Dresser Inc

Beta Test Installation Shows Dramatic Improvement in Engine Performance

Waukesha, Wis. (June 29) — Dresser Waukesha, a leading manufacturer of natural gas engines that deliver clean, cost-effective power, has introduced a retrofit kit for adding its state-of-the-art ESM® engine control system to its ATGL® Series gas compression engines.

A beta test retrofit of ESM on a 16V-AT27GL gas compression engine has delivered even higher levels of performance and reliability to the 16-cylinder, 4500 hp unit. The project was recently completed at an EQT Midstream compression site in western Virginia. The Waukesha factory-supervised project was a collaborative effort that included Kraft Power Corporation, the Waukesha distributor that was called in on the project, and EQT Midstream, the site owner-operator. EQT Midstream is a business unit of EQT Corporation.

Alan Thomas, Kraft Power’s manager of technical services for the midwestern United States, assisted with the project, which was completed in less than a week. He described it as “straightforward” and one that significantly improved the engine’s performance. “ESM dramatically improved the engine’s startability – it started on the first crank – and kept the engine operating within the parameters we had set for it,” Thomas said. He explained that the volume of gas changes frequently at this site, so the power output of the engine needs to change as well. ESM automatically adjusts engine operating parameters for these varying power requirements.

Chris Akers, senior vice president, EQT Midstream – Operations, agreed. “At this point, we’ve had the engine up and running with the ESM control system for just a few weeks, but it looks really good. ESM is a completely integrated system and a more robust design. With ESM, the engine has successfully handled the changes in pressures and volumes on both sides of the pipeline. It’s a huge improvement.” 

ESM is a reliable, total engine management system designed to optimize engine performance and maximize uptime by integrating spark timing control, turbocharger control, speed governing, knock detection, start-stop control, diagnostic tools, fault logging, engine safeties and air/fuel ratio (AFR) control.

This is the first time that ESM is being made available for the ATGL Series. ESM has been proven on the company’s VHP® Series and the state-of-the-art APG (Advanced Power Generation) Series and is included on Waukesha’s new 275GL Series gas compression engine. The retrofit kit consists of the latest version of Waukesha’s easy-to-use ESM and all of the related equipment and components required to make an engine in the field ESM ready. The 16VAT27GL ESM kit is available now and the 12V-AT27GL ESM kit is scheduled for release during the first half of 2010.

ESM is Easy to Set Up and Use
ESM is factory-calibrated and tested to minimize on-site setup requirements. It optimizes performance by providing startup with the touch of a button and adjusting engine operating parameters for variable fuel quality. ESM continually monitors engine operation and provides alerts, ensuring peace-of-mind for operators with equipment running at remote, unstaffed locations.

Communication between ESM and the compressor package control panel is via a standard, cost-effective MODBUS protocol. A key feature of ESM is an Electronic Service Program (ESP)that provides full access to all information logged by ESM along with links to an E-help function for step-by-step troubleshooting or any alarm or shutdown code. ESP software and upgrades can be downloaded for free and there are no maintenance fees.

ESM Retrofit Supports Competitive Advantage in Efficiency and Fuel Flexibility
The ESM retrofit kit adds improved performance and controls to ATGL engines, which already demonstrate at least a two percent fuel efficiency advantage over the competition. In addition, the ATGL Series is known for its fuel flexibility and the ability to operate at full power on a much wider range of fuels than the competition – without the added cost and complexity of a fuel treatment system. When comparing power output on actual fuel samples, the 16V-AT27GL operates at full load while the competition requires derates that range from 5 to 14 percent. In addition, the 16V-AT27GL can operate with only minimal derate on fuels where the competition cannot operate at all.