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GE Oil & Gas chose its annual conference to unveil several new products. Foremost among them was the latest iteration of its Integrated Compressor Line (ICL). It launched its first single-shaft ICL, designed for applications such as pipelines, where gas must maintain pressure over long distances. The ICL incorporates GE Power Conversion motors and drive systems to provide up to 20% more operating range flexibility and greater efficiency over previous ICLs while costing about the same as conventional BCL/PCL compressors.
The previously introduced ICL products were mainly intended for gas storage, with multi-stages and multi-impellers. This marks the first of the line with one impeller, which transmits power from the motor to the gas by accelerating it. The static part at the outlet of the impeller translates the speed of the gas into pressure. This design enables high performance in applications where pressure ratio is low (1.1:1.4), such as pipeline gas compression stations. It has two magnetic bearings and no split parts while offering full access to components.
In long pipelines, this new ICL provides gas boosting to counteract gas pressure drops in transit. After a certain distance the gas needs to be recompressed until it reaches the next station or its destination. These units do not require a gearbox, lube oil system, shaft seals or external cooling system.
The single-stage ICL has a power range of 2 to 15 MW, an inlet pressure of 20 to 80 bar, a discharge pressure up to 120 bar and maximum speed of 18,000 rpm. Its commercial applications are expected in the 2014 to 2015 time frame.
The GE Blue-C compressor is for gas compression below the ocean surface. It is in the final phase of qualification tests and has accumulated more than 2,300 running hours while installed in a pool. The testing is being done to verify that the equipment can survive continuous, maintenance-free operation for years. It will eventually be sent to the Ormen Lange Subsea Compression Station Project off the coast of Norway for unattended operation at over 2,950 feet below sea level with power up to 12.5 MW. Installation on the seabed is expected in 2019.
Sixteen ICL units are running and have accumulated more than 33.000 running hours and 1,000 starts and stops for gas storage and pipeline operation in Europe.
Triconex Safety View software from Invensys provides safety integrity for critical alarm and bypass management applications. It is the first software solution certified by TÜV Rheinland to IEC 61508:2010 Systematic Capability 3 for use in applications up to Safety Integrity Level 3 (SIL 3). Safety View draws attention to changes in process conditions that require immediate attention, giving operators, maintenance engineers and shift personnel visibility into the process so they can take actions that reduce risk, optimize total cost of ownership and increase asset performance. It is a PCbased system that exists independently of the control system.
On the oilfield front, the GE Oil & Gas Artificial Lift business showcased its first Motor Cooling System that offers lower motor temperatures while removing pressure and size constraints. It also launched a higher efficiency electric submersible motor. For the mapping of deeper wells, GE Oil & Gas has reached an agreement with Sharewell Energy Services, a Houston-based supplier of directional drilling solutions. This gives GE exclusive worldwide rights to sell Sharewell’s proprietary electromagnetic telemetry technology as part of GE’s Measurement While Drilling (MWD) portfolio. MWD technology is said to improve efficiency and accuracy because measurements are sent to the surface continuously during drilling.
A new redundant valve manifold (RVM) by Norgren brings increased safety and efficiency to safety instrumented systems and other applications. The RVM offers a two out of three (2oo3) configuration, meaning if one of the three pneumatic logic circuits should malfunction there are two logic circuits still operational so redundancy is maintained. Norgren has integrated its SIL-certified valves on a single manifold to create the RVM, available in aluminum or stainless steel. The unit eliminates duplicate piping typically required to install redundant valves.
NOx Johnson Matthey’s Stationary Emissions Control group has designed a more compact, extruded ceramic SCR (selective catalytic reduction) catalyst designed for gas turbines. The Concat GT SRC catalyst is made of a honeycomb structure that provides up to 95% NOx reduction with less catalyst required. The result is a smaller catalyst package, lower pressure drop across the catalyst and less ammonia slip. The Concat provides turbine owners and SCR engineers flexibility in system design for replacement or new installations. www.jmsec.com LM6000 test cell TransCanada Turbines (TCT) recently completed the construction and commissioning of a purpose-built test cell in Calgary, Alberta, Canada. This latest investment provides the company with the capability for full load testing of the GE LM6000 gas turbine used for power generation applications. TCT, a joint venture between TransCanada Corporation and Wood Group GTS, provides maintenance service for operators of GE LM6000 series gas turbines and this new facility enables the company to offer incoming engine test, troubleshooting and diagnostic services for PA, PB, PC, PD and PF variants of the LM6000. Test cell design features, including quick release mechanisms for essential engine services, are expected to enhance the company's ability to respond to customer requirements. TCT is a licensed overhaul, repair and maintenance service provider for GE and Rolls-Royce aeroderivative industrial gas turbines.
Schneider Electric’S PlantStruxure Process Expert System (PES) provides a single software environment that integrates control applications, supervision and field devices to configure an entire control system. It brings together programmable automation controllers (PAC) and Distributed Control Systems (DCS) to form a system that combines energy and process data in one platform. StruxureWare Process Expert, the software component of PES, leverages a single database to enable users to interface with a process element, such as a pump, during runtime operations. Historically, choices have been limited to simple PACs or more complex DCS, with no customizable option for processes with different needs. PlantStruxure PES gives operators a complete picture of the production process, and enables single-screen configuration and diagnostic access traditionally found only in a DCS operator interface. It supports a range of controllers and a full range of input and output modules.
Invensys Operations Management has updated its Off-sites Software, including a batch-tracking option for its Order and Movement Management module. The newest version enables traceability of quality, composition, ownership and batch in movement. Additionally, its line management feature has been reworked to provide full line handling with similar information about batches, ownership, composition and quality actually flowing in lines or line segments. The blend optimization system is enhanced to optimize blend plans for multi-blend header process environments. Additionally, the tank information system has been improved to support redundant level measurements and transparent synchronization of alarms with PLC or distributed control systems. www.invensys.com Spain opts for wave power Dresser-Rand, in collaboration with Spanish electric company Iberdrola Ingenieria and other companies, received the Etorgai Grant from the Basque government to help fund the development of offshore wave technology. It will use an array of wave energy converters, including Dresser-Rand’s HydroAir variable radius turbine, to convert the waves’ energy into electricity. The first stage of the project focuses on modeling the behavior of the elements of a power plant. The second consists of studying and analyzing interactions between power plant models developed from actual sea trials. The final stage will define the optimum power technology and provide a simulation of expected energy costs. Built with a combination of stainless steel, aluminum and reinforced composites to resist corrosion, the HydroAir turbine is said to withstand the rigors of a marine environment. With a wide operating range and lower rotational speeds, the turbine demonstrates increased efficiency across a range of incident flows when compared to existing turbines. The rotor is the only moving part of the turbine, which results in higher reliability and more cost-effective production. In addition, it is designed for up to 500kW, is self-starting and produces less noise. The variable radius turbine is comprised of a rotor and several vanes that act as route guides for the airflow. Air enters the duct at a relatively low speed then swirls and gains speed as it is guided through the vane toward the turbine rotor. The air drives the rotor, and then decelerates as it travels back through the expanding duct before passing over the outlet guide vanes. The process is repeated in reverse for the next wave cycle.
GE Measurement & Control has introduced its new CAP Software Update and SecurityST Appliance to protect existing industrial controls systems from cybersecurity threats. To keep pace with constantly evolving threats, the update will manage digital patch levels and anti-virus/host intrusion detection signatures. It also enhances backup capabilities. The SecurityST Appliance minimizes security lifecycle costs and provides enhanced recovery capabilities, as well as centralized account management, event logging and management, network intrusion detection and update and backup change management. www.ge.com. Thermal history coatings Sensor Coating Systems (SCS) has launched a user club for the development of its core sensing technology known as Thermal History Coating (THC). Club members include Alstom, MAN Diesel & Turbo, SNECMA of France and SCS. The objective is to develop THC technology that can be applied in engine development programs to lower development costs and accelerate low-emission engine introduction. The aim of THC is to replace thermal paints. A handheld reader is also being developed as part of the system to assess test results objectively. Originally developed by a team at Imperial College, London, THC is based on the light emitting properties of a class of ceramic materials, which when exposed to particular levels of temperature, undergo irreversible changes in the material structure or chemistry. When excited with a probing light, the material starts to phosphoresce and this can be observed with specialized optical components to establish a correlation between the observed light and the past temperature. The ceramic material can be applied as a coating onto a component using manufacturing techniques such as atmospheric air plasma spraying (APS), or (for low temperature regimes) as a paint. The club gives its members rights to future use of the technology. www.sensorcoatings.com Soft foot corrections Soft foot is every alignment technician’s worst nightmare. It means improper contact between a machine casing and the baseplate used to support it. Correcting soft foot may not be straightforward, but once it is done, alignment of machines becomes an easier task. A soft foot video (http://youtube.com/ludecainc) provides insights and instructions on solving various types of soft foot and demonstrates workable techniques using laser-alignment equipment.
Siemens has introduced the Scalance WLC711 industrial wireless local area network (IWLAN) controller. It is centrally configured and monitors up to 32 access points and client modules. Parallel operation of two controllers increases the availability of the communication network. Designed to work seamlessly with the Scalance W786C and W788C controller access points and Scalance W748 client modules, the controller offers data rates of up to 450 Mbps. Security features restrict system access to only authorized users. Additionally, the controller authenticates wireless devices connecting wireless access points.