| Situation |
Customer
had OEM cylinders w/o nameplates and no known pressure rating. This was considered a safety
hazard. Driver is an I-R KVG and cylinders were non I-R but those of
another OEM. |
| Customer's Need |
Replacement
cylinders with certified pressure rating and capacity, appropriate flange
size and rating and suitable attachment adapter for existing I-R
driver. |
| ACI's Solution |
Selected
Cooper ductile iron cylinder with proper features, designed piston and rod
assembly, bored liner to correct size and produced appropriate adapter. Reworked accessories such as packing and
valves to supply fully
remanufactured assemblies. |
| Follow-up |
Remanufactured
cylinders provided ahead of customer's schedule and they performed
mechanically and thermodynamically in accordance with customer's specs. |
| Situation: |
Existing
OEM's gas transmission service failed in service. |
| Customer's Need: |
Structurally
stronger, functional equivalent cylinder bodies with liners to replace
failed OEM cylinder bodies. |
| ACI's Solution: |
Replaced
I-R 30 grade iron with 45 grade iron and heavier wall sections in weak
areas at a lower price and shorter delivery. Subsequent cylinders were made available in ductile iron at the
same price after pattern and tooling and engineering costs were absorbed
by initial cylinder purchase. |
| Follow-up: |
OEM
price was quoted lower than ACI price but invoice was $10,000 higher to
reflect 45 grade iron. Quoted price was based on 30 iron. Customer was very
irate. |
| Situation: |
OEM
high stage cylinders failing on a consistent basis. |
| Customer's Need: |
New
cylinder design to eliminate failures and maintain major piping connection
locations. |
| ACI's Solution: |
New
cylinder geometry eliminated the stress concentration factors associated
with the OEM design. Design simplified service function and extended valve
life. The ACI designed cylinders were less expensive -- so much so that
the OEM refused to submit a quote. |
| Follow-up: |
New
cylinder has run for over 18 years. Original designed cylinders were only for the 5th
stage. Customer came back to have 4th stage cylinders
redesigned in same fashion as 5th stage cylinders. Later, they wanted to have 3rd stage
done also. However, due to the tandem arrangement, this was not possible.
So, ACI designed a semi-four valve arrangement that simplified
valve maintenance and eliminated the personnel hazard associated with the
OEM's design. Again, the OEM declined to offer a bid on these cylinders. |
| Situation: |
A
total revamp of the refinery process resulted in the obsolescence of all cylinders
previously used on two different integral angle compressor units. |
| Customer's Need: |
Customer
required 10 cylinders in a platform service and three cylinders for a
platform service on OEM integral angle compressor units. In addition, two cylinders were required for an OEM integral angle
machine for a D. U. Recycle service as well as the revamp of two existing
cylinders on the OEM unit which were to be utilized in a D. U.
Booster service. |
| ACI's Solution: |
The
two different services on the I-R engines required substantially different
bore sizes to accommodate the specific flow rates for the two services. Since the compression ratios of the two services were not high,
fixed clearance did not have a major influence on cylinder sizing. As a result, both services utilized a common body with different
liner bores. The use of a slip fit liner offers the customer maximum
flexibility. The ten inch liner bore, platform cylinder utilizes a filler
piece in the front head which is omitted from the front head of the
unifiner service. The filler piece is used as a potential clearance adjustment for
the ten inch bore cylinders and permits the addition of an insert to the
8-7/8 bore cylinders to reduce fixed clearance. The ductile iron cylinders were fitted with a full complement of a
unique design, failsafe, suction valve bypass unloaders to permit loadless
start up and shutdown. Cylinders were of a non lubricated design and were provided with
distance pieces to accommodate piston rod oil dams. While the larger bore I-R cylinders were of an eight valve
configuration, the new D. U. Recycle cylinders for the Worthington engine
were of a four valve design. These cylinders attached directly to the existing distance pieces
and maintained the centerline of crank to centerline of suction and
discharge flange location that was associated with the original cylinders.
The new cylinders featured the same type of suction valve bypass unloader.
These cylinders were also of a non lubricated design. Because it is a refinery application, cylinders were produced to
API-618 specifications. |
| Follow-up: |
Some
ten years after installation the cylinders continue to meet the customers
performance expectations from both a thermodynamic and mechanical stand
point. |
| Situation: |
Customer
owned four throw nine inch stroke, DeLaval units previously in a natural
gas BTU stabilization service were to be re-cylindered for natural gas
injection/withdrawal service. |
| Customer's Need: |
The
availability of existing low pressure wells created a natural storage
cavity for a natural gas storage/withdrawal operation. In order to take advantage of this facility, very versatile and
flexible compressor equipment would be required. |
| ACI's Solution: |
New
custom designed cylinders were created for the application. The range of operating conditions was such that, in addition to
double acting operation, single acting operation would be required. In
addition, fixed volume bottles over valves were required. The single acting capability was facilitated through special
porting in the body and front head which, with the application of a large
plug valve in the front head, permitted the connection of the head end
compression chamber with the suction gas passage. The result was the ability to provide the required flows in both
operating modes with small unloading steps without exceeding rod loads. ACI supplied crossheads to replace those which were required to
duplicate the majority of those used in the previous application. |
| Follow-up: |
The
OEM was going to apply some non DeLaval cylinders which provided no single
acting capability. The OEM would not provide new crossheads which meant that not all
compressors would have the same weight. A built in service problem. Without single acting capability, performance would be
compromised. |
| Situation: |
Customer
was operating multi-stage hydrogen compressors in a refinery that
compressed a gas which was hydrogen rich. Flow requirements changed in more recent times and in addition load
requirements had become more variable. |
| Customer's Need: |
To
meet the ever changing flow rates, new capacity control equipment was
required. In some
applications, the working pressures approached 3500 psi. |
| ACI's Solution: |
Unloader bodies were primarily machined from block
forgings. Volumes for the unloaders were sized by ACI to meet customer flow
specifications. All seals
were special designs and materials to address the difficult gas analysis,
temperatures. |
| Follow-up: |
Unloader assemblies ran for many years in
continuous duty before requiring seal replacements. |
| Situation: |
Customer
required the reapplication of large horsepower integral engines and
compressors. The range of ratios required a reduction of existing fixed
clearance. |
| Customer's Need: |
The customer was
on a tight budget and required reuse of as much hardware as possible. |
| ACI's Solution: |
ACI
reconfigured front and rear heads and liner ports to reduce fixed
clearance. Valves were
redesigned to maximize lift area and minimize fixed clearance. A multiplicity of fixed volume unloaders provided the flexibility
necessary to meet the wide range of compression ratios associated with the
new application. Novel piston
designs permitted the use of existing rods while providing piston to rod
attachment features which result in reduced torque values for assembly. |
| Follow-up: |
The
revamped units provided the required performance. The OEM approach would not have matched that provided by
ACI. In addition, the customer would have been saddled with the archaic
piston to rod attachment features associated with OEM design. |
| Situation: |
Customer
has large integral angle compressor units with infinite step capacity
control devices over compressor valves to effect the desired load and
capacity control of the units. The system was basically a one of a kind system and the OEM no
longer made replacement parts available. Maintenance of the valve plate depressors required specialized
skills which also are not generally available. |
| Customer's Need: |
A
suitable replacement system that would provide the required capacity
control and one that would be simpler in design and easier to service as
well as being more thermodynamically efficient. |
| ACI's Solution: |
Replace
infinite step capacity control system with appropriately sized fixed
volume capacity control devices. These would include front head and valve pocket fixed volume
unloaders. Existing front heads were checked to determine the interior
volumes. These volumes were available for use in the capacity control
systems. Utilization of the existing heads reduced the customers cost of the
revamp. The multiple, valve-cap pockets, each provided with strategically sized volumes
created an unloading schedule that minimized the step size associated with
the opening and closing of the individual pockets. The deviation from an infinitely variable flow rate by the fixed
volume pockets is more than offset by an increase in compression
efficiency. The infinite step system is associated with very substantial
back flow losses when the suction valves are held open to reduce capacity. |
| Follow-up: |
Performance
of the units has demonstrated that the desired capacity/load control has
been accomplished along with the improved efficiency. |
| Situation: |
Customer
was operating integral angle compressor units that were experiencing
excessive valve losses. |
| Customer's Need: |
Replacement
cylinders with larger valves and with more modern design concepts and
resulting in simplified maintenance features. |
| ACI's Solution: |
ACI
remanufactured customer selected used cylinders to replace the existing
inefficient cylinders. Some
of the used cylinders proved to be defective and new ones were no longer
available from the OEM. ACI produced new functional equivalents to satisfy the customers
needs. Both remanufactured and new cylinders were provided with
appropriate capacity control equipment and remanufactured valving. New piston assemblies feature TFE rider rings and piston
rings. Packing cases were reworked as were rods, where possible, and new
rods supplied as required. |
| Follow-up: |
After
more than ten years of service, the cylinders continue to provide the
customer with satisfactory and efficient service. |
| Situation: |
Customer
had a need for an increase in capacity at a station whose future was
uncertain. Management was contemplating the removal of the station from
service in the years ahead. The existing cylinders were at the maximum size offered by the
OEM. The OEM's solution required the use of the next larger class of
cylinder. This approach would necessitate piping and pulsation vessel changes
and perhaps an analog study. |
| Customer's Need: |
A
low cost solution to the need and one that maintained the existing piping. |
| ACI's Solution: |
Working
with the customer, a design was developed that safely overcame the
limitations of the existing cylinders and permitted the creation of a bore
size beyond that established by the OEM as a limiting size. The new design made the use of rider rings a possibility and a
special piston nut permitted the use of the existing piston rod. The original valving was maintained and the installation time and
cost was minimal. |
| Follow-up: |
Now,
almost 20 years later, the cylinders are still in operation and the
customer is considering more conversions. Customer ordered four
additional cylinder conversions (along with other unloading changes) to
maintain their commitment to improving station performance. |
| Situation: |
Customer
operating integral angle I-R units in a multi stage injection/withdrawal
service using cylinders equipped with an infinite step capacity control
system. |
| Customer's Need: |
The
inherent inefficiency, high cost of maintenance and unavailability of
replacement parts required an alternate means of accomplishing the same
capacity control function. |
| ACI's Solution: |
The
application of fixed volume unloading on both stages provided a dramatic
improvement in efficiency, maintained interstage pressures, kept rod loads
within unit ratings and greatly simplified maintenance. |
| Follow-up: |
|
| Situation: |
Customer
had the need to compress large volumes of a hydrogen and methane gas
mixture. Because of the range
of operating conditions, capacity control equipment would be a major
factor in the machines performance. |
| Customer's Need: |
Two
stage motor driven compressor units to satisfy customer specifications. |
| ACI's Solution: |
ACI
utilized two throw, seven inch stroke compressor frames supplied by the
Superior Division of CES and attached custom engineered cylinders of a
valve in head design which resulted in low fixed clearance and good gas
flow to the valves. The head
to body seal was of a unique design that eliminated flat fiber gaskets. The seal design provided a total seal against the hydrogen rich gas
and assured that pressure testing with helium would be no problem. Slip fit liners, custom designed pistons that facilitated assembly
of rider rings, multi-stud rod to piston attachment are among some of
features incorporated in the cylinder design to facilitate service if and
when required. In addition to
multiple fixed volume unloader pockets, the front head was supplied with a
unique actuator device that provided control for both a fixed volume
pocket and a bypass system that deactivated the head end of the cylinder
when energized. |
| Follow-up: |
|
| Situation: |
Customer
requirement for ethylene gas at elevated pressures without contamination
from hydrocarbon type lubricants. |
| Customer's Need: |
Single
stage compressor unit to compress ethylene gas from psig to psig using a food grade lubricant. |
| ACI's Solution: |
ACI
selected a two throw, six inch stroke Superior frame and applied two
custom engineered ______ inch diameter, four valve cylinders. Distance pieces and oil slingers on the piston rods prevented the
migration of crank case oil from the sump into the cylinders. The cylinders featured all of the advanced design features
associated with ACI cylinders and related components. The cylinders, with the use of new
large bore liners readily offer an
increased throughput to meet the customers future requirements. |
| Follow-up: |
|
| Situation: |
Customer's
existing cylinders were constantly under attack from the extremely
corrosive nature of the gas being compressed. Cylinder life norm was 3 to 5
years. OEM offered no assistance in resolving the problem and customer
attempted to produce replacement cylinders of the same geometry in a ni-resist
material. The cylinder geometry and jacketed design were not compatible
with ni-resist foundry practices and requirements. |
| Customer's Need: |
The
customer required a functionally equivalent cylinder design that would
directly replace the existing cylinder to the extent that all other parts
of the assembly could be used with the replacement body. |
| ACI's Solution: |
ACI
modified the exterior of the cylinder body to simplify and enhance foundry
procedures. Core support and clean out and pattern orientation in the mold
resulted in sound castings when produced in a 300 series stainless. The new design improved and simplified inspection techniques and
improved the ability to make weld repairs. Ultimately ACI produced other cylinder components, exposed to the
compression medium, in stainless materials. |
| Follow-up: |
The
change from cast iron to stainless steel resolved the corrosion problems
and eliminated the need for periodic inspections that cast iron cylinders
required to avoid dangerous failures. The units have become more productive and maintenance costs have
been reduced. This type of conversion has been applied to many cylinder sizes and
geometries. |
| Situation: |
Customer
experienced a crack in a ____ inch bore cylinder in hydrogen service. Loss of the cylinder would curtail plants production of
gasoline. OEM replacement cylinder delivery time was unacceptable. |
| Customer's Need: |
A
replacement cylinder on a temporary or permanent basis was needed to serve
as a backup until an OEM cylinder became available. |
| ACI's Solution: |
With
no duplicate cylinder on the used equipment market, ACI selected a used
cylinder produced by the same OEM that did not include API-618 features. ACI modified the cylinder to meet all API-618
requirements. The modified cylinder is a functional equivalent of the cracked
cylinder even though the individual components are not interchangeable. The ACI cylinder matched flange connections and crosshead
attachments. The cylinder was supplied in a shorter time and a lower price than
that of a new OEM replacement cylinder. |
| Follow-up: |
The
ACI cylinder provided the needed back-up to avoid an untimely shut down
due to an OEM cylinder failure. The ACI cylinder, if it was needed, did not compromise the
customers specifications and safety requirements. |
| Situation: |
The
piston in the customers first stage hydrogen service experienced
excessive wear and in some cases structural failures. Designs by other aftermarket suppliers provided no
improvements. |
| Customer's Need: |
Customer
asked for a design with infinite structural life and wear life that would
permit a minimum of two years wear life of piston rings and rider rings. An improvement in wear resistance of the rod was also
required. |
| ACI's Solution: |
The
ACI piston design incorporates a combination of steel and aluminum to meet
the needs of weight control and wear resistance. Piston rider rings are of the heavy section, rubber band
style. When installed, they are virtually an integral part of the piston
component onto which they are assembled. Piston rings are of a heavy cross section and angle cut snap
ring design. Rider and piston rings are of non metallic materials. Piston rods feature a wear resistant
coating. Piston to rod attachment is of the multi-stud design that
simplifies piston assembly and disassembly. |
| Follow-up: |
Recent
discussions with the customer indicate that the experience to date
predicts a six year life of wear components. Structural integrity is
unchallenged. |
| Situation: |
Customer's
well head pressure was declining and as a result oil flow rates also were
declining. |
| Customer's Need: |
Customer
was recylindering an existing integral engine to provide the required high
pressure natural gas to boost the oil field pressure. A suitable final stage high pressure, 10,000 psi cylinder was not
available on the used equipment market and the customer rejected new
cylinder offerings which featured a tail rod design. |
| ACI's Solution: |
ACI
offered a single acting design which operated only on the crank end. Suction gas pressure was maintained on the head end and thereby
assured piston pin bushing load reversal. A unique piston rod and rod nut design provide cylinder end
clearance adjustment that will permit the last stage cylinder respond
properly to changes in previous stage unloading. The design and manufacturing details were developed in conjunction
with the customers engineering personnel. |
| Follow-up: |
|
| Situation: |
Customer
had large volumes of a gas mixture, which was primarily comprised of
carbon dioxide, available for use elsewhere in their system. The gas was to be delivered at a pressure of 1580
psi. |
| Customer's Need: |
An
existing Worthington motor driven frame and cylinders that was available
in the customers facilities appeared to be a candidate for the new
application. In addition to determining the suitability of the unit for the new
application, the customer wanted to determine the cost of the revamp and
the practicality of the new hardware. |
| ACI's Solution: |
The
first stage cylinder proved to be the controlling factor in determining
the suitability of unit for the new application. The first stage bore was substantially larger than required by the
new specifications. Given the fact that the existing bore was in good condition, it was
decided to use a heavy wall liner to create the required new bore size. The new liner featured a clearance fit with the old bore and was
held in place with a unique spring arrangement. An equally unique seal system permitted the use of the existing
lube oil porting in the old liner to deliver lubricating oil to the new
bore. A new piston assembly was created for the new bore along with
appropriate unloading to assure that interstage pressures met the new
computer generated performance. |
| Follow-up: |
The
designs were produced in a manner that allowed the conversion to be
accomplished in the field without the need of re-machining or special
tools. The start up was smooth and the performance matched the predicted
values. The project cost was well within the customers budget. |
| Situation: |
A
packager sold a packaged compressor unit for application in a hops
processing plant. The process required a substantial volume of oil free CO2
gas. |
| Customer's Need: |
Two
stages of CO2 compression picking up suction at the first stage
at ? psi and discharging at 1000 psi on the second stage. Operation was to be without
lubrication. |
| ACI's Solution: |
ACI
provided engineering drawings to permit the customer to manufacture the
complete cylinder assemblies for both stages. Because of process requirements, the cylinders and other components
in contact with the gas also stainless materials. The cylinders were assembled to a new OEM frame and packaged and
delivered by ACI's customer. |
| Follow-up: |
The
start up suffered minor difficulties due to customer piping changes and
the ingestion of solid material at the first stage suction. Additional problems were caused when unqualified valve plates were
used to replace the original plates which were damaged by the ingested
foreign material. After these start-up problems were resolved, the units operated in
a flawless manner. |
| Situation: |
The
customer had purchased several five stage, single throw, 3000 psi air
compressors from an OEM. These were skidded and incorporated with portable air separation
plants. Mechanical problems with the compressors proved to be highly
resistant to repair or modifications that would permit them to operate in
a reliable manner. |
| Customer's Need: |
Because
of the air separation plants remote locations, reliability and ease of
maintenance were essential characteristics of any new machines. They needed to be of an uncomplicated design and of a configuration
that would be readily understood by service people with even average
mechanical ability. |
| ACI's Solution: |
ACI
selected a five stage, two throw machine configuration. The frames were purchased from a major
OEM. The first and third stages were coupled on one side of the frame
and the second, fourth and fifth were coupled on the opposite side of the
frame. While the fourth and second stage pistons, like the first and third
stage pistons, were rigidly attached to each other, the fifth stage piston
had a loose attachment to the second stage piston. This cylinder arrangement was a major departure from that utilized
by the OEM whose machines we replaced. All stages featured non metallic piston and rider rings, slip fit
liners and fastener types and sizes which could be serviced with standard
socket, box and open end wrenches. Pliers are not acceptable. |
| Follow-up: |
Our
customer laughingly complained that he had one major problem with our
cylinders -- no replacement parts sales! He admitted that it was a good
feeling. After completion of the first unit, a second, smaller size machine
was produced. Multiple units of each size machine were produced over the
years. |
| Situation: |
Customer's
attempt to obtain gas transmission cylinders to re-cylinder existing
engines met with no response from the OEM. |
| Customer's Need: |
Customer
required six gas transmission cylinders to re-cylinder 3 medium speed
integral angle engines. The required delivery was eleven weeks. An extremely short time
interval. A substantial amount of unloading and special performance
curves along with complete manuals and parts lists and assembly drawings
were required. |
| ACI's Solution: |
ACI sized, designed, manufactured, tested,
assembled and shipped all six cylinders within eleven weeks. The
final five were produced after the first body casting was machined and
tested to assure dimensional compliance and validity of foundry techniques.
All cast components followed the same 3 procedures -- a standard ACI
practice. All facets of the cylinder assembly design were in
accordance with the ACI standards for gas transmission cylinders. |
| Follow-up: |
Subsequent
to producing the group of six cylinders, two more orders were received for
two cylinders each. All cylinders operated trouble-free. |
| Situation: |
Customer experienced an increase in natural gas
supplies which they could make available for industrial and residential
use. |
| Customer's Need: |
Customer
required the installation of three integral engine compressor units to
provide the necessary capacity to deliver the available natural gas.
Capacity, pressure and capacity control requirements dictated the
design of new compressor cylinders. |
| ACI's Solution: |
Each engine was equipped with three ____ inch
diameter cylinders. Each
cylinder featured multiple clearance pockets. In addition to the pneumatically, actuated volumes, the segmented
piston design offered the ability to vary the cylinder fixed clearance
through alternate assembly arrangements of the piston segments. The head and crank ends
or the piston assembly can be adjusted independently. These features offered the user the flexibility required to meet a
wide range of operating conditions. Cylinders
were provided with slip fit liners, non-metallic piston and rider rings,
multi-stud piston to rod attachment, ExactoTorque nut to tighten rod to
crosshead connection and other advance features associated ACI gas
transmission cylinders. |
| Follow-up: |
The
cylinders have provided trouble free service for many years. All specification requirements were
met. |
| Situation: |
Customer
installation involved a number of integral angle engines. Flow requirements changed over time and further lacked sufficient
capacity control equipment to meet expected variations in flow
requirements. |
| Customer's Need: |
The
customer required eight replacement cylinders and capacity control
equipment to responds to new flow requirements and the variations in flows
expected. |
| ACI's Solution: |
The
production of eight, ____ inch diameter, eight valve, ductile iron
cylinders to satisfy the new flow conditions and capacity control
equipment for both the new and existing cylinders which were not being
replaced. Since the units were two staged with each stage discharging into
their respective common headers, the location and operating sequence of
capacity control equipment was especially critical. This fact had been overlooked by other potential
suppliers. The order was obtained on the basis of price, delivery and the
engineering detail. |
| Follow-up: |
The
new cylinders and the total capacity control packages demonstrated the
integrity of both the hardware and the engineering analysis. |
| Situation: |
The
customer had an existing integral angle compressor engine with cylinders
which no longer served the stations requirements. |
| Customer's Need: |
The customer wished to re-cylinder the engines
with appropriately sized cylinders and related capacity control equipment.
The desire was to apply the ACI Services patented Four Poster Cylinder. |
| ACI's Solution: |
The
cylinders were offered with special valve pocket adapters that would
permit the use of either ACI poppet valves or the valves associated with
the old cylinders. The
adapters were sized so that the cylinder fixed clearance would remain a
constant value regardless of valves utilized. This was a customer request.
The
cylinders used in this application were the same as those on two different
size engines. In each case, the cylinder is fitted with specific cylinder
to crosshead guide adapters, piston lengths and piston rod sizes and
lengths. |
| Follow-up: |
All mechanical and thermodynamic requirements were
met. |
| Situation: |
A
reapplication of an existing four throw motor driven compressor unit
rendered the original arrangement incapable of meeting the new demand. |
| Customer's Need: |
The
customer needed two cylinders to duplicate two existing, identical cylinders.
The four cylinders provided two cylinders for each of two frames
for first stage service. In addition, capacity control devices were required to accommodate
the predicted varying flow. |
| ACI's Solution: |
ACI
traveled to the job site to take field measurements of one of the existing
cylinders which was to work with a new cylinder to serve as the first
stage. Drawings, patterns, casting and machining resulted in the
production of two complete cylinder assemblies. In addition to normal hydro tests, major castings were magnafluxed
in accordance with customer specifications. Unloading was supplied to provide the capacity flexibility
necessary to meet the predicted demand. The aluminum piston design associated with this cylinder was
essentially a one piece cast design that utilized rubber band style rider
rings. The piston design eliminated an integral rider ring stretch over
diameter. The rider ring installation tool also served to form the slip over diameter
which also closed the otherwise open end of the piston rider ring grooves.
As a result, the installation tools are stored on the piston. |
| Follow-up: |
Unit
performance met the customers specifications and the machine performed
without flaw. Delivery and price were less than those of the OEM. |
| Situation: |
Customer
has been operating cast steel compressor cylinders in a high pressure
application. Welded on water jackets consistently cracked and resisted all
attempts at repair. |
| Customer's Need: |
Replacement
cylinders were required which eliminated the problems associated with the
original design. |
| ACI's Solution: |
To
avoid the problems associated with cast steel compressor cylinder bodies,
ACI Services elected to change the cylinder body material to forged steel
to which water jacket covers were bolted. The use of the forged design did not detract from the
interchangeability of parts associated with the body and jacket
subassembly. |
| Follow-up: |
The
forged steel design of ACI Services totally eliminated the leakage
problems associated with the OEM design. |
| Situation: |
|
| Customer's Need: |
|
| ACI's Solution: |
|
| Follow-up: |
|
| Situation: |
Existing
cylinders attached to existing integral engines were unable to respond to
the increased flow requirements of the system. The cylinders and engines were not manufactured by the same
OEM. |
| Customer's Need: |
The
customer specifications dictated an approximate 32% increase in bore size
in a new cylinder that provided maximum operating efficiency. In addition, the cylinder was to have external dimensions that
permitted the use of the existing piping system, cylinder supports and
foundation. |
| ACI's Solution: |
It
was readily apparent that a conventional cylinder design would never meet
all of the requirements of the specification. The OEM, who supplied the engines, agreed and offered a
conventional design that did not meet the specifications. The ACI offering was sufficiently unique that a patent was received
on the new design. In addition to meeting all the specification requirements, the
cylinders were offered at a lower price and a shorter delivery than that
offered by the OEM. In this design, all valves were accessible from the top of the
cylinder and the front and rear head, piston assembly, liner and packing
case were accessible from the front of the cylinder. |
| Follow-up: |
Closed
loop tests certified the efficiency of the cylinders. In the customers words,
"This is the first job of this
magnitude we've done that stayed within budget, got done on time and
everything worked when it was installed. Nothing was missing and no parts were left
over." In addition, $1,500,000 was saved because of the re-use of the
piping and cylinder supports and the absence of foundation changes. Subsequent to the supply of these 42 cylinders, other orders were
received for four more identical cylinders and sixteen cylinders with
slight modifications for another OEM's engines. All cylinders delivered trouble free
service. |
| Situation: |
The
existing cylinders on large integral angle engines, were unable to meet
the flow and pressure conditions associated with the available gas. |
| Customer's Need: |
To
meet the new conditions, the customer needed 15 inch diameter
cylinders with a 1350 psi rating. Valving was to provide compression efficiencies associated with gas
transmission requirements. |
| ACI's Solution: |
ACI
produced 15 inch diameter, nodular iron cylinders with a 1350 psi rating. Each cylinder had a total of
8 , 10 1/8 inch diameter valves. Unloaders were placed over valves and in the front
head. Segmented pistons utilizing a multi-stud to rod attachment and slip
fit liners were incorporated in the design. |
| Follow-up: |
Multiple
orders were received for identical cylinders over a period of years. |
