Tallgrass Energy is a midstream energy supplier, transporting natural gas over 10,000 miles of pipeline between producers and end users in rural areas of the western U.S. Its Glenrock, WY, compressor station had two 50-HP rotary screw air compressors running 24-7 to supply instrument air and utility air to operate the emergency shutdown system.
The two 50-HP rotary screw air compressors were experiencing failures that shut down the emergency system and caused a huge loss of natural gas to the atmosphere. Because of the numerous stops and starts, which the existing vendor blamed on the motor starter, dirty power or lightning strikes, the overloads in the compressors’ motors tripped.
Because the gas belonged to upstream suppliers, Tallgrass had to pay for the gas losses, with major shutdowns blowing down gas for three or four hours several times a year, according to Tallgrass maintenance mechanic and compressed air subject matter expert Jim Stoneking.
The Kaishan KRSD rotary screw air compressor has been a game-changer for Tallgrass Energy, cutting downtime and providing long-term peace of mind.
Jim quickly recognized that the aging compressors were oversized, causing them to rapid cycle. He lobbied his bosses for several months until capital funds became available, then immediately contacted Phoenix Wilson, an account manager at CLS, Inc., an independent distributor of rotary screw equipment, also located in Casper.
Phoenix quickly recommended replacing one of the 50-HP units with a 20-HP Kaishan KRSD direct-drive rotary screw air compressor as the main unit, with the remaining 50-HP unit as a backup (until additional replacement funds are available). Fortunately, CLS had one in stock, and the deal was put together in 24 hours.
The compressor is a well-packaged unit with tubing, end controls and end devices well laid out. “It’s on par with or better than everybody else,” he added.
He can remotely monitor the unit from his office 30 miles away, with the MAM-200 digital control panel, working with Kaishan’s AirWatch System, alerting him when the KRSD needs service.
“Between the 10-year airend warranty and the robust stainless steel control tubing,” Jim said, “we feel like we finally have a compressor that can keep up with our 100% duty cycle.”
“I was shocked by that,” Jim said. “I have not seen that in my career.
Maintenance is also very straightforward; the layout of the unit allows easy access to all major components.
It’s also quieter. “It’s night and day,” he said.
“I don’t believe there’s been any downtime. It’s on par with or better than everybody else.”
— Jim Stoneking, Maintenance Mechanic, Tallgrass Energy
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