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The Finish Line Vol. 26 • March 2022 [Q1 2022]

NDTL and RMS Collaboration Brings Customer Benefits

Jeremy Simpson, Manager of Project Management • Joe Vanden Oever, Principal Engineer

RMS has been testing compressors with our partners at the Notre Dame Turbomachinery Laboratory (NDTL) for several years now.

A mechanical run test of an overhauled compressor provides our customers with the validation that their compressors will perform successfully when returned to service.

As RMS continues to grow its OFS business, the organization recognizes the need to support the testing of various types of seals that our customers use. To do this, RMS developed a series of test rigs that can be easily installed and removed for each compressor test. This increase in capability allows RMS to provide its customers with a reliable product that is proven in a testing environment.

Recently, RMS added a Dry Gas Seal (DGS) test panel to further improve the testing capabilities at NDTL and offer more support to our customers. The new DGS test panel is designed to support both tandem and double-opposed dry gas seals as a dedicated system with devoted clean interconnect hoses. The RMS DGS test panel was designed with the following criteria to support the open-air standard one-hour mechanical running test for OFS compressors.

Advantages

  • Provide the capability to test OFS compressors with either Tandem or Double Opposed DGS
  • Maintain very small footprint to allow ease of movement between compressor tests and allow needed space for additional test equipment setup
  • Provide convenient hook up with test building control system
  • Use a large supply header to adequately feed all individual lines
  • Maintain clean dedicated interconnect hoses to ensure cleanliness is maintained between compressor tests
  • Full supply and position feedback signals on primary supply valves for better operator control remotely

• Continued below •

In addition to the new DGS test panel, RMS and NDTL have collaborated on several other key upgrades to further improve testing capabilities:

  • Seal oil system to support oil buffered mechanical seals.
  • Air panel, which is instrumented to support our tests of compressors using carbon ring, MRC, labyrinth, and separation seals.

This system includes additional instruments used for point-of-use pressure measurements:

  • Seal Water Supply System to support water buffered mechanical seals, carbon ring seal, MRC seal, and Labyrinth seals, as well as seal water return and drain measurements.
  • Casing cooling water system for Oil Free Screw Compressors.

The continued expansion of RMS’s compressor testing capabilities will allow us to better serve our customers with a quality test that assures the reliable operation of their critical rotating machinery. Contact RMS today to learn more about our compressor testing work and how we can support your critical rotating machinery.

Service and support you can count on.

This edition of 'The Finish Line' includes:

  • NDTL and RMS Collaboration Brings Customer BenefitsJeremy Simpson, Joe Vanden Oever
  • New RMS Technical Reference Database Chris Okula
  • Dresser-Rand Axi OFS Compressor OverhaulJames Weider, Jeff Lovelady
  • The Benefits of 3D Scanning — Garrett Lewis
  • RMS hosts ASME Apollo Meeting Chris Okula
  • Upcoming Free Trainings
  • New Hires
  • Turbo Toons

New RMS Technical Reference Database

Chris Okula, Marketing Lead

With more than 150 articles and counting, RMS is pleased to introduce our new Technical Reference Database. Located on the RMS website, this new center of rotating machinery knowledge is the culmination of decades of experience written by members of RMS’s staff of rotating equipment experts. This database is conveniently located RMS website where RMS will continue to share both our passion and expertise in the rotating equipment realm.

Here at RMS, we have the most experienced rotating equipment professionals on earth. Our seasoned workforce of rotating machinery specialists has spent decades supporting critical rotating equipment for our customers. In an effort to preserve and share this wisdom and experience, the RMS Technical Reference Database was born.

The RMS Technical Reference Database represents decades of RMS knowledge and experience all in one location. This center of rotating machinery excellence is a powerful tool to help share RMS’s capabilities while also furthering knowledge in the rotating machinery space. As RMS continues to produce quality results for our customers, new articles will be added to the database to grow its impact.

Thanks to its easy-to-access location on the RMS website, the RMS Technical Reference Database is here to support rotating machinery professionals around the world. Together we can share our experiences to further the rotating machinery industry and grow our impact on critical global infrastructure.

Now our customers and young professionals can learn more about how RMS has continued to provide quality rotating equipment support for our customers for decades. The RMS Technical Reference Database is here to expand knowledge within the industry we love and help our customers expand their knowledge about the machinery they operate.

Dresser-Rand Axi OFS Compressor Overhaul

James Weider, Manager of Manufacturing • Jeff Lovelady, Engineering Fellow

A petrochemical customer experienced a bearing failure in their Dresser-Rand Axi 630HS165 Oil Free Screw Compressor. The customer contacted RMS to discover and address the root cause of this failure and repair their oil free screw compressor with goal of promptly to restoring full plant output. RMS received and inspected this Dresser-Rand Axi 630HS165 Oil Free Screw to identify the root cause of the failure and complete the required repairs to restore the customer’s plant capacity.

Upon arrival at RMS’s Bethlehem, PA shop, the Dresser-Rand Axi 630HS165 was cleaned, inspected, and disassembled by the RMS shop team with full documentation of assembled clearances. Backed by onsite engineering support, the RMS team worked to find the source of the failure. RMS team provided the customer with daily updates on inspection findings to keep the customer site informed on the condition of this critical piece of rotating machinery.

The full inspection revealed several repair opportunities. The RMS team identified a water leak at the split line seal between the cooling water connection between the upper and lower halves as the main cause of the failure. Water entered the lube oils system, which negatively affected the oil’s ability to properly lubricate the bearings causing the steam turbine to trip leading to a plant shutdown. At the split line, RMS identified, Corrosion at the O-ring location, a Teflon ring with no backing support, corrosion on mating seal surface on the upper half joint face, and Oxidation path on horizontal joint clearly showed the leak path to discharge end oil drain.

The flatness of each casing half was inspected by placing a precision straight edge across the joint and measuring gaps along with the casing. These points were then mapped to ensure the joint was flat across both casing halves.

With the inspection work completed, the RMS team got to work on the repairs required to get this Dresser-Rand Axi 630HS165 Oil Free Screw Compressor back into service. First, the O-Ring joint was opened up so the RMS team could create a counter-bore for (4) steel disks to be inserted into both upper and lower half casings. The Steel disks were inserted into the counter-bore in the casing halves and seal welded into place. The lower half disks were machined flush with horizontal joint and the O-Ring groove was machined into the lower half disks. Finally, the upper half casing was recut to eliminate corrosion to the seal surfaces around the O-ring seat.

The support areas between the bearing and seal fit on each end of the machine were welded and the upper and lower casing horizontal joint surfaces were milled to remove high spots. Rotor bearing journals were ground to remove any damage from lube oil contamination and new bearings were manufactured to meet the original bearing clearance specification.

After all repair work was completed, RMS Hydro tested the water jacket to verify the horizontal joint repair, with newly inserted disks to contain the O-rings, passed the required specifications. With a successful hydro test completed, RMS got work assembling the compressor.

The reworked rotors were assembly balanced at the RMS shop before being placed into the repaired casing. Compressor assembly was completed with rotor timing clearance set and instrument installation confirmed. After a final check, the rotor was shipped back to the customer.

This critical project was managed with daily updates on the inspection results and repair progress, with an updated Gantt chart to follow the progression of the project daily. Reports of the inspection and final repair were prepared to document the findings. The customer was also engaged in the decisions that would impact the schedule to ensure timely delivery of their machine back into production.

The Benefits of 3D Scanning

Garrett Lewis, Principal Technologist

With manufacturers across industries racing to increase productivity, every new technology and process can provide a competitive advantage. As a result of this push for more productive methods, many companies have made, or are making, the switch from 2D to 3D modeling.

Let’s dive into the advantages of 3D solid modeling over 2D modeling and find out how this technology can speed up the design process.

Digital Prototype

3D models communicate a lot of information regarding fit and potential issues. Because 2D drawings can’t adequately display that information, issues are not found until the assembly stage. In the case of a 2D drawing, the only way you can spot problems is to create the prototype, tear it down, and rebuild. This prolongs the product development cycle dramatically as you’re forced to include reworks and re-engineering of parts.

With 3D models, there is a greater ability to examine the parts in context. The models can be rotated to be seen from all sides, cross sections can be applied in real time and measurements taken. The 3D models can be used in analysis software, such as ANSYS, to verify the design. This process can catch errors before parts are made saving time in the shop and cost of manufacturing.

Ease of Use and Efficiency

3D CAD makes it easier to incorporate revisions to a drawing. With the parametric capability of the software, when a change is made on the model it is automatically applied to the drawings and assemblies where the model is used. This includes all views and dimensional information.

3D CAD can enhance design reviews. The review could consist of a designer sharing the 3D model, through a projector or on meeting software. Dimensional changes could be applied to parts and the changes would be automatically applied to the assemblies and drawings. Parts can be swapped out. Different design paths can be created. After a quick cleanup of the drawings, any design changes would be ready for production

3D models let designers construct complex geometry while retaining production capability and help visions come together with relative ease. 3D Modeling can also include the manufacturing processes needed to make the models including forgings, weld and inlay final machine and assembly features.

Collaboration

3D models lend themselves to collaboration, as non-technical individuals will be able to more easily understand the design than if it were in 2D. Marketing and sales departments can leverage 3D models, photorealistic renderings, animations, and rapid prototyping for marketing and sales purposes.

Going from a 2D image to a 3D model also allows for quicker and more productive internal design reviews. 3D modeling can foster more effective communication with suppliers, customers, and internal teams, further cutting down on time-to-market.

The parametric aspects of 3D modeling will allow us to work in design teams. A lead designer can be working on the overall assembly while other designers can be working on the components. As parts are saved and uploaded the where used assemblies are automatically updated. This will allow the lead designer to check for fit and functionalities.

3D modeling software can create photorealistic renderings of products that can be used in advertising and sales brochures. Animations can be created, using the same models, to demonstrate how a design will perform in real life. This can save time in the design cycle as clients can easily how the design functions and evaluate how certain parts work together.

More Effective Data Management

Efficient data management is always a concern for companies, particularly when working with numerous revisions and evolutions of products. 3D modeling allows you to easily keep track of your design changes. Instead of having to update a Bill of Materials for every design change, 3D modeling software can automatically update the BOM as components are added or removed from an assembly. This simplifies data exchange with other departments, keeping the product design cycle straightforward and avoiding any potential redundancies or repeated work.

Take Designs Straight to Manufacturing

With 2D, releasing a design to production often requires a manufacturing engineer to convert the 2D drawing into a 3D CAD model first in order to generate the tool paths on a machine tool being driven by a 3D CAM program. This interim step takes time and prevents you from taking a design straight to manufacturing. Integrated 3D CAD and CAM allows users to make a design change, and have the NC toolpath data update accordingly

3D solid modeling allows the time spent in design to decrease other downstream activities. The improved flow of information eliminates structural inefficiencies, human errors, and other factors that slow down the design cycle. Ultimately, 3D technology can increase the efficiency and speed of the design and manufacturing processes, resulting in cost savings, quicker time-to-market, and increased opportunities for innovation.

RMS hosts ASME Apollo Meeting

Chris Okula, Marketing Lead

Earlier this month, RMS hosted the ASME Apollo group at our South Houston Shop. This meeting included a group of experienced professionals and young engineers who joined the RMS team for a shop tour, dinner, and technical presentation about centrifugal compressors. This gathering was a great opportunity to share information and a passion for rotating machinery.

The Apollo Technical Subsection of the ASME South Texas Section promotes activities on design, manufacturing, packaging, operation, maintenance, and repair related to rotating and reciprocating machinery and auxiliary systems. This shared interest in critical rotating machinery made for a focused vent where attendees could learn from each other.

The meeting started with a full shop tour led by RMS’s Matt Miller, who is the Director of Houston Operations. Matt led attendees through RMS’s 67,000 ft2 where attendees had the opportunity to see the RMS machine shop area and weld bays during the first stop. From there, attendees entered RMS’s clean room, where chlorine compressor work takes place. Next, the tour stopped at RMS’s balance area before heading to the RMS QC room. The tour concluded in the pump repair area where skilled technicians work on a variety of pumps for our customers.

After the tour, Steve Kaulius—RMS Director of New Business Development for Centrifugal Compressors—lead both in-person and virtual attendees with a technical presentation about Centrifugal Compressor design. This training was a great exchange of ideas and sparked conversations between attendees who were able to share their own experiences.

RMS hosted the ASME Apollo group at our South Houston Shop

Come learn with the RMS Experts!

Free Single-Day Rotating Equipment Training

WHEN: April 19, 2022 • 8AM – 4:30PM

WHERE: Lake Charles, LA

WHAT: RMS is excited to announce that we are hosting a free Rotating Equipment Training event on Tuesday, April 19 at the L'Auberge Casino Resort Lake Charles . There is no charge for this training, which includes breakfast and lunch. Breakfast will be served from 7 – 8AM with training beginning at 8:15AM. We are scheduled to conclude this one-day training session at 4:30PM.

Contact your local RMS Sales Representative for more information.

Free Two-Day Power Recovery Train Round Table

WHEN: May 10-11, 2022 • 8AM – 6PM

WHERE: RMS Bethlehem, PA Headquarters

WHAT: RMS will be hosting a free two-day Power Recovery Train Round Table event on Tuesday, May 10 and Wednesday, May 11, 2022 at our Bethlehem, PA headquarters. This two-day event is at no cost to you and includes breakfast, lunch, and dinner.

Contact your local RMS Sales Representative for more information.

We look forward to seeing you!

Turbo Toons

Marc Rubino, Quality Manager

Click to enlarge

New Hires

Angel Arabie, Projects Assistant Part Time — Arabie joins RMS as a full-time student at Lamer University (Beaumont, TX) where he is pursuing his B.S. in Chemical Engineering. In addition to his current academic workload, Angel is working with the RMS Project Management team in a support role as he gains valuable experience in the world of rotating machinery.

Sean Heggood, Technical Field Advisor — With experience in rotating equipment installation, preventative maintenance, overhaul and repair, Sean joins RMS as a Technical Field Advisor. This experience includes axial compressors, steam turbine, centrifugal compressors, hot gas expanders, and pumps to name a few. Sean has a wealth of rotating machinery experience and is a registered Local 2232 Millwright. We look forward to adding Sean to RMS’s Field Service team where his wealth of experience with help customers during critical outages.

Hector Oviedo, IT Technician — Hector joins the RMS IT team as a CCNA certified and Houston Community College graduate offering a strong academic background in Networking combined with excellent work experience as an IT Professional. Hector has more than 10 years experience working with servers, desktops, and applications.

Brandon Seamann, Manager, Human Resources — A United States Air Force veteran, Brandon joins the RMS HR team as a Manager, Human Resources. Brandon possess a wealth of experience in on-boarding new team members, managing critical HR documentation, and managing other HR team members. RMS looks forward to having Brandon as a critical part of the RMS human resources team to help support the growing RMS organization.

Gary Anderson, 2nd Shift Mechanic — Gary joins the RMS shop team in Houston with more than 38 years of experience in pump repair. Gary’s career in pump repair started at Sulzer, where he honed his craft and gained the experience required to produce a quality result. We look forward to having Gary as part of the RMS team where he will support critical pump repairs for our customers.

Colby Coyle, Mechanic's Helper — Colby joins RMS early in his rotating machinery career, with experience as a millwright for the repair and maintenance of both steam turbines and gas turbines. Colby’s interest in rotating machinery lead him to join the RMS team in Houston where he can further develop his skills working with more experienced members of the shop team. RMS looks forward to having Colby on board as a future leader in rotating machinery repair and support.

Kirk Dickison, Mechanic — RMS is pleased to welcome Kirk to the RMS Houston Shop Team. Kirk has 10 years of rotating machinery experience as a millwright and he possesses an in-depth knowledge of GE Gas and Steam turbines, gearboxes, and air-/hydrogen-cooled generators that are invaluable to the RMS team. Kirk’s wealth of experience and proven track record make him a fantastic addition to the RMS team.

Alexis Gonzalez, Mechanic — Alexis is an experienced rotating machinery mechanic with great attention to detail. His experience includes documenting critical dimensions, distances, runouts before, during, and after machinery disassembly using precision instruments.

Dustin Lynn Jones, 2nd Shift Mechanic — Dustin’s diverse skillset includes the repair and support of a host of different types of rotating machinery. He has extensive knowledge of liquid ring vacuum pumps, rotary screw pumps, centrifugal pumps, reciprocating pumps and compressors, fans, electric motors, valves, actuators, roots blowers, and systems designed for chemical distillation, vapor recovery, oil and gas processing, metallurgy, heat treating, pneumatic conveyance, and food packaging. This unique skillset is a perfect fit for the RMS Houston shop team, where Dustin’s experience will be a valuable asset in serving our customer’s needs.

Tyler Jordan, Mechanic — Tyler grew up around the rotating machinery space spending much of his time during high school working on Elliot, Coppus, and Terry steam turbines. With previous work experience sand blasting parts, performing test runs of completed jobs, and pulling rotors in the field, Tyler is a critical addition to the RMS team. In his free time, Tyler enjoys dirt track racing in his 1972 Oldsmobile Cutlass.

Remington Rodriguez, Mechanic — Remington joins RMS with an Associate Degree in Process Technology (San Jacinto College) and a rich history of engineered equipment repair experience. With previous work experience at Ethos Energy, Remington has experience in the disassembly inspection and reassembly of steam turbines, gas turbines, and compressors. RMS looks forward to adding Remington’s robust skillset to the RMS shop team in Houston.

Frank Seay, Senior Mechanic — Frank joins RMS with more than 25 years of domestic and international experience in precision measurement as a machinist/millwright in the petrochemical, construction, and oil and gas industries. Frank’s extensive experience includes Dresser Rand Steam Turbines, Elliot Steam Turbines, Abb steam turbines, Dresser Rand Centrifugal Compressors, AC Compressor Centrifugal Compressors, Elliot compressors, and pumps. RMS is excited to welcome Frank to the shop team in Houston where his depth of experience will be an important asset.

Pictured: Brandon Seamann - Manager, Human Resources

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