and expansions reflecting off of the edge of the separation layer. There is also a shock set up on the pressure side just downstream of the leading edge that intersects with the bow shock. CONCLUSIONS Figure 16A: Comparison of axial nozzle breakout area to equivalent annular height Figure 14: Radial location and extent of clean suction surface leading edge With an axial spacing between the nozzle exit and the first rotor row leading edge on the order of 1.27 mm, it doesn’t seem likely that the flow could make the transition. However, the data indicate that the transition actually begins in the nozzle. The constant Mach number, combined with the requirement for unique rotor incidence, implies that the axial flow area and absolute flow angle must compensate to achieve these conditions. For the test unit, operating at the design condition the resulting streamtube height is 9.98 mm. This height is much closer to the 7.95 mm height noted in the dirt patterns than the full nozzle exit height of 11.84 mm. Thus, the transition to the 7.95 mm flow height begins at the last “covered” portion of the nozzle. developed two-equation k-e turbulence model. For efficient use of computing resources, a phase-lag approximation is available to enable use of only one blade passage per blade row in the simulation. Modeling indicates for the design conditions of this turbine, the suction side leading “flat” to circular arc occurs too early and, for this solidity, results in the flow separating from the suction surface. Some additional interesting features include: • Disruption of the bow shock of the rotor by the nozzle wake. The bow shock is near the leading edge of the rotor at a time where the nozzle has not yet passed by and subsequently, when the nozzle wake just starts to influence the rotor. The bow shock system is completely The high error band in Curtis stage performance prediction is due mainly to the complexity of the interaction between the nozzle and the first rotor row. The first rotor row of a Curtis stage has a supersonic inlet, and resulting unique incidence, due to low velocity ratio and high stage energy. In order to maintain the supersonic inlet, the rotor leading edge streamtube must be considerably smaller in height than the blade trailing edge (and thus, the provided blade leading edge height), or the flowfield will shock down to a subsonic inlet, with the attending high positive stage reaction. Dirt and wear patterns confirm the streamtube contraction into the first rotor row. Maintaining the rotor’s unique incidence requires that the nozzle angle, and/or streamtube height, must adjust as wheel speed changes, and this was noted in the behavior of nozzle static pressure taps during Curtis stage testing. Figure 24: Mach Contours interaction with separation region Stage reactions, measured on these Curtis stage tests confirm the low, actually negative, reaction noted on other supersonic rotor tests. The nozzle to rotor streamtube contraction and geometric expansion is very aggressive, and the drilled-hole nozzle type was challenging to model in CFD. However, CFD did confirm the separation of flow off the leading edge suction surface (as seen in the dirt patterns), and the resulting impingement of that high energy flow stream on the pressure surface of the adjacent blade (observed in both dirt, and wear, patterns). The unsteady flow behavior caused by the thick “trailing edge” of the nozzle was also shown to significantly influence the behavior of the rotor flow well past what traditional Curtis-stage design methodologies account for. ■ For additional technical papers, visit our website at: www.dresser-rand.com Figure 15: Typical areas of first rotor blade wear for long service units 15 Dresser-Rand Succeeds With Applied DATUM Technology For Major U.S. Refinery in Record Time Just over ten years ago, Dresser-Rand (D-R) debuted its high-efficiency DATUM centrifugal compressors – a technologically advanced line that set new standards for the industry. Their unique design resulted in superior product performance, and reduced cycle time. Because of its ability to be applied to upgrade installed units (even those of D-R’s competitors), DATUM technology gave D-R an opportunity to assist clients faced with the challenge of maintaining the reliability and performance of their older compression units. A decade later, the DATUM design concept continues to successfully meet clients’ equipment performance needs. Recently, Dresser-Rand succeeded in providing such a client with a performance upgrade solution that applied DATUM technology to another OEM’s equipment within a scheduled sevenday plant shutdown. A major oil refinery in the Midwest United States contained a horizontally split three-stage refrigeration compressor that had been installed by a D-R competitor in 1965. The company sought a more efficient design to lower the horsepower required by the current compressor because the steam turbine’s existing power capability was insufficient during high-ambient temperature days. They also wanted the ability to compress 15 percent more propylene within the existing steam turbine horsepower capability. The refinery needed a solution that would address the change in design and the greater efficiency needed, while still being cost effective and timely. D-R approached the client’s management team with a proposal to revamp this equipment using a high-efficiency DATUM rotor, diaphragms, and impellers, commonly referred to as a “bundle.” Because of Dresser-Rand’s history with this client, and a proven track record with similar projects for other clients, the company was confident that D-R could address the goals of the revamp. This project, however, did present some challenges. The refinery had several unique accessibility and timing issues regarding this revamp that D-R would have to work around. The facility was scheduled for a plant turn-around, and the compressor would not be accessible to D-R until that time. The plant would be operational again in seven days, giving D-R only one week to complete installation of the revamp hardware after the parts were completed. Because the unit could not be shipped before the actual installation of the DATUM internals, D-R would not have early access to all the dimensional details required for final machining of some parts.“ While this timing is normal for a plant turn-around, it was unusual to not have all the dimensions needed to complete the manufacturing of the new compressor internal components,” explained Jeff Worst, senior product design engineer for Dresser-Rand. “D-R was missing the required information to fit the new bundle into the existing compressor case.” Although the refinery’s management understood the complexity of the task it was putting before D-R, the final fit dimension would have to wait. The biggest challenge was trying to design parts without benefit of original design drawings. DresserRand was required to develop the internals with very little information. D-R workers realized they could get close to the dimensions needed, but not close enough to trust making the cuts. They would have to wait until they received the equip- ment and then complete the project in seven days to have the equipment back in service. Dresser-Rand accepted the challenge, relying on its unique processes for Applied Technology revamps, as well as its ability to schedule and manage all activities from field service to manufacturing. With an understanding of the critical need to have the plant up and running after a turn-around per schedule, Dresser-Rand confirmed they had the expertise for the seven-day timetable. “D-R’s Olean, New York operations worked closely with the D-R service center in Cincinnati to prepare for the arrival of the compressor,” Worst explained. “The initial plan was to work around the clock to complete the required work on time. Two D-R Applied Technology design engineers were on hand to give 24-hour coverage in the service center to insure that any problems were handled quickly. “In the end, only one 24hour shift was necessary. We were able to complete the work by scheduling 12hour shifts, positive interaction between the service center personnel, good on-site engineering support, and thorough planning.” To successfully complete a revamp on a competitor’s equipment, D-R uses proprietary software for configuring DATUM equipment, Unigraphics three-dimensional design program, and dimensions from the client’s spare parts inventory to design a compressor layout that approximates the final fit dimension. This technique enables D-R to fit all the new parts into an existing casing. For this project, the D-R Applied Technology team was able to use the plant’s original compressor spare rotor, which was stored in D-R’s Cincinnati repair center as part of D-R’s rotor storage program. This program allows clients to have spare rotors manufactured by any OEM to be stored, inspected, delivered, and ready for installation in 24 hours. Participating in DresserRand’s rotor storage program also reduces a client’s storage and maintenance requirements by freeing warehouse space, improving the use of manpower, and transferring responsibility for storage documentation control to Dresser-Rand. D-R’s storage facilities feature a climate-controlled environment to prevent corrosion, and vertical hanging to eliminate shaft bowing. All rotors are routinely visually inspected while in storage to detect physical abnormalities, as well as being inspected more carefully before being prepared for installation. Furthermore, before shipment, rotor balance is checked to maintain sound rotor installation and reliable operation. In the case of this project, storing the spare rotor at the Dresser-Rand facility gave the D-R team the means to prepare for a revamp of non-Dresser-Rand equipment. Components for the refinery revamp were manufactured at D-R’s Olean facility and shipped to the Cincinnati service center. The facility turn-around took place as scheduled, at which time the compressor was taken out of service and shipped to the service center. Seven days later, the revamped compressor was returned to the client, and restarted. Immediate results, obtained by performance testing at the plant, indicated that the project goals were met. One year later, performance of the compressor was shown to be consistent. “It’s been calculated that we were able to enhance the compressor efficiency by increasing the flow by 15 percent without significantly increasing the steam power requirement,” Worst stated. “The revamp enabled the plant to stay on line and keep producing, where in the past they would not have been able to stay on-line. Continued on page 18 16 17 Dresser-Rand Succeeds With Applied DATUM Technology For Major U.S. Refinery in Record Time Just over ten years ago, Dresser-Rand (D-R) debuted its high-efficiency DATUM centrifugal compressors – a technologically advanced line that set new standards for the industry. Their unique design resulted in superior product performance, and reduced cycle time. Because of its ability to be applied to upgrade installed units (even those of D-R’s competitors), DATUM technology gave D-R an opportunity to assist clients faced with the challenge of maintaining the reliability and performance of their older compression units. A decade later, the DATUM design concept continues to successfully meet clients’ equipment performance needs. Recently, Dresser-Rand succeeded in providing such a client with a performance upgrade solution that applied DATUM technology to another OEM’s equipment within a scheduled sevenday plant shutdown. A major oil refinery in the Midwest United States contained a horizontally split three-stage refrigeration compressor that had been installed by a D-R competitor in 1965. The company sought a more efficient design to lower the horsepower required by the current compressor because the steam turbine’s existing power capability was insufficient during high-ambient temperature days. They also wanted the ability to compress 15 percent more propylene within the existing steam turbine horsepower capability. The refinery needed a solution that would address the change in design and the greater efficiency needed, while still being cost effective and timely. D-R approached the client’s management team with a proposal to revamp this equipment using a high-efficiency DATUM rotor, diaphragms, and impellers, commonly referred to as a “bundle.” Because of Dresser-Rand’s history with this client, and a proven track record with similar projects for other clients, the company was confident that D-R could address the goals of the revamp. This project, however, did present some challenges. The refinery had several unique accessibility and timing issues regarding this revamp that D-R would have to work around. The facility was scheduled for a plant turn-around, and the compressor would not be accessible to D-R until that time. The plant would be operational again in seven days, giving D-R only one week to complete installation of the revamp hardware after the parts were completed. Because the unit could not be shipped before the actual installation of the DATUM internals, D-R would not have early access to all the dimensional details required for final machining of some parts.“ While this timing is normal for a plant turn-around, it was unusual to not have all the dimensions needed to complete the manufacturing of the new compressor internal components,” explained Jeff Worst, senior product design engineer for Dresser-Rand. “D-R was missing the required information to fit the new bundle into the existing compressor case.” Although the refinery’s management understood the complexity of the task it was putting before D-R, the final fit dimension would have to wait. The biggest challenge was trying to design parts without benefit of original design drawings. DresserRand was required to develop the internals with very little information. D-R workers realized they could get close to the dimensions needed, but not close enough to trust making the cuts. They would have to wait until they received the equip- ment and then complete the project in seven days to have the equipment back in service. Dresser-Rand accepted the challenge, relying on its unique processes for Applied Technology revamps, as well as its ability to schedule and manage all activities from field service to manufacturing. With an understanding of the critical need to have the plant up and running after a turn-around per schedule, Dresser-Rand confirmed they had the expertise for the seven-day timetable. “D-R’s Olean, New York operations worked closely with the D-R service center in Cincinnati to prepare for the arrival of the compressor,” Worst explained. “The initial plan was to work around the clock to complete the required work on time. Two D-R Applied Technology design engineers were on hand to give 24-hour coverage in the service center to insure that any problems were handled quickly. “In the end, only one 24hour shift was necessary. We were able to complete the work by scheduling 12hour shifts, positive interaction between the service center personnel, good on-site engineering support, and thorough planning.” To successfully complete a revamp on a competitor’s equipment, D-R uses proprietary software for configuring DATUM equipment, Unigraphics three-dimensional design program, and dimensions from the client’s spare parts inventory to design a compressor layout that approximates the final fit dimension. This technique enables D-R to fit all the new parts into an existing casing. For this project, the D-R Applied Technology team was able to use the plant’s original compressor spare rotor, which was stored in D-R’s Cincinnati repair center as part of D-R’s rotor storage program. This program allows clients to have spare rotors manufactured by any OEM to be stored, inspected, delivered, and ready for installation in 24 hours. Participating in DresserRand’s rotor storage program also reduces a client’s storage and maintenance requirements by freeing warehouse space, improving the use of manpower, and transferring responsibility for storage documentation control to Dresser-Rand. D-R’s storage facilities feature a climate-controlled environment to prevent corrosion, and vertical hanging to eliminate shaft bowing. All rotors are routinely visually inspected while in storage to detect physical abnormalities, as well as being inspected more carefully before being prepared for installation. Furthermore, before shipment, rotor balance is checked to maintain sound rotor installation and reliable operation. In the case of this project, storing the spare rotor at the Dresser-Rand facility gave the D-R team the means to prepare for a revamp of non-Dresser-Rand equipment. Components for the refinery revamp were manufactured at D-R’s Olean facility and shipped to the Cincinnati service center. The facility turn-around took place as scheduled, at which time the compressor was taken out of service and shipped to the service center. Seven days later, the revamped compressor was returned to the client, and restarted. Immediate results, obtained by performance testing at the plant, indicated that the project goals were met. One year later, performance of the compressor was shown to be consistent. “It’s been calculated that we were able to enhance the compressor efficiency by increasing the flow by 15 percent without significantly increasing the steam power requirement,” Worst stated. “The revamp enabled the plant to stay on line and keep producing, where in the past they would not have been able to stay on-line. Continued on page 18 16 17 More than 900 of these robust and reliable units have been supplied to more than 62 countries. Applied Datum Technology.... Continued from page 17 The compressor has performed mechanically and aerodynamically to meet the client’s expectations.” The client is also pleased with the results. The increased cooling through the high ambient temperatures of summer helped increase propylene production significantly. In fact, this revamp contributed to some of the client’s largest propylene sales in their history without increasing their energy demand.■ Dresser-Rand Equipment Powers Australia’s BassGas Project Original Conditions Revamp Conditions 7968 RPM 10458 RPM 7968 RPM 10458 RPM Design conditions Design speed Design gas 9960 RPM 90% propylene 9612 RPM 95% propylene Section one inlet conditions Suction flow Suction temp Suction pressure 2110 lb/min 30 deg. f 80 PSIA 2461 lb/min 23 deg. f 60 PSIA Min speed Max speed Section two side steam inlet conditions SS inlet flow SS inlet temp SS inlet pressure 600 lb/min 61 deg. f 121 PSIA 535 lb/min 42 deg. f 95 PSIA Discharge conditions Discharge flow Discharge temp Discharge pressure 2710 lb/min 136 deg. f 273 PSIA 2995 lb/min 121 deg. f 205 PSIA When a critical offshore platform is expected to operate efficiently and continuously, without the benefit of a topside crew, equipment reliability is paramount. This is certainly true for the BassGas platform, positioned in the Bass Straight above the Yolla gas field, nearly 150 kilometers off Australia’s Victorian Coast. Dresser-Rand, one of the largest global suppliers of rotating equipment solutions to the worldwide oil, gas, petrochemical and process industries, provided the base-load power generation equipment for the unmanned platform. Origin Energy awarded the contract early in 2003 through its engineering, procurement and construction contractor, Clough Engineering Limited. The project called for DresserRand KG2-3E gas turbine generator packages to generate approximately 3300 kW base load power at an ambient temperature of 25 degrees C. 18 “The KG2 is a perfect solution for this application because of its simplicity of design and reliable performance requiring a minimal amount of maintenance,” said Olav Luraas, manager of KG Product Sales at Dresser-Rand in Kongsberg, Norway. "We are very pleased to have played a role in this important project, helping the BassGas joint venture provide a vital source of clean energy to Australia's south eastern states.” The KG2 gas turbine is equally at home running continuously in hostile marine environments, in remote desert power stations and in demanding industrial cogeneration applications. The unit can use various types of liquid hydrocarbons for fuel, as well as a large variety of gas fuels – even at very low calorific values and pressures. In addition to the KG2, Dresser-Rand offers gas turbines in the 14 to 43 MW power range. Dresser-Rand has vast experience in packaging aeroderivative gas turbines from General Electric and Rolls-Royce, driving both compressors and generators for the world’s energy industry. DresserRand’s high-speed VECTRA® power turbine is lightweight and compact, and was developed to match the LM2500 family of gas generators. Together they offer one of the most efficient power packages available in the 30 MW class. Dresser-Rand is experienced in providing a variety of gas turbine packages, supporting power generation applications on and offshore, as well as equipment drivers for centrifugal compressors. A recognized leader in the field, D-R has delivered more than 2,500 gas turbine driver packages for compressors and generators in more than 62 countries.■ The Dresser-Rand KG2 units for the BassGas project were manufactured at the company's facility in Kongsberg, Norway. In June 2003, following thorough factory testing, the units were shipped to the Nippon Steel fabrication yard on the Indonesian Island of Batam, where they were installed in the platform structure. With 99.3 percent start reliability, a full load throw-on capacity, the KG2 turbine is ideal for base load and emergency power supply, onshore and offshore. The KG2 generator set has been specifically designed to meet these requirements for power from 1 MW to 10 MW (single and multiple units). 19 More than 900 of these robust and reliable units have been supplied to more than 62 countries. Applied Datum Technology.... Continued from page 17 The compressor has performed mechanically and aerodynamically to meet the client’s expectations.” The client is also pleased with the results. The increased cooling through the high ambient temperatures of summer helped increase propylene production significantly. In fact, this revamp contributed to some of the client’s largest propylene sales in their history without increasing their energy demand.■ Dresser-Rand Equipment Powers Australia’s BassGas Project Original Conditions Revamp Conditions 7968 RPM 10458 RPM 7968 RPM 10458 RPM Design conditions Design speed Design gas 9960 RPM 90% propylene 9612 RPM 95% propylene Section one inlet conditions Suction flow Suction temp Suction pressure 2110 lb/min 30 deg. f 80 PSIA 2461 lb/min 23 deg. f 60 PSIA Min speed Max speed Section two side steam inlet conditions SS inlet flow SS inlet temp SS inlet pressure 600 lb/min 61 deg. f 121 PSIA 535 lb/min 42 deg. f 95 PSIA Discharge conditions Discharge flow Discharge temp Discharge pressure 2710 lb/min 136 deg. f 273 PSIA 2995 lb/min 121 deg. f 205 PSIA When a critical offshore platform is expected to operate efficiently and continuously, without the benefit of a topside crew, equipment reliability is paramount. This is certainly true for the BassGas platform, positioned in the Bass Straight above the Yolla gas field, nearly 150 kilometers off Australia’s Victorian Coast. Dresser-Rand, one of the largest global suppliers of rotating equipment solutions to the worldwide oil, gas, petrochemical and process industries, provided the base-load power generation equipment for the unmanned platform. Origin Energy awarded the contract early in 2003 through its engineering, procurement and construction contractor, Clough Engineering Limited. The project called for DresserRand KG2-3E gas turbine generator packages to generate approximately 3300 kW base load power at an ambient temperature of 25 degrees C. 18 “The KG2 is a perfect solution for this application because of its simplicity of design and reliable performance requiring a minimal amount of maintenance,” said Olav Luraas, manager of KG Product Sales at Dresser-Rand in Kongsberg, Norway. "We are very pleased to have played a role in this important project, helping the BassGas joint venture provide a vital source of clean energy to Australia's south eastern states.” The KG2 gas turbine is equally at home running continuously in hostile marine environments, in remote desert power stations and in demanding industrial cogeneration applications. The unit can use various types of liquid hydrocarbons for fuel, as well as a large variety of gas fuels – even at very low calorific values and pressures. In addition to the KG2, Dresser-Rand offers gas turbines in the 14 to 43 MW power range. Dresser-Rand has vast experience in packaging aeroderivative gas turbines from General Electric and Rolls-Royce, driving both compressors and generators for the world’s energy industry. DresserRand’s high-speed VECTRA® power turbine is lightweight and compact, and was developed to match the LM2500 family of gas generators. Together they offer one of the most efficient power packages available in the 30 MW class. Dresser-Rand is experienced in providing a variety of gas turbine packages, supporting power generation applications on and offshore, as well as equipment drivers for centrifugal compressors. A recognized leader in the field, D-R has delivered more than 2,500 gas turbine driver packages for compressors and generators in more than 62 countries.■ The Dresser-Rand KG2 units for the BassGas project were manufactured at the company's facility in Kongsberg, Norway. In June 2003, following thorough factory testing, the units were shipped to the Nippon Steel fabrication yard on the Indonesian Island of Batam, where they were installed in the platform structure. With 99.3 percent start reliability, a full load throw-on capacity, the KG2 turbine is ideal for base load and emergency power supply, onshore and offshore. The KG2 generator set has been specifically designed to meet these requirements for power from 1 MW to 10 MW (single and multiple units). 19 Equipment Operators Face Critical Shortage of Experienced Mechanics Dresser-Rand Training Programs Address the Need Operators of gas compression equipment throughout the world are facing a shortage of experienced mechanics. To help address this critical need, DresserRand has expanded its offering of training programs covering the operation and maintenance of centrifugal and reciprocating compressors, integral gas engines, steam turbines, and related control systems. “It’s no secret that the petrochemical industry is facing an extreme shortage of skilled service personnel, 20 especially when it comes to operating and maintaining gas compression equipment,” said Mark Jones, product training manager at Dresser-Rand. “Through normal attrition rates alone, including retirements, transfers, and promotions, companies find themselves operating with a lessqualified workforce as newer and younger employees replace those with more experience.” While many colleges and technical schools continue to supply the labor pool with talented, well-trained technicians, many focus on industries such as over-theroad trucking, earth moving, and automotive. “Currently, only a few technical schools offer a curriculum that includes gas compression,” Jones states. “So we’ve taken the initiative to expand our course offerings, and make them more readily available to companies who wish to prepare their mechanics, operators, and reliability engineers for their new responsibilities. Our proven courses provide them with the skills and the knowledge required to keep their equipment operating efficiently,” Jones said. The company has announced its 2007 product training schedule and course offerings, and in addition to offering its widely accepted factory and regional courses DresserRand is featuring several new course offerings to provide clients with more detailed training that is flexible, convenient, and affordable. on programs. Related topics have been bundled together and are conducted in succession over a two- to three-day period, giving students the opportunity to attend one or all of the programs scheduled for that location. training program, D-R will advertise, market, and conduct the course at the client's facility. This eliminates travel costs and provides other clients in the area an opportunity to attend and share the lower travel and living expenses. Web-Based Training (WBT): With more than 20 courses in the Dresser-Rand library (and more being added each year), WBT programs continue to gain popularity with many clients who operate and maintain steam turbines, integral gas engines, and centrifugal and reciprocating compressors. These online courses provide self-paced instruction for operators and mechanics and support scheduled, just in time, or refresher training requirements. For detailed information about any of the training programs, clients can view D-R's 2007 product training schedule or register for courses by visiting the D-R web site at: www.dresserrand.com, under "Product Training 07." To receive a copy of Dresser-Rand 2007 training literature by mail, requests may be made by calling (607) 937-2303 or by sending an email to: [email protected].■ Operator Training: Designed specifically for equipment operators, these general courses familiarize students with the major components that make up rotating equipment, and give indepth insight into theory as it relates to operational issues. "As always, customized programs specific to a client’s machinery can be arranged if desired," Jones explained. "If there's a group of people to be trained from a specific facility, we'll research the equipment records and provide a program matched to that machinery. Our instructors can travel to a client's site to conduct the course, keeping travel costs to a minimum." Short Courses: One-day courses cover topics selected from Dresser-Rand’s longer classroom and hands- If open-registration courses are not held in a location convenient to a client, and the client is willing to host the Dresser-Rand Manufactures Largest Single-Casing Steam Turbine Another milestone achievement has been reached by Dresser-Rand -- its Steam Turbine Strategic Business Unit (SBU) recently completed production and testing of the largest singlecasing steam turbine ever produced by the company. The landmark unit is the result of nearly 16 months of engineering and production, according to Mike McGuinness, sales and marketing manager for Dresser-Rand's Steam Turbine SBU. “This is a 69 MW steam turbine measuring 24 feet in length. When coupled to the generator, the length of the unit measures more than 49 feet.” The unit is a doublecontrolled extraction/ condensing turbine that will be used to generate power by a major paper manufacturer in the southeastern United States. “This steam turbine is part of the client’s overall effort to reduce power generation costs at their facility,” McGuinness added. “Steam for the turbine will be generated by a boiler fired by tree bark and petroleum coke (which replaces an older, natural gas-fired boiler), making the system more economical as the price of natural gas rises.” By replacing the gas-fired boiler with the more flexible bark-and-coke-fired boiler, the client anticipates reducing overall purchased power by 90 percent, and reducing natural gas consumption for steam generation by 70 percent. Additionally, the two extraction steam pressure levels produced will be used in the papermaking processes. The success of the project is the result of teamwork and innovation, according to McGuinness. “Every team member contributed and worked efficiently to meet the requirements of the project, with these very favorable results.” With decades of experience in designing, manufacturing and servicing steam turbines, Dresser-Rand provides unmatched knowledge in a full range of standard products as well as custom-engineered solutions. Dresser-Rand’s worldwide installed steam turbine equipment base includes approximately 62,000 units in more than 100 countries. ■ 21 Equipment Operators Face Critical Shortage of Experienced Mechanics Dresser-Rand Training Programs Address the Need Operators of gas compression equipment throughout the world are facing a shortage of experienced mechanics. To help address this critical need, DresserRand has expanded its offering of training programs covering the operation and maintenance of centrifugal and reciprocating compressors, integral gas engines, steam turbines, and related control systems. “It’s no secret that the petrochemical industry is facing an extreme shortage of skilled service personnel, 20 especially when it comes to operating and maintaining gas compression equipment,” said Mark Jones, product training manager at Dresser-Rand. “Through normal attrition rates alone, including retirements, transfers, and promotions, companies find themselves operating with a lessqualified workforce as newer and younger employees replace those with more experience.” While many colleges and technical schools continue to supply the labor pool with talented, well-trained technicians, many focus on industries such as over-theroad trucking, earth moving, and automotive. “Currently, only a few technical schools offer a curriculum that includes gas compression,” Jones states. “So we’ve taken the initiative to expand our course offerings, and make them more readily available to companies who wish to prepare their mechanics, operators, and reliability engineers for their new responsibilities. Our proven courses provide them with the skills and the knowledge required to keep their equipment operating efficiently,” Jones said. The company has announced its 2007 product training schedule and course offerings, and in addition to offering its widely accepted factory and regional courses DresserRand is featuring several new course offerings to provide clients with more detailed training that is flexible, convenient, and affordable. on programs. Related topics have been bundled together and are conducted in succession over a two- to three-day period, giving students the opportunity to attend one or all of the programs scheduled for that location. training program, D-R will advertise, market, and conduct the course at the client's facility. This eliminates travel costs and provides other clients in the area an opportunity to attend and share the lower travel and living expenses. Web-Based Training (WBT): With more than 20 courses in the Dresser-Rand library (and more being added each year), WBT programs continue to gain popularity with many clients who operate and maintain steam turbines, integral gas engines, and centrifugal and reciprocating compressors. These online courses provide self-paced instruction for operators and mechanics and support scheduled, just in time, or refresher training requirements. For detailed information about any of the training programs, clients can view D-R's 2007 product training schedule or register for courses by visiting the D-R web site at: www.dresserrand.com, under "Product Training 07." To receive a copy of Dresser-Rand 2007 training literature by mail, requests may be made by calling (607) 937-2303 or by sending an email to: [email protected].■ Operator Training: Designed specifically for equipment operators, these general courses familiarize students with the major components that make up rotating equipment, and give indepth insight into theory as it relates to operational issues. "As always, customized programs specific to a client’s machinery can be arranged if desired," Jones explained. "If there's a group of people to be trained from a specific facility, we'll research the equipment records and provide a program matched to that machinery. Our instructors can travel to a client's site to conduct the course, keeping travel costs to a minimum." Short Courses: One-day courses cover topics selected from Dresser-Rand’s longer classroom and hands- If open-registration courses are not held in a location convenient to a client, and the client is willing to host the Dresser-Rand Manufactures Largest Single-Casing Steam Turbine Another milestone achievement has been reached by Dresser-Rand -- its Steam Turbine Strategic Business Unit (SBU) recently completed production and testing of the largest singlecasing steam turbine ever produced by the company. The landmark unit is the result of nearly 16 months of engineering and production, according to Mike McGuinness, sales and marketing manager for Dresser-Rand's Steam Turbine SBU. “This is a 69 MW steam turbine measuring 24 feet in length. When coupled to the generator, the length of the unit measures more than 49 feet.” The unit is a doublecontrolled extraction/ condensing turbine that will be used to generate power by a major paper manufacturer in the southeastern United States. “This steam turbine is part of the client’s overall effort to reduce power generation costs at their facility,” McGuinness added. “Steam for the turbine will be generated by a boiler fired by tree bark and petroleum coke (which replaces an older, natural gas-fired boiler), making the system more economical as the price of natural gas rises.” By replacing the gas-fired boiler with the more flexible bark-and-coke-fired boiler, the client anticipates reducing overall purchased power by 90 percent, and reducing natural gas consumption for steam generation by 70 percent. Additionally, the two extraction steam pressure levels produced will be used in the papermaking processes. The success of the project is the result of teamwork and innovation, according to McGuinness. “Every team member contributed and worked efficiently to meet the requirements of the project, with these very favorable results.” With decades of experience in designing, manufacturing and servicing steam turbines, Dresser-Rand provides unmatched knowledge in a full range of standard products as well as custom-engineered solutions. Dresser-Rand’s worldwide installed steam turbine equipment base includes approximately 62,000 units in more than 100 countries. ■ 21 insights A PUBLICATION OF DRESSER-RAND Editorial Statement: ® “insights” is a periodical publication of Dresser-Rand. Its editorial mission is to inform our readership in the areas of energy industries, as well as business and world affairs that have an impact on our mutual concerns. Comments, inquiries and suggestions should be directed to: Janet Ofano Communications Coordinator DRESSER-RAND insights Editorial Office Paul Clark Drive Olean, New York 14760 USA Phone: (716) 375-3000 FAX: (716) 375-3178 insights VOLUME 10, NO. 1 Featured in this issue of insights: Candid Visions: Safety – The Goal Is Zero Dresser-Rand Introduces Integrated Compression SystemTM For Onshore And Offshore Projects, Including Sub-Sea D-R Succeeds With Applied DATUM Technology For Major U.S. Refinery In Record Time © Copyright 2007 Dresser-Rand