TULSA, OK, February 19, 2013- FW Murphy continues to find success with its Engine Integrated Control System (EICS®). Designed and tested for specific spark-ignited, natural-gas-fueled engines, EICS integrates key components for engine optimization including ignition systems, air/fuel control, speed governing, interface and diagnostics, sensors and, harnessing into a single Engine Control Module (ECM) making it a complete package. By combining these products, the EICS saves money and man-hours associated with the installation and set-up of separate components.

“Historically, operators have purchased and installed each component separately, dedicating a huge amount of resources to calibrate each device to work with their specific engine” said Rick Harris, Director of Marketing, Natural Gas Compression (NGC). “With EICS, all the components have been integrated into one package and calibrated specifically for your engine, ensuring your engine will run at optimum performance.”

The EICS was designed and tested to work with specific engine models. FW Murphy conducted extensive dynamometer testing to ensure each specific engine will run at optimum performance across all loads and with varying BTU without the need for manual field adjustments. By completing this testing upfront, operators can be certain their site will pass required testing without the need for pretesting to get dialed in or the need to make adjustments later.

“In the field it can be difficult for operators to identify which component triggered the initial alarm,” said Harris. “The benefit of the EICS is that all the components are integrated into one box which sees everything, and can identify the root cause of the malfunction.”

For operators facing emissions regulations, the EICS system offers an optional emissions package which can be added to EICS systems after the purchase.

The success of EICS was showcased when Exterran, a Houston-based global market leader in full service natural gas compression, was presented with a significant challenge. The Environmental Protection Agency (EPA) proposed a regulation that would require about 8,500 units in the company’s North American fleet of natural-gas-engine-powered compressors to include emissions-control equipment. After extensive research into potential retrofit solutions, Exterran selected (EICS) to meet emissions-compliance and performance-optimization needs for impacted compression equipment.

“Due to the material impact of that proposed EPA regulation — and because, in our opinion, other currently available equipment was insufficient for keeping equipment in continuous compliance under changing operating conditions — we turned to FW Murphy,” says Mike Wasson, Director of North American Fleet Services at Exterran. “We heard about how they had been doing this successfully on similar engines and were interested to see if their EICS product could provide the same long-term and credible solution for the possible EPA regulation that we were looking at.”

While emissions compliance was a driving force behind the decision to implement the EICS for Exterran, the potential for increased engine efficiency and optimized equipment performance was equally influential. Since piloting the first EICS-equipped compressor in September 2010, Exterran and its customers have realized emissions-compliance and performance benefits from the FW Murphy product — and the packager, expects additional advantages as the equipment accumulates run time.

“We’ve seen a lot of things in our EICS-equipped engine packages to get us excited about the future in terms of engine management and emissions controls,” says Ray Purtzer, Exterran Vice President of North American Fleet Services.

Besides increased fuel efficiency, Exterran anticipates that the EICS features will deliver improved uptime when facing load swings and changes in natural gas well flow conditions that would typically shut down an engine. “I see us being able to address a portion of the unscheduled callouts related to low suction pressure, which equates to more uptime for our customers,” says James Harrison, Technical Field Services Manager for Exterran.

By combining key components into one package, the EICS saved Exterran cost and labor associated with the installation and calibration of separate products. “It’s probably a 15 to 20 percent savings in labor hours versus if we had to install each component individually and the engine control systems weren’t all integrated,” says Harrison.

When developing the EICS, FW Murphy leveraged its existing ignition system, which features a capacitive discharge ignition system and uses Smart Coil technology to measure and display kilovolt (kV) readings required to fire the spark plug in each cylinder. By measuring the kV readings, the EICS provides comprehensive engine diagnostics and prognostics.

When operational issues arise, the EICS simplifies and streamlines troubleshooting by monitoring all integrated system components. If an out-of-limit event occurs, the EICS can pinpoint the malfunction. The advanced diagnostics eliminate the need for operators to test and troubleshoot each component separately, resulting in reduced downtime and service costs.

“The EICS makes the engine run better, and when the engine runs better, we have less downtime and less repair costs involved,” Harrison says. “The EICS diagnostics allow us to quickly troubleshoot issues, thus saving us downtime in the field, keeping the compression services online for our customer. We think there’s a lot of opportunity for better performance. I also think we could see a lengthened life cycle between engine overhauls, which would equate to bottom-line dollars.”

The FW Murphy EICS product line will be showcased at the EICS at the East Texas Oil Expo, March 6-7 in Longview, Texas. The East Texas Oil Expo is the largest expo of its kind in Arkansas, Texas and Louisiana. The EICS will also be showcased at the Gas Compressor Association Annual Expo & Conference, April 14-17, 2013, in Galveston, Texas. For more information about the FW Murphy EICS product line, please contact us at 918-317-4100 or visit our web site at http://www.fwmurphy.com/eics.

Leading natural gas compression services provider Exterran anticipates performance and emissions benefits with the Engine Integrated Control System (EICS®) from FW Murphy.

As a global market leader in full service natural gas compression, Exterran offers the latest technology and proven industry standards in a wide range of high-speed reciprocating and rotary screw compressor packages. Houston-based Exterran was presented with a significant new challenge in 2009. The Environmental Protection Agency (EPA) proposed a regulation that would require about 8,500 units in the company’s North American fleet of natural gas engine-powered compressors to include emissions control equipment. After extensive research into potential retrofit solutions, Exterran selected the Murphy Engine Integrated Control System (EICS) to meet emissions-compliance and performance-optimization needs for the impacted compression equipment.

One Solution, Multiple Benefits
Designed and tested for specific spark-ignited, natural gas-fueled engines, the EICS integrates key components for engine optimization – including ignition system, air/fuel control, speed governing, interface and diagnostics, sensors, harnessing, catalyst and the engine control module – into one complete package.

“Due to the material impact of the proposed EPA regulation, we turned to FW Murphy Production Controls. In our opinion other product offerings were insufficient for keeping equipment in continuous compliance under changing operating conditions,” says Mike Wasson, Exterran director of North American fleet services. While emissions compliance was a driving force behind the decision, the potential for increased engine efficiency and optimized equipment performance was equally influential. Since piloting the first EICS-equipped compressor in September 2010, Exterran and its customers have realized emissions compliance and performance benefits – and the packager expects additional advantages as the equipment accumulates run time.

“We’ve seen a lot of things in our EICS-equipped engine packages that excites us about the future in terms of engine management and emissions controls,” says Ray Purtzer, Exterran vice president of North American fleet services.

Initial Performance Results Promising
Exterran incorporated the EICS into packages featuring four specific continuous-rated engine models:
Arrow VRG 330 (68 bhp)
Caterpillar® G3304NA (95 bhp)
Caterpillar G3306NA (145 bhp)
Caterpillar G3306TA (203 bhp)
(since this case study, EICS has expanded to include the Caterpillar 3406 and the Cummins KTA19.)

By combining key components into one package, the EICS saved Exterran cost and labor associated with the installation and calibration of separate products. “It’s probably a 15 to 20 percent savings in labor hours versus if we had to install each component individually,” says James Harrison, Exterran technical field services manager.

The EICS integrates the three main components for engine optimization – ignition system, air/fuel ratio control and speed governing – into a single engine control module (ECM) to ensure optimum performance across all scenarios without the need for manual field adjustments.

EICS air/fuel control is achieved through the combination of an innovative Murphy direct electronic pressure regulator (D-EPR) valve with a wide-band oxygen sensor. The D-EPR valve accommodates wide variations in fuel composition and speed/load range, maintaining efficiency with load-following technology for even the toughest gas lift applications. The speed governing component of the EICS consists of an integrated throttle used to manage the flow of the air/fuel mixture to the engine, which maximizes engine performance and helps maintain emissions.

Upon deployment, the EICS had an immediate impact on engine efficiency and operational performance of Exterran equipment. “The EICS definitely improves fuel economy, which is very important to us and our customers,” Harrison says. “The EICS has the ability to change the ignition timing and speed of the engine on demand, which results in increased fuel economy estimated around 2 to 3 percent in most applications.”

Besides increased fuel efficiency, Exterran anticipates that the EICS will deliver improved uptime when facing load swings and changes in natural gas well flow conditions that would typically shut down an engine. “I see us being able to address a portion of the unscheduled callouts related to low suction pressure, which equates to more uptime for our customers,” Harrison says.

When developing the EICS, FW Murphy Production Controls leveraged its existing ignition system, which features a capacitive discharge ignition system and uses Smart Coil technology to measure and display kilovolt (kV) readings required to fire the spark plug in each cylinder. By measuring the kV readings, the EICS provides comprehensive engine diagnostics and prognostics.

When operational issues arise, the EICS streamlines troubleshooting by monitoring all integrated system components. If an out-of-limit event occurs, the EICS pinpoints the original malfunction event even when multiple alarms are triggered as a result of the original event.The advanced diagnostics eliminate the need for operators to test and troubleshoot each component separately.

“The EICS makes the engine run better, and when the engine runs better, we have less downtime and less repair costs involved,” Harrison says. “The diagnostics allow us to quickly troubleshoot issues, keeping the compression services online for our customer.

“We think there’s a lot of opportunity for better performance. I also think we could see a lengthened life cycle between engine overhauls, which would equate to bottom-line dollars.”

Early Impact on Emissions EncouragingFor gas compression operators facing emissions regulations, the EICS is available in an emissions version, which integrates the catalyst into the package. Exterran opted for the emissions version to achieve compliance with a spectrum of local, state, federal and customer-mandated standards.

Incorporation of the EICS reduces the resources required by allowing automation of emissions control. Because FW Murphy Production Controls conducted extensive dynamometer testing up front, operators can be certain that their site will pass required emissions testing.Exterran expects the EICS to be much more dependable than previous emissions solutions, which included a standard air/fuel controller, traditional stepper fuel control valve and catalyst. While Wasson acknowledges that these solutions can be effective in controlling emissions, he says obtaining emissions limits with existing controls equipment requires an extensive amount of manual intervention, programming and labor hours.

“The problem with programming is that it takes considerable time and experience,” Wasson says. “With the EICS, (FW Murphy Production Controls) has done that work for us by mapping out the engine’s performance on a dynamometer and programming it into the software of the system.”

“If the machine remains as consistent as it has in field testing, we can significantly reduce the amount of effort required to maintain compliance even with the most stringent emission standards,” says Kyle Jantzen, Exterran manager of air programs. “That translates to less labor and less setup time, so we have great hope for reducing our cost. And with this system, there is no tweaking necessary to maintain emissions compliance.”

Jantzen expects ease and speed in testing equipment that has historically proven difficult in emissions testing. “One of our pilot packages has shown we can cut testing time on difficult equipment by at least 30 percent,” he says. “Another perceived benefit would be a reduction in emissions control-related nuisance calls.”

Jantzen expresses optimism that the EICS-equipped products not only meet current emissions regulations in a safe range but will achieve future requirements. “We feel like the EICS is by far the most comprehensive long-term solution out there,” Jantzen says. “We have confidence that our equipment and maintenance practices are going to keep the equipment in compliance around the clock, now and in the future.”

Ultimately, Exterran expects the EICS to strengthen its leadership position in the market by revitalizing older assets with a retrofit solution providing increased engine efficiency, optimized equipment performance and emissions compliance.

“We think the EICS is another tool in our belt that will allow us to continue to offer superior solutions,” Purtzer says. “This system will revitalize some aging portions of our compressor fleet of equipment. And our customers’ perception is that Exterran is willing to get on the cutting edge of technology and lead the industry.”

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Natural Gas Services Group is known for its CipJr and CipSr reciprocating compressors. The company grew the product line to include several variations, which required many different Murphy controllers. Jim Hazlett, NGSG’s VP of Production and Engineering, worked with Murphy to consolidate multiple controllers into one by using the Centurion™, a flexible and cost-effective controller for midlevel compressor applications.

PROBLEM
Multiple controllers used on various compressor packages.
NGSG supported four Murphy controllers: the TTDJ, 447, S400 and Millennium.
Too many inventory resources spent matching the correct controller to each variation of compressor package and application.
Variations in software for each controller required regular updates. All programming changes had to come from Murphy on EEPROM chips.
NGSG used the full-featured Millennium controller for its communications features, but additional features went unused. They were paying for more control than they needed.

“We started considering the number of different controllers we were supporting in our fleet. Four controllers combined with our various panels complicated our product line, our inventory and our support services. The Centurion™ allowed us to get away from so many different products and focus on one controller across several panels.”

IMPLEMENTATION
Murphy proposed using the flexible Centurion™ controller to replace most of NGSG’s controllers.
The Centurion™ controller fully replaced three controllers on several packages.
Murphy’s S400 controller is still used on two screw compressor packages, but will ultimately be updated.
Software variations are now maintained by keeping a blank Centurion™ in stock.
Software can be downloaded from Murphy, or NGSG can directly modify the software in-house.

“We opted to bite the bullet and standardize our controllers with the Centurion™. It replaced two-thirds of our controllers. It had the communications capabilities that we needed, and we could make flash programming changes on the fly. We didn’t have to wait for new software or burned program chips.”

“The Centurion™ really helped us streamline our inventory. It reduced the need for carrying components to support several variations of panels.”

RESULTS
NGSG streamlined five controllers to two. The company also reduced the number from panels supported from 10 to 3.
Panel versatility on several applications as well as process conditions.

“It simplified our work. We still support those controllers from the past. But our newer installs are much simpler because we just focus on the Centurion™.”

“We now have one controller that can take care of all the jobs that four controllers used to do. We have the automated restart capabilities of the S500, plus the communications tools of the Millennium. We can also see diagnostic information.”

“It wasn’t a hard decision. The features and economics of the Centurion™ matched up better. And we gained extra productivity by letting Murphy streamline our controllers.”

CONTACTS:

Natural Gas Services Group
Jim Hazlett, VP of Production and Engineering

FW Murphy
Danny Phillips
dphillips@fwmurphy.com
(281) 633-4561

Quicksilver Resources is a natural gas and crude oil producer engaged in the development and acquisition of long-lived producing natural gas and crude oil properties. The company is widely recognized as a leader in the development and production of unconventional natural gas reserves, including coal bed methane, shale gas, and tight sand gas.

Problem
Reduce operating costs by maximizing fuel usage
Quicksilver is very proactive; always looking for savings on fuel use and cost
The company has traditionally been wiling to test new equipment if it can deliver improved performance.

“I used Murphy Power Ignition (MPI) products at my previous company, and I wanted to try a couple at Quicksilver. I planned to datalog the fuel usage before and after the installation to see what kind of savings we could get. If there’s an opportunity to save money, we’ll do it.”

Implementation
The MPI-16 system includes coils, wires, sensors and mag pickups.
Purchased 12 MPI-16 ignition controllers.
Controllers were installed on Caterpillar 399 and Waukesha 7042 engines to test under various conditions.
Average fuel usage for each install was monitored the same engine with and without the MPI ignition controller.
Quicksilver also purchased and installed more than 45 Compliance Controls air-fuel ratio controllers – mostly rich-burn models – to maximize the performance of the catalytic converter for emissions control.

“Rather than stick with an old magneto-based ignition system, we opted to put Murphy Power Ignition on it. I tested MPI on several different engines, loaded differently, to see the difference on fuel savings.”

Results
Murphy’s ignition controllers saved an average 7-10 MCF (thousand cubic feet) of fuel per day.
With an average fuel price of $6 per MCF, that saves Quicksilver $42 per unit each day.
At that rate, Quicksilver is expected to save $15,330 per unit each year.
Quicksilver’s cost savings paid for each units within the first 5-1/2 months of installation.
The integration between the Murphy ignition controls, Compliance Controls’ AFR controllers and the catalytic converter delivers consistently smooth operation and higher engine performance.

“We save an overall average of 7 MCF every day. At $6 per MCF, it adds up pretty quickly. The MPI system pays for itself in a few months, and we save thousands of dollars on each unit every year. MPI also works well with our Compliance Controls AFR controllers to get cleaner emissions.”

Contacts

Quicksilver
Randy Reiman, Emissions
Techrreiman@qrinc.com

Hague Equipment
Don DePeel, Sales
Engineerddepeel@chartermi.net

FW Murphy
Michael Jendral
mjendral@fwmurphy.com

Darrell Schmitt
dschcmitt@fwmurphy.com

Ranger Gas is a stripping facility that removes NGLs from gas in order to make it ready for pipeline transport. The main plant is located in a remote site just outside Ranger, TX. Mike Gryder is one of the site’s primary mechanics.

PROBLEM:
Too many resources spent on maintenance.
Older equipment, some from the 1980s.
Turbocharger damage due to backfiring engine.
Lots of time/energy/resources used up on repairs.
Constant replacing and repairing of magnetos.
Lack of troubleshooting capabilities, repairs were done through manual testing.
Not getting maximum efficiency from the engines.
No remote monitoring.
Spark plug life not long enough.

Ranger Gas wanted a definitive upgrade. They wanted to catch up to the present, with the ability to add remote monitoring in the future.

“Our Murphy engine controls were still running after 20 years, but we needed new ignitions and new technologies. Our old ignition systems kept backfiring the engine and damaging the turbocharger. We also didn’t have all the end devices we needed, just a basic annunciator panel. We had a lot of end devices still on the engine. We were doing all our troubleshooting manually. It was real spread out and hands-on all the time. It could be done, but it took more work for us.”– Mike Gryder

IMPLEMENTATION:
Murphy replaced 20-year old pneumatic Tattletale® panels with two new compressor panels that combined the main end devices into a single group interface.
Outfitted panels with TTD annunciators for shutdown and TDXM pyrometers for temperature scanning.

The panel and controller selections
Included communications capabilities.
Replaced traditional magneto-based ignition controllers with microprocessor-based Murphy Power Ignition controllers (MPI-8 and MPI-32).
Added Murphy’s patented Smart Coils™ to the ignition system for true secondary diagnostics and benefits such as longer spark plug life.
Installation performed and supported locally by Gulf Coast Ignition, a member of Murphy’s international dealer network.
Murphy and Gulf Coast Ignition coordinated on providing operational training classes for Ranger employees.

“When we upgraded, we wanted automated startups. We wanted secondary diagnostics. And we wanted remote communications for the future. Murphy supported us through the installations, and even included training on the new equipment. We were very satisfied.” – Mike Gryder

RESULTS:
Longer uptime on engines.
Longer spark plug life.
More reliance on pre-scheduled preventative maintenance instead of surprise equipment failures.
Automated ignition and shutdown that reacts to conditions of the engine and surrounding environment.
Measuring fuel usage, and expects to see strong savings in consumption and related fuel costs.

“Now we can set the timing on each individual cylinder, we can adjust the Kv to each plug. We’ve got the automation we wanted, and we’re getting longer plug life.”

“The remote communications are very good. Someday we want to be able to check our compressors from our house.”– Mike Gryder

CONTACTS:
FW Murphy
Mark Pelham, territory sales manager
432.520.3348 (w)
432.634.4324 (c)
mpelham@fwmurphy.com

Gulf Coast Ignition
Ed Ansell
281.844.4402

Doug Irwin
972.672.8723

Ranger Gas
Robert Beard, president
254.631.1546 (c)

Mike Gryder, mechanic
254.631.2759 (w)
254.647.5263 (f)