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OFFICINE MARIO DORIN S.P.A.:REFRIGERATION AND AIR-CONDITIONING TECH NOLOGY SINCE 100 YEARS Page 20

HOERBIGER COMPRESSION TECHNOLOGY:SERVICE EXCELLENCE IN LATIN AMERICA Page 42

MND GAS STORAGE:NO BREAK FOR COMPRESSORS Page 52

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ŽANDOV, CZECH REPUBLIC: For more than 40 years, HOERBIGER has offered service solutions for reciprocating compressors, engines and turbomachines and has an extensive presence in all regions in which the oil, gas, and process industries operate, including in the Czech Republic and Slovakia. HOERBIGER Žandov s.r.o. produces valves and key components in the city bearing the same name and additionally is one of the leading service providers in both countries. (Page 57)

ŽANDOV, CZECH REPUBLIC [50° 43’ N, 14° 24’ E]

Ladies and gentlemen,

Dr. Martin KomischkeCEO and Chairman of the Executive BoardHOERBIGER Holding AG

EDITORIAL

Innovation and responsible corporate management—these have been the guiding principles of Officine Mario Dorin S.p.A. since the company was founded approximately a century ago. In this issue of HOERBIGER@MOTION, we introduce you to this manufacturer of refrigeration and air-conditioning compressors, which to this day has remained a family-run business.

Like many of our customers, the reason behind Dorin’s partnership with HOERBIGER is not only the quality of the components we supply, but also and in particular the respect and appreciation which the customer and supplier display when it comes to designing new solutions at an early development stage.

The situation is similar for our business relationship with Shanghai Automo-tive Industry (Group) Corporation (SAIC). While the structure of one of the largest automobile manufacturers in Asia clearly differs from those of a medium-sized specialty machine manufacturer, it is also proximity and dependability in the development of new synchronizer systems as well as quality and reliability in production and logistics that count in this relationship.

Wherever we operate around the world—be it at Dorin in Italy or SAIC in China—we always attach utmost importance to being close to our customers.

This also holds true for KSB in France and MND Gas Storage in the Czech Republic, two additional very interesting companies we present in this cus-tomer magazine. During the joint development as well as in service, it is im-portant to us that we take our customers’ concerns seriously, recognize their needs early on and develop solutions that make a lasting contribution to the customers’ added value.

To achieve this, we repeatedly develop new, tailor-made business models. One example of a business model which is both innovative and customer-oriented is the Wellhead Compression Project in Latin America. In this

issue, we introduce you to Daniel Vazquez, an employee who together with his team developed and very successfully implemented a new service model for the oil and gas industry.

At HOERBIGER, we are interested in creative, entrepreneurially thinking minds that develop new ideas and then implement them, clearly and with structure.

In this issue, we feature Martin Lachmann, who at HOERBIGER Kompres-sortechnik GmbH in Schongau consults our customer Officine Mario Dorin S.p.A.; Leo Feng, Key Account Manager at HOERBIGER Drive Technology Asia Pacific who attends to SAIC; Remy Hoerdt, Key Account Manager for KSB in France; Pavel Hafner, the Service Partner for MND Gas Storage in the Czech Republic, and Daniel Vazquez, Business Development Manager at HOERBIGER Service Latin America Inc., who developed a new business model—they are all representative of HOERBIGER employees who in cooperation with you, our customers, actively tackle new challenges time and again.

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CONTENTCONTENTCONTENT ISSUE 2/12 ISSUE 2/12 ISSUE 2/12CONTENT ISSUE 2/12CONTENTCONTENT ISSUE 2/12CONTENT

OFFICINE MARIO DORIN S.P.A.:

ENVIRONMENTALLY FRIENDLY REFRIGERATION AND

AIR-CONDITIONING TECHNOLOGY PAGE 20HOERBIGER COMPRESSION TECHNOLOGY:

SERVICE EXCELLENCE IN LATIN AMERICA PAGE 42MND GAS STORAGE IN UHŘICE:

GAS: 24 HOURS A DAY, 365 DAYS A YEAR—

NO BREAK FOR COMPRESSORS PAGE 52

SHORTCUTS: DREAM CONVERTIBLES ARE THE STARS AT THE OLYMPIC GAMES IN LONDON // HOERBIGER AT MEDICA 2012: HYDRAULIC DRIVE

SOLUTIONS FOR PATIENT POSITIONING // GAS MACHINERY CONFERENCE 2012: PLATFORM FOR EXPERTS // AWARD FOR HOERBIGER INDIA //

HOERBIGER AT “TURBOMACHINERY AND PUMP USERS SYMPOSIUM” // HOERBIGER SMARTCONTROL PDA: UNIVERSAL REMOTE CONTROL FOR TES-

TING AND DIAGNOSTIC SYSTEMS // SELFLESS EFFORT: HOERBIGER EMPLOYEES RESCUE WOMAN FROM SINKING CAR // HOERBIGER 2011/12 YEAR-

BOOK: TOP MARKS FOR “TOP PERFORMERS” // HOERBIGER FOR THE FIRST TIME AT POGEE IN PAKISTAN PAGE 6 HOERBIGER LAUNCHES

NEW WEBSITE PAGE 16 EUROBLECH 2012 IN HANNOVER: HOERBIGER ePRAX—THE eDRIVE REVOLUTION PAGE 28 KSB S.A.S.

FRANCE: MECHATRONICS À LA CARTE PAGE 30 SHANGHAI AUTOMOTIVE INDUSTRY (GROUP) CORPORATION: CHINA’S AUTOMOTIVE

SUCCESS STORY PAGE 36 HOERBIGER eHydroCOM: A GROUNDBREAKING CONTROL SYSTEM FOR RECIPROCATING COMPRESSORS PAGE 48

BCD RINGS: LESS WEAR, LONG SERVICE LIFE, LOWER EMISSIONS PAGE 50 LIBEREC: INDUSTRIAL REGION WITH CHARM PAGE 58

BUENOS AIRES, ARGENTINA [34° 36’ S, 58° 23’ W][34° 36’ S, 58° 23’ W]BUENOS AIRES, ARGENTINA [34° 36’ S, 58° 23’ W]BUENOS AIRES, ARGENTINA

UHUHŘICE, CZECH REPUBLIC [49° 10’ N, 17° 4’ E]ICE, CZECH REPUBLIC [49° 10’ N, 17° 4’ E]

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COMPIOBBI/FLORENCE, ITALY [43° 47’ N, 11° 21’ E]COMPIOBBI/FLORENCE, ITALY [43° 47’ N, 11° 21’ E]

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Top performance thanks to HOERBIGER technology.

The hydraulic roof drive ensured that no unnecessary

noise stole Jessie J’s show.

The new Phantom Series II Drophead Coupe from Rolls Royce was featured for

the fi rst time with the redesigned emblem without the double R-R.

It was a spectacular performance for Rolls-Royce at the Olympic Games in London: during the closing ceremony on August 13, British stars Jessie J, Taio Cruz and Tinie Tempah performed “A Symphony of British Music” as part of the event televised around the world, using three Phantom Series II Drophead Coupes as their stage.TexT: Peter Schwerdtmann · Ludwig Schönefeld

PHOTOs: auto-medienportal.net · Rolls-Royce · dpa

S pecially trained Rolls-Royce employees drove the three vehicles, which were handmade at Rolls-Royce’s headquarters in Good-wood. The appearance of the three vehicles was a historical

moment for Rolls-Royce. For the first time in the company’s 108-year his-tory, the British luxury vehicles were featured with a newly designed badge which did not include the traditional double-R logo. The new grille emblem features the iconic Spirit of Ecstasy with the Union Flag replacing the traditional flowing gown.

In addition to the traditional laurel wreath, the centers of the steering wheels of the three Dropheads also featured a torch and the lettering “London 2012,” framed by the Olympic motto, “citius, altius, fortius” (“faster, higher, stronger”). The emblems were supplemented with spe-cial sill plates denoting the vehicles’ “One of Three” status. All elements were designed by the Rolls-Royce Bespoke team. Only three cars were made, which should make them the most sought-after (and most inac-cessible) collectible Rolls-Royce Bespoke has ever manufactured. Hid-den from view, Jessi J, Taio Cruz and Tinie Tempah first drove through the

spectator area in the Dropheads. The stars only became visible at the center of the stadium when the soft tops opened hydraulically—driven silently by hydraulic convertible top drives made by HOERBIGER Automo-tive Komfortsysteme GmbH. This was a highlight of the show with no room for error.

The hydraulic top drive for the Phantom Series II Drophead Coupe is one of the most powerful roof drives made by HOERBIGER. Six hydraulic cylinders open and close the soft top, exactly synchronized, in less than 25 seconds. In addition to the hydraulic top drives for the coupes, HOERBIGER Automotive Komfortsysteme GmbH also supplies hydraulic door drives for Rolls-Royce. They facilitate gracious opening and closing—which was also a particular detail that benefited the British stars during the closing cere-mony of the Olympic Games in London—albeit unknowingly.

DREAM CONVERTIBLES ARE THE STARS AT THE OLYMPIC GAMES IN LONDON

At the end of August, HOERBIGER India Private Ltd. received the “National Award for Excellence in Energy Management 2012” for the continuous HydroCOM control sys-tem in Hyderabad, India. The award is presented by the Confederation of Indian Industry (CII). The Hydro-COM System has therefore been assessed as the “Most Innovative Energy Saving Product.”

A total of 17 companies com-peted in the “Energy Saving Cate-gory,” seven of which made it to the shortlist and were invited to the

AWARD FOR HOERBIGER INDIApresentation. HOERBIGER was ul-timately among the four finalists and was able to achieve one of the coveted awards.

Thanks to state-of-the-art mech-atronics, the innovative HydroCOM system made by HOERBIGER al-lows fast and precise control of re-ciprocating compressors without power loss. HydroCOM thus makes a contribution to saving energy and reducing carbon dioxide emis-sions. With approximately 800 in-stallations so far, the system is very successful internationally.

HOERBIGER will once again ex-hibit at the 41st Turbomachinery/ Pump Users Symposium at the George R. Brown Convention Cen-ter on September 24-27, 2012. HOERBIGER has been a long-time supporter of the event which is sponsored annually by the Tur-bomachinery Laboratory at Texas A&M University.

Annually, the event draws about 6,000 attendees with experience in the petrochemical, process, chemical, and utility industries. The technical program promotes professional development, technol-ogy transfer, peer networking, and information exchange among in-dustry professionals.

HOERBIGER AT “TURBOMACHINERY AND PUMP USERS SYMPOSIUM”

The symposium features lec-tures, tutorials, case studies, dis-cussion groups, and short courses, as well as exhibits of the latest ro-tating equipment, components, and services. HOERBIGER repre-sentatives will meet with existing and prospective customers to demonstrate how its technologies like RecipCOM, HydroCOM, com-pressor components and turboma-chinery rebuild services improve the reliability and performance of their equipment.

HOERBIGER Micro Fluid is a specialist for customized solutions in the field of microhydraulic systems. Its portfolio encompasses tailor-made hydrau-lic components, electronic controllers and complete lifting columns for op-erating tables, together with guide mechanisms. This year, the Column Trend Line, or CTL, will be the primary focus at the completely redesigned trade show booth. The CTL lifting column was successfully featured in April at the CMEF in Shenzhen, China, and is now scheduled to be launched in Europe. The new lifting column was developed in the low to medium patient weight market segment and for low heights. This comple-

ments HOERBIGER’s modular “patient handling” solutions for high and now also low patient weights, based on hydraulic components, hydraulic sys-tems as well as mechatronic lifting columns for operating tables in all global markets.

With the Column Trend Line (CTL), HOERBIGER (Hall 14, Booth D20) will feature an innovative product in the fi eld of hydraulic drive solutions for patient positioning from November 14 to 17, 2012 at the MEDICA in Düsseldorf. PHOTO: HOERBIGER

HOERBIGER at MEDICA 2012

HYDRAULIC DRIVE SOLUTIONS FOR PATIENT POSITIONING

The Gas Machinery Conference takes place in Austin, Texas, from September 30 to October 3. With an emphasis on the operation, maintenance, and testing of gas compression machinery, the con-ference draws approximately 1,000 design engineers, facility engineers, technicians and others to educational sessions and net-working opportunities. The con-ference will include three days of technical training and presenta-

GAS MACHINERY CONFERENCE 2012:PLATFORM FOR EXPERTS

tions. The 2012 program offers 13 short courses, 38 technical pa-pers (5 from HOERBIGER) and 13 new technology updates (3 from HOERBIGER). HOERBIGER’s ex-hibit will be a showcase of new ideas and technologies that reduce engine emissions and greenhouse gas emissions. Since the conference’s conception in the late 1980s, HOERBIGER has sponsored the Tuesday morning breakfast.

The new CTL lifting column was

developed in the low to medium

patient weight segment. It is one of

the highlights of the HOERBIGER

booth.

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Weeks of rainfalls during the month of July resulted in extensive fl ooding in the region surrounding Houston, Texas, USA. A young woman underestimated the danger. On her way to work, she drove her ve-hicle into a fl ooded underpass and nearly drowned trapped in her car. She was lucky: Cristobal Lobo and Walter Villalobos, both employees in the Molding Department of HOERBIGER’s Houston site, happened to pass by and rescued the woman just in time. They demonstrated responsibility and courage—and embodied two of HOER-BIGER’s corporate values.TexT: Keith Farnham · Tim Wohlfarth

PHOTOs: Tom C. Robison · HOERBIGER

We did not think twice and immedi-ately responded,” Cristobal Lobo recalls. The 23-year-old

HOERBIGER employee and his col-league Walter Villalobos were com-ing back from their lunch break when they observed the young woman driving directly toward the flooded underpass. “We thought she would stop, but she just contin-ued on,” 21-year-old Walter Villalobos recounts.

Since both are very familiar with the area, they knew how high the water in the un-derpass can rise during rainfall. And they were right: the vehicle sank in the water with the woman inside, and the driver was not able to free herself.

Lobo and Villalobos reacted instinctively, jumped into the water and with the help of a third man, they pulled the helpless

HOERBIGER EMPLOYEES RESCUE WOMAN FROM SINKING CAR

Selfless Effort

For the very first time, HOERBIGER KT Asia Services Pte Ltd (HKTAS), has participated in POGEE, held in Karachi in May 2012. The Pakistan Oil, Gas & Energy Exhibition & Conference (POGEE) is the most impor-tant event of the oil and gas industry in Pakistan. The exhibition was officially opened by Dr Farooq Sattar, foreign minister for Pakistan, at Karachi Expo Centre on May 8, 2012. The three days’ event provided a plat-form for exhibitors from Pakistan and the region to showcase different technology of the oil & gas industry and was visited by more than 8,000 industry experts. HOERBIGER showcased the latest innovations of HOERBIGER Compression Technology such as HydroCOM and BCD rings with emphasis on energy saving.

HOERBIGER SMARTCONTROL PDA

UNIVERSAL REMOTE CONTROL FOR TESTING AND DIAGNOSTIC SYSTEMS

HOERBIGER FOR THE FIRST TIMEAT POGEE IN PAKISTAN

Bonnam Koo (left) and Nikolaus Lubega (third from left)

from HOERBIGER KT Asia Services Pte. Ltd. accept a

token of appreciation from Akhtar Shazad, General Manager

of the trade show organizer Pegasus.

Walter Villalobos (left) and

Cristobal Lobo were in the right

place at the right time.

The photographs of the

site of the accident taken

with a mobile phone high-

light how continuous rain-

fall can quickly turn an un-

derpass into a dangerous

trap. Here the location

before ...

The HOERBIGER SmartControl

PDA is an all-in-one device for

mobile use.

... and after the rain. The woman’s

car was completely under water.

driver through the open side window. It was just in time, considering that by then the water was

already more than 1.60 meters (over 5 feet) high—and continued to rise un-

abatedly. When the first responders arrived, the car was almost com-

pletely flooded. Had Cristobal Lobo and Walter Villalobos

not responded so quickly, this likely would have been a catastrophe. The irony of the story is that the incident hap-pened on Friday the

13th. For the young woman, it was effectively a

lucky day. While her vehicle is lost, she escaped with no more than a scare—thanks to Cristobal Lobo and Walter Villalobos.

Incidentally, the two HOERBIGER employees at first did not mention a word about their effort. After they

made sure that the woman was doing well, they started out on their way back to work—drenched as they were. It was only when a supervisor asked why they were so soaked that the story came to light.

It offers versatile configuration options and is highly mobile and extremely robust: the new HOERBIGER SmartControl PDA remote control featuring a touch- screen and integrated barcode scanner simplifies the work of testing and instrument technicians. The de-vice has been in production since August of this year and it is available around the world.

The SmartControl PDA developed by HOERBIGER Elektronik GmbH in Ammerbuch, Germany, allows easy remote control of all HOERBIGER testing and diagnostic systems of the Porty, ISTL and ISTK product groups. The device in PDA format additionally controls WLAN-capable PC systems as needed.

The SmartControl PDA is equipped with a wide variety of software applications. Because of its high configurability, it can be optimally tailored to the customer’s specific needs. Its touch-sensitive 3.5-inch display guides the user reliably through the testing process.

The touchscreen, the integrated database and the barcode scanner for reading product or unit numbers make the SmartControl PDA an all-in-one mobile de-vice. It offers flexibility in its use for technical testing, diagnosis and monitoring. Possible fields of application include industry, medical engineering, the automotive industry, mining and logistics.

For tough everyday use, the SmartControl PDA is equipped with an especially robust housing featuring an integrated radio antenna. A protective rubber edge helps to prevent damage if the unit is dropped.

Top marks for “Top Per-formers.” The panel of judges of the International ARC Awards, the most significant competition worldwide for annual re-ports, in New York again gave the HOERBIGER Yearbook top marks: Gold in the “Photography” cat-egory, Gold in the “Print-ing & Production” category, Silver in the “Interior De-sign” category, Bronze in the “Written Text” category, and Honors for the Chairman’s Letter. The coveted awards were presented in New York on September 20, 2012. The ARC (Annual Report Competition) Award is the most prominent competition for annual reports worldwide. The judging panel, under the direction of the International Academy of Arts & Science, Ossining, NY, USA, is staffed by distinguished communications ex-perts with global ties from the fields of investor relations, public relations, journalism and design.

HOERBIGER 2011/12 YEARBOOK

TOP MARKS FOR “TOP PERFORMERS”

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COMPIOBBI/FLORENCE, ITALY COMPIOBBI/FLORENCE, ITALY COMPIOBBI/FLORENCE, ITALY [43° 47’ N, 11° 21’ E]

COMPIOBBI/FLORENCE, ITALY: Whenever effi cient refrigeration is required—be it in trade or industry, in railroad traffi c or on the road—technologically sophisticated compressors made by Dorin are the fi rst choice in Italy. The family-owned business has manufactured compressors for approximately 80 years. Thanks to the collaboration with HOERBIGER, which began in the 1990s, the machines are very reliable. Marketing Manager Giovanni Dorin says: “They are as good as perfect.” (Page 20)

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BUENOS AIRES, ARGENTINA: Argentina’s prosperity is based to a large extent on the enormous natural sources. However, oil and gas deposits continually decrease. With the Wellhead Compression Project, HOERBIGER has created an option to continue to utilize even mature wells. The project uses mobile gas compressors to artifi cially stimulate the fl ow of resources from the reservoir—a business model with a future. (Page 42)

BUENOS AIRES, ARGENTINA BUENOS AIRES, ARGENTINA [34° 36’ S, 58° 23’ W]

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UHŘICE, CZECH REPUBLIC: MND Gas Storage is operating an underground gas storage facility in Uhřice, Czech Republic. For almost ten years now, gas has been compressed around the clock and delivered through wells located at depths of close to two kilometers (1.25 miles) in the immediate vicinity of the Austrian and Slovakian borders. A close partnership has existed with HOERBIGER through the Žandov branch ever since the storage facility was commissioned. Trust is essential in this partnership, as the HOERBIGER products play a central role in Uhřice: they ensure the safety and reliability of the compressors operated by MND Gas Storage. (Page 52)

UHŘŘICE, CZECH REPUBLIC ICE, CZECH REPUBLIC [49° 10’ N, 17° 4’ E]

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A key objective of the new development was to make the updated general information technology of the past few years, such as higher band-widths and new development tools, usable for the HOERBIGER site.

The maxim for the project was: Through the intelligent use of innovative tech-nology, HOERBIGER meets the information needs of customers, business partners and competitors better than ever before.

Succinct Information, Personalized Product RangeOn the home page of the new HOERBIGER website, alternating starting se-quences provide information about product highlights, trade show activities and news from all Strategic Business Units. The four key navigation items “Products and Services,” “People and Values,” “Company” and “Performance Stories” allow visitors to enter the HOERBIGER online world in a targeted man-ner. Relevant information is never more than three mouse clicks away. The presentation of the product and service information follows a uniform design. It accommodates visitors who want to explore the site in-depth, but quickly.

The most important facts on products and services can be grasped at one glance. A brief list of unique selling propositions is followed by concise infor-mational text, which is supplemented on the product pages by tables contain-ing the technical details. The photography concept of the new website employs a combination of product photography, application photos and employee portraits. This creates product worlds that convey to the visitor a concrete image of HOERBIGER’s technology, yet places emphasis on people as the drivers of technological progress.

Another new feature is that HOERBIGER lists contact persons in the product and service section as well as on the career pages. “We demonstrate close-ness to the customer. Visitors to the website receive the desired information quickly and conveniently,” says Ludwig Schönefeld, Head of Corporate Com-munications at HOERBIGER.

Modern Technology for a better Web ExperienceA highlight of the web technology that is employed is the targeted output of content based on Internet Protocol (IP) addresses. Every Internet user has such an address when surfing the web. Based on the IP address transmitted by the user’s browser, the HOERBIGER website detects the region from which a page is accessed. The system then automatically supplies the user with con-tent that is relevant for the current location. This so-called geotargeting con-trols the language output, for example, or the display of contact persons and product information.

HOERBIGER LAUNCHES NEW WEBSITE

Visit our newWebsite:www.hoerbiger.com

On September 3, 2012, HOERBIGER launched its new website. The www.hoerbiger.com site was completely redesigned. It is based on the latest web technology and replaces HOERBIGER’s website created in 2006. At the same time, it provides new impetus for the dialog with the customer. TexT: Jens Geisel · sCReeNsHOTs: HOERBIGER

A direct line to

HOERBIGER: all product

pages contain the contact

information for the sales

managers in charge.

People come fi rst

The employees of the Group play an

important role in the communication

between HOERBIGER and its customers.

For this reason, the image concept of

the new website moves the people to

the center of attention. Large-size

portraits underscore the employees’

signifi cance for customer satisfaction.

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And there is good news for all mobile surfers: all pages of the new web pres-ence are designed so that they can be accessed on tablet PCs of the latest generation. With this, HOERBIGER takes the unabated trend toward mobile Internet use into account.

On all Channels: HOERBIGER across all MediaMovies are a fundamental component of HOERBIGER’s online communica-tion. Film sequences are embedded on numerous product, service and corpo-rate pages and are output around the globe with maximum performance via a high-capacity network. The video portal of the new HOERBIGER website con-tains professionally produced clips. The clips draw a genuine picture of the HOERBIGER Group, its products and services and, last but not least, the peo-ple who define HOERBIGER.

HOERBIGER pursues a cross-media approach by integrating the Performance Stories in the new web presence. The stories are online-optimized adaptations of current features from the customer magazine HOERBIGER@MOTION. The Performance Stories demonstrate HOERBIGER’s expertise in the oil, gas, and process industries, as a partner to the automotive industry, and in the mechanical and plant engineering industry.

Online communication is a fast-paced medium: in just a few years, the technological options have fundamentally changed.

The new HOERBIGER website therefore relies on state-of-the-art web technology.

HOERBIGER website undergoing change

website till 2006 website till 2012 website since 2012

Home page. Alternating starting

sequences provide

information about

news from the

company.

Product page. Related products are

combined in a well-

organized design.

Video portal. The video portal

allows HOERBIGER

to be experienced in

its entire diversity.

Drop-down menus for

the user-controlled selec-

tion of service locations

serve as an alternative to

automatic IP control.

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www.dorin.comOffi cine Mario Dorin S.p.A.

ENVIRONMENTALLY FRIENDLYREFRIGERATION AND AIR-CONDITIONING TECHNOLOGYThe Dorin family has been dedicated to developing and manufacturing refrigeration and air-conditioning equip-ment for almost 100 years. To this day, the success is driven by innovation and responsible corporate management. The company, which is now run by the fourth generation of the Dorin family, today operates worldwide in the refrigeration industry—and does so very successfully, especially when it comes to carbon dioxide compressors. In this market segment, the family business from Compiobbi near Florence is a global leader. TExT: Alessandra Fraschini · PHOTOs: Ralf Baumgarten

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T he story of Officine Mario Dorin S.p.A. began in 1918, when Mario Dorin’s passion and intuition prompted him to invest in the mechanical engi-neering field and build machine

tools, air compressors and liquid pumps. Soon thereafter, the refrigeration field offered the most interesting development prospects. After 1932, the company started to build compres-sors and refrigeration systems. Originally, pro-duction revolved around open-type compres-sors. After 1957, when Giovanni Dorin, an engineer, joined the team, the company for the first time also planned the development of semi-hermetic compressors for air-conditioning and refrigeration.

The seventies were marked by strong growth and intensive trade activities, which were pur-sued by son Mario. At the beginning of the 1990s, the first compressors with inverters were built. While cooling compressors were operated at a constant speed until then, the inverter con-trolled the rotational speed as a function of the required refrigeration output. At the same time they were developing compressors with invert-ers, Dorin also developed the first compressors operated with carbon dioxide as the refrigerant. Dorin mainly focused on the transcritical proper-ties of carbon dioxide. The higher compression pressure poses a particular design challenge.

The first few years of the new millennium were shaped by the launch of the second generation of compressors for transcritical applications (CD series). The product range was also systemati-cally expanded for the inverter applications (HI series). At the same time as these develop-ments, the company expanded the production of compressors operated with traditional refrig-erants. For example, the new HEP ECOpremium product line was created, which uses the R134a refrigerant. In conjunction with the CDS com-

pressors, which operate subcritically with carbon dioxide, this new series is optimally suited for cascade applications. Recently, Dorin has sent another signal in favor of the continued develop-ment of environmentally compatible refrigeration and air-conditioning technology, and notably for the use of environmentally compatible refriger-ants, with its HEX series, which also uses hydro-carbons such as propane as the refrigerant.

4,000 Compressors per MonthAt the corporate headquarters in Compiobbi near Florence, Officine Mario Dorin S.p.A. pres-ently has more than 100 administration and pro-duction employees. The average production output is 4,000 compressors per month. Over the last few years, Dorin was able to expand sig-nificantly. Thanks to a tireless dedication to the business, the family enterprise is now active around the globe. Approximately 70 percent of the approximately 35 million euros in sales is generated outside Italy. An important strategic step was the founding of a commercial agency in China. Shanghai Dorin Compressors Ltd. operates in the Asian market—primarily in China—and affords the company considerable logistical advantages. In addition to the trade business, Dorin plans to set up an assembly line of its own in China in the coming months in an effort to be even closer to the Asian customers in terms of assembly, delivery and service.

Reliability under Extreme ConditionsSince the company was founded by Mario Dorin, quality has been an integral part of the corpo-rate philosophy: “The most important thing is that our products are always perfect,” founder Mario Dorin would say to his staff in the early years, and to this day business partners can ex-pect reliable and technologically perfect com-pressors for their cooling and air-conditioning needs from Officine Mario Dorin S.p.A.—espe-cially under extreme conditions.

Even leading up to a new contract, maintenance and repair services as well as customer service are top priorities at Dorin. During the fitting phase, machines for special applications are in-dividually tailored to the customer’s needs. Aside from these custom solutions, the exten-sive product range also encompasses numerous standard compressors. Dorin offers compre-hensive customer service, which its business partners value, especially when it comes to overhauling and repairing compressors. Officine Mario Dorin S.p.A. trusts in reliable partners during development as well as the production of the compressors. One example is the long-standing relationship with HOERBIGER Kom-pressortechnik GmbH in Schongau, Germany. The company has supplied fully assembled reed valves for Dorin’s compressors for many years.

2012: Year of InnovationsIn an effort to maintain the company’s growth rate of the previous years, Dorin relies on contin-uous innovation and the dedication of the team of merchants and technicians. By making signif-icant investments, Dorin managed to revise key portions of the product range over the last few years and offer even more efficient models of the compressor series in 2012. The subcritical CDS series for cascade and booster applications was completely redesigned to improve the effi-ciency. Because of its progressive technology, the CD series continues to be regarded as the leading product for transcritical applications in the international marketplace. One aspect in the new development was the pressure control valves newly developed by HOERBIGER. Be-cause of their consistent functionality over the entire service life, they guarantee the system’s operational reliability and consequently the last-ing quality of the refrigerated product. The HI series featuring inverters, which was launched in 2002, can be operated in a broad frequency range of 20 to 90 Hertz. The most impressive

“The most important thing is that our products are always perfect.” Mario Dorin, founder of Officine Mario Dorin S.p.A.

Testing the compressor at maximum pressure.

Here the pistons are assembled.

The electrical panels are installed on the compressors.

A stock of crankcases awaiting the next steps.

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and cooling applications since 1957. Today, these form the company’s core business. Officine Mario Dorin S.p.A. offers an entire range of semihermetic and open-type compressors to its global customers—allowing the compa-ny to ideally respond to the requirements of the markets. The product spec-trum includes more than 70 models ranging from 0.4 HP to 150 HP for use with both CFC and HCFC refrigerants. A number of two-stage compressors as well as an extensive range of accessories round out the product portfolio.

Dorin is certified according to ISO 9001-2000 (LRC 170322) by Lloyd’s Register Quality Assurance. All compressors comply with the European standards EN 292-1/-2, EN 294, EN 60204, prEN 349, EN 60529, IEC 336-1 and IEC 335-2-34.

www.dorin.com

PARTNERSHIP Dorin and HOERBIGER have worked successfully together on the develop-ment of valve systems since the mid-1990s. Dorin selected HOERBIGER, a worldwide innovation, technology and market leader in valve technolo-gy, primarily because of the development expertise and reliability of the products.

PART The valve plates used by Dorin for the production of refrigeration and air-conditioning compressors are supplied by HOERBIGER Kompressortech-nik GmbH in Schongau, Germany. The reed valves are considered to be the most important part of the compressors: they are precision components, and their performance strongly influences the performance of the custom-ers’ machines. HOERBIGER supplies the reed valves as a complete mod-ule. The reeds, which are produced from high-strength spring band steel, must be both robust and elastic to achieve a long service life. Additionally, the component geometry must be optimally tailored to the use of the end product. www.hoerbiger.com

PART OF Dorin was founded in 1918 as a manufacturer of machine tools, air com-pressors and liquid pumps. It also offered repairs of motor vehicle engines. In 1932, the company began to build compressors and refrigeration sys-tems. Dorin has produced semihermetic compressors for air-conditioning

features of these HI compressors include high efficiency, low wear and vibration-free operation.

Solutions for Extreme ConditionsThe new HEX series is used primarily for applica-tions with flammable refrigerants such as tradi-tional hydrocarbons or propane. The compres-sors are designed specifically for hazardous and

flammable environments. The new two-stage 2SH compressors equipped with four or six cylin-ders. are especially innovative Their key design feature is the integrated gas flow management. Because of the lower number of gaskets and con-nections, this compact solution minimizes leaks. The HEP ECOpremium compressors employ new technical solutions to boost the efficiency of sys-

tems which use R134a as the refrigerant. For this purpose, Dorin has optimized the compressor for low condensation temperatures of up to 10 degrees Celsius (50 degrees Fahrenheit)—for example by using valve plates specially devel-oped by HOERBIGER.

At present, the headquarters in Compiobbi has more than 100 administration and production employees.

The site produces approximately 4,000 compressors a month.

HOERBIGER@MOTION spoke with Giovanni Dorin, Marketing Manager of Officine Mario Dorin S.p.A., Mauro Dallai, Technical Direc-tor, and Giacomo Pisano, Brand Manager CO2, to learn more about the partnership between Dorin and HOERBIGER.

HOERBIGER@MOTION: Doctor Dorin, what was the basis on which the partnership between Officine Mario Dorin S.p.A. and HOERBIGER was created?Giovanni Dorin: Around the mid-1990s, Dorin made the decision to look for a special-ty supplier for the procurement of premium and reliable valve reed and safety valves. These are precision components, and their performance strongly influences the perfor-mance of the compressors we build. They must be both robust and exhibit flexural fatigue strength at high rotational speeds. They must also withstand varying conditions, which differ depending on the refrigeration

that is used. HOERBIGER supplies Dorin with the complete module, which is tailored to the compressor type that is produced.

HOERBIGER@MOTION: What new solutions do you offer?Giovanni Dorin: We are especially committed to the use of carbon dioxide as a refrigerant and accordingly advertise our compressors with the “environmentally correct” label. For us, this is the right step into the future. In addition, we consider carbon dioxide to be the primary refrig-erant in cascade systems.

HOERBIGER@MOTION: What are your custom-ers’ requirements?Giovanni Dorin: Our partners demand a reliable product and progressive technology, without losing sight of the equipment’s consumption and operating costs. Thanks to the commitment of our research and development department, we are in a position to guarantee this.

Dorin and HOERBIGER have worked together for almost two decades. The partnership dates back to the mid-1990s and has continually intensified thanks to mutual respect and appreciation. The valves are an important but critical component of the compressor. The more the standards evolved in this techno-logical niche, the more Dorin considered it necessary to turn to a specialist for developing the valve technology. Dorin decided in favor of HOERBIGER because of their valve expertise. When Dorin plans new compressors today, the Florence company relies heavily on HOERBIGER components. INTERVIEW: Alessandra Fraschini · PHOTOs: Ralf Baumgarten

DORIN AND HOERBIGER:A vAluABlE PARTNERSHIP

HOERBIGER supplies central compo-

nents such as reed valves and

valve plates.

Giovanni Dorin, Marketing Manager of Officine Mario Dorin S.p.A.

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HOERBIGER@MOTION: What role does Dorin play today in the market?Giovanni Dorin: Officine Mario Dorin S.p.A. is among the circle of five market leaders—this is due in particular to the specialized exper-tise with carbon dioxide compressors as well as transcritical and subcritical applications we have developed over the course of the years. We are strengthening this market posi-tion through our exposure in the field of fre-quency modulation technology which we have developed over the last ten years and intensified especially with regard to energy-saving systems. We have created a dedicat-ed product line of compressors with inverter technology. These products are geared to a high degree toward the requests of our cus-tomers, without losing the focus on efficiency and performance capability. This in particu-lar has helped us evolve into a preferred part-ner of the railway industry.

products with greater efficiency. In addition, we have expanded the range of products that oper-ate with ecologically more compatible refriger-ants. Dorin is a company that is strongly focused on the protection of the environment and ecolo-gy. This is also the reason behind structural changes that are imminent in our production operation to improve the company’s energy effi-ciency.

HOERBIGER@MOTION: What contribution does HOERBIGER make that adds value?Mauro Dallai: The components developed and produced by HOERBIGER constitute value added for our machines because they blend quality that is recognized by the market with our quality. These are components where the primary factor does not revolve around the price, but reliability. When we design new products today, we use HOERBIGER standards as a reference.

greatest. We count on this product line to counteract the shrinking of the market. This technologically sophisticated product requires know-how. Europe plays an important role in this regard because this is where we develop top-notch solutions.

Using carbon dioxide as the refrigerant plays an important role for our business for a variety of reasons. In countries where traditional, HFC or HCFC refrigerants are banned, carbon diox-ide complies with the statutory requirements. In other countries where traditional refrigerants cannot be used, for example, chain stores cam-paign for the use of more environmentally com-patible solutions in their marketing.

At Dorin, the range of compressors that are operated with carbon dioxide accounts for ap-proximately 10 to 15 percent of sales. We con-tinue to see high growth in the future.

We also anticipate more significant devel-opments in terms of efficiency and therefore in

HOERBIGER@MOTION: What are your plans in terms of export?Giovanni Dorin: Previously, we exclusively supplied our global customers from the Com-piobbi plant in the Province of Florence. For the continued development in the future, we are building a production plant in Asia to be able to offer our services there locally, close to the customer. We intend to incrementally open additional trade and/or production sites in key countries where we, in our view, need to be present.

HOERBIGER@MOTION: What is your envi-ronmental policy?Giovanni Dorin: Years ago, we made the decision to invest our efforts in the research and development of increasingly more effi-cient products, always searching for greater energy efficiency. Over the course of the years, we have succeeded in manufacturing

HOERBIGER@MOTION: What contribution does HOERBIGER make to the growth of Officine Mario Dorin S.p.A. in Italy and around the world?Mauro Dallai: What matters to us is not just the mere delivery of components. Active and effi-cient support when problems arise and cooper-ation during the advanced engineering phase are all important when working together. Espe-cially when it comes to valves for specialty com-pressors, such as the product range of the car-bon dioxide compressors, we give preference to HOERBIGER so that we can be assured of max-imum reliability. In addition, personal relations have also strengthened over time and are marked by mutual respect and trust.

HOERBIGER@MOTION: What is the significance of the carbon dioxide compressor product range in your portfolio?Giacomo Pisano: The carbon dioxide series in-cludes the equipment that is the latest and

environmental compatibility—greater refriger-ation output with lower power consumption.

With approximately two decades of experi-ence with carbon dioxide compressors, Dorin offers a product range that is unrivalled on the market. Dorin is a global leader of carbon diox-ide equipment.

HOERBIGER Kompressortechnik GmbH in Schongau is a partner of fundamental impor-tance to us because the company supplies the reed valves, the core of the compressor. HOERBIGER offers everything we expect from our suppliers: technical experience and sup-port in development, quality, traceability and high delivery performance.

It doesn’t matter whether they are used for cool-ing containers and supermarket product cases or for air conditioning buildings. The Italian com-pany Officine Mario Dorin S.p.A. supplies refrig-eration and air-conditioning compressors for various applications. The reed valve is the heart of every refrigeration and air-conditioning com-pressor—regardless of whether the compressor output is 15 or 150 kW.

“Considering the mode of operation, pressure-controlled reed valves are of simple construc-tion. Each valve, however, is specifically tailored to the respective usage conditions of the com-pressor,” explains Martin Lachmann, Develop-ment Engineer and Key Accounter for Dorin at HOERBIGER Kompressortechnik GmbH.

“In addition to the geometric design, the func-tional properties of the valve later on in the final

application must be taken into account when developing a customized valve design,” Lachmann emphasizes. Using special computa-tion and simulation programs, HOERBIGER experts determine and optimize both the move-ment properties and the valve reed opening and closing behavior. A major competitive advantage is HOERBIGER’s knowledge of materials and the valve design know-how gained over the years.

Martin Lachmann adds: “In order to ensure the reliability of our valves, our engineers define not only the design, but the spring rigidity of the reeds, the valve lift and the borehole geometry. The resulting flow rates are determined based on the valve cross-sections. By reducing the dead space and optimizing the flow geometries, HOERBIGER develops a tailor-made valve sys-tem that offers great efficiency and a long ser-vice life for any application.”

In addition to valve performance, constant func-tionality must be guaranteed in everyday opera-tion over the course of millions of intake and compression cycles. Material fatigue must not be an issue, especially for the reeds which are subjected to pressure and vibrations.

“The HOERBIGER team develops all the com-ponents of a new valve system with utmost pre-cision and in partnership with the customer here, in Schongau’s Center of Competence,” Martin Lachmann explains. “Our production operation has very high vertical integration and measures up to automotive standards when it comes to quality management. Together with our development department, they assure that in the end the customer receives a customized yet well-engineered product.”

HOERBIGER Kompressortechnik GmbH, Schongau, Germany, is HOERBIGER’s center of competence in the area of reed valves. using state-of-the-art simulation methods, a wide variety of valve systems are developed in consultation with the customer. Despite multiple application ranges and sizes, they all have one thing in common: they make refrigeration and air-conditioning compressors efficient, economical, reliable and especially long-lived.TExT: Simon Schmid · PHOTO: Hans-Helmut Herold

DEvElOPMENT ExPERTISE FOR REED vAlvES

“We advise our customers during all product development stages, which helps them to increase the performance potential of their refrigeration and air-conditioning compressors.” Martin lachmann, HOERBIGER

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With the HOERBIGER ePrAX, an intelligent drive system for press brakes, HOERBIGER will unveil one of the featured outstanding innovations at the EuroBLECH 2012. The international trade show, which will be held from October 23 to 27, 2012 at the Hannover Exhibition Center, is considered the leading sheet metal working exhi-bition worldwide. In 2012, approximately 1,400 exhibitors from 40 countries are expected to participate. The focus of the 2012 trade show, which is anticipated to draw approximately 60,000 visitors, will revolve around effi cient technologies and environmentally friendly production processes. TexT: Ludwig Schönefeld · ReNDeRING: Wolfgang Garber, Eckstand

with its hydraulic gearbox.” The new system will be reliable, clean and ef-ficient in tough everyday operation— and assure maximum precision of press brakes.

“The HOERBIGER ePrAX blends the advantages of electrical and hydrau-lic systems,” says Katja Ebenhoch. “The combination of these benefits is what defines the performance of modern press brakes. Compared to the existing customary drive sys-tems, for a new investment the HOERBIGER ePrAX provides end customers with a sustainable in-crease in productivity due to short-ened cycle times.”

Innovative Technology forLaser Cutting MachinesIn addition to the HOERBIGER ePrAX, HOERBIGER Automatisie-rungstechnik GmbH will feature two innovative products for laser cutting systems at its booth: the Laser Gas Regulator (LGR) and the new LiftAx for raising the pallet table.

The innovative HOERBIGER Laser Gas Regulator (LGR) combines the advantages of piezotechnology with precision engineering, electronics, and sensors. A decisive unique sell-ing proposition is that the gas can be changed in just a few hundred milli-

HOERBIGER ePrAX—THE eDRIVE REVOLUTIONAT THE EUROBLECH 2012 IN HANNOVER

HOERBIGER Laser Gas Regulator is also excellently suited for thin metal sheets. The compact design and the low weight of the system, which is at-tached directly to the cutting head, also allow the laser unit to be moved more quickly.

The HOERBIGER LiftAx system, a hydraulic innovation for automatical-ly loading and unloading flat bed la-ser cutting machines, also has im-pressively high process reliability. The pallet table is equipped with four LiftAx units for raising and lowering the metal sheets. The synchronous speed of the units is hydraulically controlled. This novel, decentralized solution entirely eliminates the space requirement for a central hydraulic power unit, creating more design freedom for our customers. The self-sufficient LiftAx units at the corners of the pallet table ensure minimal in-stallation effort and maximum con-venience.

Proven Components and Systems for Industrial Mechanical EngineeringIn addition to the HOERBIGER ePrAX, the innovation of the year 2012, HOERBIGER will feature prov-en components and systems for in-dustrial mechanical engineering at the EuroBLECH 2012.

The booth will, for example, exhibit the latest design of the high-perfor-mance Hybrid Direct Drive Linear (HDDL) punch drive. The patented punch drive uniquely blends the dy-namics and precision of a servo-electric linear drive with the power density and stability of hydraulics. Its efficiency and optimized energy management are other compelling features. With a positioning accuracy of 0.01 millimeters or better, the HDDL achieves up to 1,300 strokes per minute in stamping operations and 3,000 strokes per minute in marking operations. Another unique

A s a mechanical engineering partner for application-orient-ed solutions HOERBIGER will

showcase itself at the EuroBLECH 2012: “In the Industrial Machinery market segment, HOERBIGER offers innovative solutions for demanding niche markets in the mechanical and plant engineering industry,” says Katja Ebenhoch, Head of the Indus-trial Machinery Business Segment, who also manages the HOERBIGER booth. “The company benefits from the know-how it has developed over the decades relating to perfor-mance-defining hydraulic and piezo-pneumatic components and special solutions.”

HOERBIGER ePrAX—MaximumDynamics for Press BrakesThe HOERBIGER ePrAX, a com-pletely innovative drive system for press brakes, which will revolutionize all existing eDrive developments, will take the center stage.

“We will not unveil the biggest secret—the technical design of the HOERBIGER ePrAX—until the trade show,” adds Katja Ebenhoch. There is only a small part that is being re-vealed now: “With the HOERBIGER ePrAX, we have developed an elec-tric drive that overcomes all the drawbacks of mechanical systems

seconds, making it five times faster than conventional systems. Because of the high gas pressure stability that is achieved with the piezotechnolo-gy, the HOERBIGER LGR creates precise cutting edges in consistent quality. At an output pressure of up to 28 bar, especially thick metal sheets can be cut efficiently and in the highest quality. With its pressure stability of +/-0.03 bar, the

selling proposition is the dynamic speed adjustment of the stroke, re-ducing tool wear and tear and noise.

Time and Space for In-DepthDiscussions with VisitorsThe HOERBIGER trade show booth has been completely redesigned. At the EuroBLECH, HOERBIGER for the first time built a two-story booth on floor space measuring approxi-mately 65 square meters (700 square feet).

“The EuroBLECH is the most impor-tant trade show for our industry,” says Katja Ebenhoch. “It goes with-out saying for us that we need to be present here for our international customers. Our new booth offers ample room for communicating and exchanging ideas. We have created a pleasant atmosphere for in-depth technical discussions, mainly on the second floor.”

Room for presentations and communication: the HOERBIGER trade show booth, which was de-signed for the EuroBLECH in Hannover. The drive system for press brakes newly developed by HOERBIGER will take the center stage. The biggest secret, the technical design of the innova tive HOERBIGER ePrAX, will not be unveiled until the show.

The HOERBIGER Laser Gas Regulator (LGR) is five times faster than conventional systems.

This is the latest design of the high-performance Hybrid Direct Drive Linear (HDDL) punch drive.

Hannover Trade Show, October 23 to 27, 2012, Hall 12, Booth H30

www.ksb.com

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KSB S.A.S. France

INNOVATION BETWEEN COGNAC AND BORDEAUX

mECHATROnICS À LA CARTE

Not far from the small town of La Roche-Chalais situated in the Dordogne Département, several futuristic buildings interrupt the park-like landscape. The complex, which nestled between old trees and small ponds at fi rst glance resembles a hotel or winery, is one of the world’s leading centers of competence for butterfl y valves, nonreturn valves, actuators and automation systems: KSB S.A.S. France. In 1989, the French subsidiary of Germany�s KSB Group acquired the former AMRI S.A.—“Applications Mécaniques de Robinetterie Industrielle.” Since then, AMRI has become the brand name for valves made by KSB Group. Boasting sales of approxi-mately two billion euros worldwide, the Group is one of the leading provid-ers of pumps, valves and associated systems.TEXT: Nikolaus Fecht · PHOTOS: Ralf Baumgarten

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At KSB S.A.S. France, approximate-ly 450 employees are in charge of development and production of the products manufactured in La Roche-Chalais. A key production

line is the butterfly valves. KSB S.A.S France is considered the market leader in Europe in this market segment.

Given the variety of eccentric and centric butter-fly valves offered by KSB, ranging from a few millimeters to several meters in size, the range of application opportunities is broad. The manual-ly, electrically, pneumatically or hydraulically ac-tuated valves are used in many markets of in-dustry, in the crude oil, gas, chemical and petro-chemical industries, but also in the industrial

generation of low-pressure steam and vacuum as well as in the sugar and paper fields. Addi-tional areas of application include building, water and power plant technology, as well as shipbuilding. This has created a multicolored production environment, since the different col-ors at KSB identify the use of the finished prod-uct. KSB blue, for example denotes industrial applications, orange is for buildings, and light blue for drinking water.

High Complexity in ProductionKSB S.A.S. France manufactures almost the entire range in-house. The plant generally procures only the cast casings, raw materials, electronics components and—in very few ex-ceptions—mechatronics modules from outside suppliers. This has led to high complexity in the production operation. Antoine Casteleyn, Prod-uct Manager Actuator and Automation states: “We produce over 1,000 different combinations

of valves, actuators and automations, which gives a big variety of products for many applica-tions. The trick is to control this enormously high complexity in assembly, in order to ultimately deliver the products on time.” Six manufacturing cells were set up for producing the butterfly valves, which employ high vertical integration to manufacture the different product groups—seals, seat rings and valve control units.

Leading Edge in Seals,Seat Rings and Control UnitsKSB Group continues to market the product portfolio produced in La Roche-Calais under the AMRI brand, which is well known beyond France’s borders. A special feature of the facto-ry is the Rubber Production department, which develops and produces the elastomeric liners in-house. The vertical integration here is ex-tremely high, because KSB also develops the blends for the seals. “We manufacture the liners for the entire KSB Group right here,” explains Christophe Bouffin, Manager of the Rubber Pro-duction Department. “Our plant only receives the raw material for our 15 standard blends which we use to cover our customers’ require-ments.” Depending on the lots, the seals are press-formed or injection-molded. The diame-

ters of the liners, which are integrally molded and then vulcanized, range from 20 millimeters to as large as one meter (0.78 to 39.3 inches). The French plant produces seals larger than that in individual parts, which are then com-bined into a gigantic liner at the sister plant in Burgos, Spain. Thanks to special contact points, which allow renewed vulcanization at the Burgos facility, elastomeric seals with diameters as large as 3.8 meters (149 inches) have been produced here, which due to the vulcanization have a con-sistent mixing ratio and high strength. Like the seals, the seat rings for the eccentric butterfly valves are also manufactured under KSB’s own auspices. Materials used include metal or high-performance polymers such as PFA or Teflon. The latest manufacturing cell is currently in the process of being set up. It is intended for the new generation of multifunctional valve control units and positioners for pneumatic part-turn and linear actuators, which the KSB Research and Development Center in Gradignan near Bordeaux developed. An assembly developed there is the AMTRONIC control unit with pneu-matic valve-limit switch. It can be mounted directly on pneumatic KSB part-turn actuators, without the use of added adaptation parts such as bracket and external piping.

The carbon for the rubber blend is weighed with precision.

A piezopneumatic positioner module made by HOERBIGER is used in the electropneumatic SMART-RONIC MA positioner. The production steps at KSB are diverse: the picture above shows a stop being welded to the Danais disk.

A special feature is the Rubber Production department, which develops elastomeric liners. The weighing of the rubber blends is computer controlled. The raw material is processed in the molds (top). Quality control of the seal is an integral step (bottom).

KSBKSB Aktiengesellschaft, Frankenthal, Germany, is one of the leading producers of pumps and valves worldwide. While other companies in the mechanical and plant engineering in-dustry suffered declining sales following good results in 2011, KSB Group and its 16,000 employees around the world realized strong growth. Between January and June 2012, the company increased its semiannual sales by approximately 13 percent to 1.1 billion euros— in all segments, for pumps and valves, as well as in service. KSB Group generated sales of 2.13 billion euros for the entire fiscal 2011 year. Like the parent company in Germany, the plant of French KSB subsidiary KSB S.A.S. France in La Roche-Chalais is one of the long-standing customers of HOERBIGER�s Strategic Business Unit Automation Technology. KSB sells the butterfly valves manufactured in La Roche-Chalais, France, in Burgos, Spain, and in Houston, Texas, USA, under the AMRI brand name. The valves are used in building tech-nology, industrial engineering, water and power plant technology as well as in shipbuild-ing. The product portfolio of the AMRI brand includes pneumatic, hydraulic and electric valve actuators as well as control units, which are developed by the 50 employees of the Research and Development Center in Gradignan near Bordeaux.

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PARTAt the ACHEMA 2012 in Frankfurt am Main, Ger-many, the KSB Group unveiled a new generation of multifunctional valve control units and smart positioners for pneumatic part-turn and linear actuators. The functions range from simple open-close control of a pneumatic valve with lim-it position detection—AMTRONIC—to control tasks which are completed independently of a higher-level control station—SMARTRONIC PC. Users will benefit from a comprehensive pack-age consisting of the valve, actuator and smart control unit or positioner, which is fully config-ured and tested at the plant. KSB typically relies on high vertical integration. The well-known valve manufacturer only makes an exception when an excellent outside solution is available. This was the case with a piezopneumatic posi-tioner module from HOERBIGER Automatisie-rungstechnik GmbH, Altenstadt, Germany, which is used in the SMARTRONIC MA positioner for pneumatic part-turn and lift actuators.

According to KSB, great features of the HOERBIGER module include fast positioning, the technology for intrinsically safe devices, low energy consumption and resistance to air pollution. A look at the technical data of the

HOERBIGER@MOTION: Mr. Casteleyn, what makes your products stand out?Antoine Casteleyn: We are one of the very few manufacturers that completely develop valves, actuators and automation systems and produce these with very high vertical integration. Our unique selling proposition is that control units can be mounted directly onto KSB part-turn ac-

tuators, without added parts and pneumatic piping.

HOERBIGER@MOTION: At the ACHEMA 2012, KSB unveiled a new generation of multifunction-al valve control units and positioners for pneu-matic part-turn and linear actuators. What does the innovation consist of?

“Actually, we were only looking for a pilot valve!”—KSB S.A.S. France has treated its new, intelligent control systems for pneumatic actuators to a mechatronics icing on the cake, made in Germany. Antoine Casteleyn, Product Manager Actua-tor and Automation at KSB’s Research and Development Center in Gradignan explains why it had to be HOERBIGER piezopneumatics.InTERvIEw: Nikolaus Fecht · PHOTOS: Ralf Baumgarten

Antoine Casteleyn: This is an actuator series with three development stages. The AMTRONICS open/close control unit for pneumatic actuators is the first stage. The electropneumatic SMART-RONIC MA positioner is the second stage, which is supplied with power via a four- to 20-milliam-pere signal and controls the pneumatic part-turn and lift actuators. In the third stage, the control loop is closed by the multifunctional SMARTRONIC PC valve control unit, which can be programmed specifically for the customer’s process on the computer.

HOERBIGER@MOTION: What was the greatest leap you implemented in the development pro-cess?Antoine Casteleyn: Definitely with the SMART-RONIC MA, since our major customers would like to integrate the automation components in their central process control system at the field level. The SMARTRONIC MA offers the neces-sary conditions.

HOERBIGER@MOTION: What improvements did you make on the new control unit?Antoine Casteleyn: The compressed air supply, the electronic control boards as well as the elec-

trical connections are located in separate com-partments of the device. This protects each of these functions during start-up and mainte-nance work. The spatial separation and a poly-carbonate housing assure that the units are very robust and reliable.

HOERBIGER@MOTION: Does the air upstream of your unit have to be conditioned?Antoine Casteleyn: Generally not. Unlike our competitors, which provide for class 2 or 3 filtra-tion, we rely on class 4 air filtration for the con-trol air with pressure of two to eight bar, which removes particles greater than 15 micrometers.

HOERBIGER@MOTION: How did piezopneu-matics made by HOERBIGER come into play?Antoine Casteleyn: We wanted to replace the existing solenoid valve in the SMARTRONIC MA for a variety of reasons. Great features of piezo-pneumatics include faster positioning, greater resistance to air pollution, lower energy con-sumption and intrinsic safety. The last advan-tage allows an intrinsically safe design according to ATEX II 1 G, using the same pilot valve.

In addition, the actuating speed of the in-stalled seat valve is not dependent on the cur-

rent signal when using piezopneumatics. We ultimately decided in favor of HOERBIGER tech-nology among the piezopneumatic pilot valves because HOERBIGER has also proven to be a great development partner, who supplies us now with the entire positioner module—contrary to our originally planned in-house development.

HOERBIGER@MOTION: You offer your custom-ers complete packages consisting of the valve, actuator and intelligent control unit, which are fully configured and tested in your plant. Does the relationship with HOERBIGER play a role there too?

Antoine Casteleyn: HOERBIGER supports us very significantly when it comes to adapting the positioner modules to our system. We therefore have a kind of simultaneous engineering in place at a very early stage. This ability to support the system development is one of the key rea-sons that speak in favor of HOERBIGER.

Nonetheless, this is only one aspect of our cooperation. We have been purchasing end products from HOERBIGER for quite some time, including electrohydraulic systems, for ex-ample.

HOERBIGER@MOTION: What strategy do you pursue for launching the new actuator control units and positioners for pneumatic part-turn and linear actuators?Antoine Casteleyn: Here, we are already one step further. We have already completed the test phases. The tests were carried out in compa-nies which place high demands on pneumatics. We are now already at a point where our sys-tems are being marketed successfully around the world and used in companies from the oil, gas and food industries as well as in drinking water purification.

PIEzOPnEUmATICmechatronics à la carte—the right Ingredients

Antoine Casteleyn, Product Manager Actuator and Automation, KSB

The new generation of products made by KSB:

AMTRONIC-SMARTRONIC.

HOERBIGER Positionersreplace Solenoid valveAn especially innovative system is the electro-pneumatic SMARTRONIC MA positioner, which is used to control pneumatic part-turn and lin-ear actuators. Unlike with the majority of its leading products, KSB here relies on the perfor-mance of a component made by a development partner: in the SMARTRONIC MA, a piezo-pneumatic positioner module with extremely low internal air consumption of less than 0.4 liters per minute (0.024 cubic meters/hour) made by HOERBIGER has replaced the solenoid valve of the predecessor model. “Our objective was to develop an intrinsically safe pneumatic-elec-tronic controller,” Christophe Amagat recalls, Automation Development Engineer at KSB S.A.S. France. “In fact, we were only looking for a supplier that could offer an intrinsically safe

piezo pilot valve with very low internal air con-sumption.” HOERBIGER Automatisierungstech-nik GmbH in Altenstadt, Germany, had just completed its development of an innovative po-sitioner module for intrinsically safe positioners.

The newly devised positioner module was so well received in Gradignan that they dispensed with a new development of their own and KSB, in this instance, departed from the high internal vertical integration: “We decided against an in-house development and in favor of the system made by HOERBIGER because the company is known to have very extensive know-how and ex-perience when it comes to piezopneumatics,” says Christophe Amagat.

KSB SMARTRONIC MA positioner module dem-onstrates just how extremely economically the piezopneumatic positioner module developed by HOERBIGER operates. Thanks to the integrated piezopneumatic pilot valves, the internal air con-sumption of the positioner module is less than 0.4 liters per minute (0.024 cubic meters/hour), regardless of the operating pressure. This is less than half of the compressed air consumption of conventional systems.

www.hoerbiger.com

PART OFThe new AMTRONIC and SMARTRONIC units made by KSB are suitable for a broad spectrum of applications. The testing conducted by pilot users from the oil, gas and food industries as well as in drinking water purification was stringent. In-trinsically safe models are especially suited for applications in explosion-prone atmospheres. The HOERBIGER piezopneumatic positioner modules particularly stand out in these difficult environments: they are typically produced in in-trinsically safe designs, which meet the ATEX II 1 G standard.

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Shanghai Automotive Industry (Group) Corporation (SAIC): the story of one of China’s most important automobile manufacturers is driven by famous car models. It began with the Shanghai 760

built in the late fi fties, a sedan weighing more than a ton. And today, in 2012, SAIC is really gaining traction with state-of-the-art transmission technology.

TEXT: Gerd Golbach · PHOTOS: Ingo Bulla · SAIC

www.saicgroup.com

Shanghai Automotive Industry (Group) Corporation

CHINA’S AUTOMOTIVE

SUCCESS STORY

A BRIGHT FUTURE

The Roewe 750 is one of

SAIC’s models for success.

HOERBIGER supplies com-

plete synchronizer systems

for the transmission.

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039

T he Shanghai 760 was developed in Maoist China. The heavy-weight sedan was the vehicle of choice of the Chinese political upper class, whose positions were not high enough for the dream car, the “Red Flag.” In top years, the

plant manufactured as many as 9,000 vehicles annually. Even as late as the 1990s, being chauffeured through Beijing in a Shanghai 760 taxi was a highlight among tourists.

Today, the Shanghai 760 is a museum piece. The true success story of the automotive industry in China began in the eighties—with Shanghai Automotive Industry Corpora-tion as the trailblazer. The joint venture Shanghai VW has been producing the Shanghai Santana since 1983. The first Santana generation dominated the urban landscapes of the Chinese metropolises until the nineties. It was a robust and comfortable vehicle, which did well on China’s roads and soon could be found even in the remotest of spots of the country.

Even though it was produced in China, drivers were always proud of sitting behind

the wheel of a “German” automobile.

The success of the Santana paved the way for SAIC devel-oping an entirely new supplier industry for automotive components in the late 1980s and 1990s. While in 1987 the only locally manufactured components of the Shanghai Santana were the tires and car radio, the share of locally produced parts was expanded to more than 90 percent in a matter of ten years. This was due in part to the govern-ment of the City of Shanghai, whose goal at the time was to double Shanghai’s share in the national production of vehi-cle components. In 1997, a new joint venture was created: this time with General Motors. In 1996, Shanghai GM began to produce Buicks and Chevys and helped SAIC double its annual production between 2000 and 2006.

From China’s Number One to a Global PlayerWith the onset of the new millennium, SAIC prepared its presence on the international market. In 2002, SAIC acquired a majority stake in the Korean automobile manu-facturer SsangYong Motor, gaining access to the Korean’s international dealer network.

SAIC had grown with the Chinese automobile market until 2002. Driving factors for this growth were the joint ven-tures. For almost ten years now, the Chinese automotive industry has attempted to become established on the worldwide market with new products it developed on its own. And it has done so successfully: in 2005, SAIC acquired the licenses to the Rover 25 and Rover 75 mod-els from the insolvency assets of MG Rover Group. The production equipment and machines were acquired in 2006 by its then competitor, Chinese automaker Nanjing Automobile Corporation (NAC), which holds the naming rights to MG and founded the subsidiary NAC MG.

Upon intervention by the Chinese government, the two en-tities merged to jointly produce the almost identical models of SAIC and NAC MG. SAIC continued to develop the Brit-ish models and is selling them with a newly designed com-pany logo under the Roewe marque. The name had to be changed because the naming rights to Rover as well as the logo are owned by Ford.

SAIC is presently the largest automobile conglomerate in China. In 2011, the company produced more than 4 mil-lion vehicles, of which the two joint ventures Shanghai GM

and Shanghai VW manufactured 2.4 million cars. The most popular minivan in China, the “Wuling Sunshine,” accounts for 1.2 million vehicles.

Brand Diversity: Cars for Everyone’s TasteSAIC sells vehicles under various brands. The Yuejin, Roewe, MG and Maxus brands are exclusive to SAIC. The brands used by the joint ventures are Buick, Chevrolet, Bajun, Volkswagen, Skoda, Iveco and Wuling. SAIC Motor Passenger Vehicle Company (SMPV), which is wholly owned by SAIC, is in charge of developing and manufac-turing the Roewe and MG series. SMPV plans to sell 700,000 Roewe and MG vehicles annually by 2015, which equates to three times the 2011 sales figure. SMPV addi-tionally plans to launch three to four new models every year beginning in 2015. Professor Fang Weirong, Trans-mission Vice Director at SMPV, started with SAIC Motors in 1986. “I began,” he reported in an interview with HOERBIGER@ MOTION, “at precisely the time when VW came to China. My first major project was to implement the production of the Santana five-speed transmission in China starting in 1988.”

On right: In 2012, the trans-

mission production operation

was relocated to the new

factory in Shanghai. One of

the products manufactured

at this site is the transmission

for the Roewe 750.

Above: Professor Fang

Weirong, Transmission Vice

Director of SAIC Motor

Passenger Vehicle Company

(SMPV), has worked for the

company since 1986.

040

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PART Synchronizer systems are an important component in man-ual transmissions. Because of HOERBIGER’s intensive prod-uct development process and extensive transmission testing, its synchronizer systems are always optimized. Premium components assure the performance of the transmission.HOERBIGER produces the synchronizer components that are intended for SAIC at its sites in Schongau, Germany, and Changzhou, China. In Changzhou, the synchronizer systems are completed before they are shipped to the customer. HOERBIGER supplies SAIC with complete synchronizer sys-tems for the SH78Z transmission installed in the Roewe 750. In 2012, SAIC relocated the transmission production to a newly constructed factory. This is where the new SCM 250 transmissions for the Roewe 350 and MG 5 as well as the SCM 360 transmissions for the MG 6 will soon roll off the line with synchronizer systems made by HOERBIGER. HOERBIGER will continue to support SAIC with innovations. Engineers from both companies are currently working on an Electrical Drive Unit (EDU). The center of this collaboration revolves around the application of a synchronizer unit in the drivetrain of an electric vehicle.

PART OF China, the world’s largest automobile market, now has more than 6,500 companies which serve the continually growing automobile market. Based on annual production, companies leading by a wide margin in 2011 included Shanghai Automotive Industry (Group) Corporation (SAIC) with 4 million vehicles, Dongfeng Motor Corporation (DMC) with 3.5 million vehicles, China First Automobile Group Cor-poration (FAW) with 2.6 million vehicles, and Chang’an with 2 million vehicles. These four companies accounted for 64 percent of China’s total automobile production. As sales growth in China is decreasing, notably SAIC and FAW are making a push into the international market, attempting to also gain a foothold in the electric vehicle market segment.

After years of unabated growth and investments, the Chi-nese automotive sector is facing a consolidation process in the medium range. SAIC is positioned well and has solid financial backing, so that it is very likely to gain from the consolidation and maintain its position.

PARTNERSHIP SAIC was the first Chinese state-owned company to enter into a joint venture: this was with Volkswagen Group. SAIC has been collecting experience from this international co-operation since 1983. The collaboration was expanded in the mid-1990s to include General Motors (GM). After 20 years as a “junior partner” to international automobile groups, SAIC now also operates internationally and is an equal partner and investor. In 2002, SAIC participated in the acquisition of Korea’s automobile manufacturer Dae-woo by GM. SAIC currently holds a ten percent stake in GM Daewoo. In 2004, SAIC gained control of the Korean auto-mobile manufacturer SsangYong Motor. Through its merger with Nanjing Automobile Corporation, which had produc-tion plants not only in China, but also in Longbridge, Eng-land, SAIC further expanded its position as an international car manufacturer. Six years ago, SAIC and HOERBIGER jointly optimized the transmission for the Roewe 750. Over the years, the two partners have continued to expand their close working relationship. HOERBIGER supplies not only complete synchronizer systems for the Roewe 750, but is now also involved in the development of innovative syn-chronizer systems for the current and future model series. HOERBIGER cooperated with the engineers in Longbridge even before they have been acquired by SAIC. This rela-tionship had a global focus right from the start. While the SAIC Motor Technical Centre (SMTC) in England works closely with HOERBIGER Antriebstechnik GmbH in Schon-gau, Germany, SAIC engineers in Shanghai value the prox-imity of HOERBIGER development engineers at HOERBIGER Drive Technology (Changzhou) Co. Ltd. HOERBIGER’s global nature assures shorter paths for the customer and tailor-made solutions for any market.

The MG and Roewe models are developed primarily in Shanghai. A total of 1,800 engineers in Shanghai work closely with 300 engineers in Nanjing and 250 engineers in Longbridge near Birmingham, England. Longbridge re-cently opened the SAIC Motor Technical Centre (SMTC). The focus of the company still lies on successfully develop-ing the brand, which is apparent alone from the fact that the engines and transmissions departments employ in total more than 130 engineers.

With Joint Ventures toward Cutting-Edge Technology developed in ChinaProfessor Fang Weirong says: “The joint ventures with VW and GM gave us access to sophisticated technology. We now independently continue to develop it. We strive to bring our technology up-to-date with the acquisition of MG and through the collaboration with SMTC in England, while also hiring qualified engineers in China.”

The MG 6, the Roewe 550, the Roewe 950 and the new MG 3 are presently manufactured in Shanghai, the Roewe 350 and the MG 5 in Nanjing, while Roewe 750 and the particularly for the Chinese market important W5 SUV in Yangzhou. In Longbridge, the models developed in China are assembled with components manufactured in China for the European market.

Professor Fang Weirong says: “Our models are positioned in the mid-range and luxury market segments. We have strict requirements in terms of performance and quality. Our low production costs give us a competitive edge. How-ever, we are not a low-cost brand; our company produces high-quality vehicles. In the next five years, China will be the most important market for SMPV,” adds Professor Fang Weirong. “Tough we are also starting to develop the international market. For example, we have already shipped approximately 6,000 vehicles abroad.” SMPV plans to sell the drive assemblies together with the trans-missions to other companies, for example the SCM 250. The demands on the technical quality and cost- effective pricing are therefore very high.

“In the future, we hope to achieve progress with regard to developing new synchronizer

system designs through the excellent cooperation with HOERBIGER.”

In the near future, the sales figures will not rise as drasti-cally as over the past few years. The annual growth rate that can be anticipated is approximately 10 percent. SAIC will maintain the collaboration with international business partners. Notably the cooperation with GM continues to be very close: they produce everything jointly, from the drive assembly to the transmission. This allows the technology to be kept up-to-date.

Modern Synchronizers foran Edge in the CompetitionHOERBIGER is also an important international business part-ner: “HOERBIGER supplies complete synchronizer systems for the three manual transmissions of SAIC Group which are the most advanced technologically. In the future, we hope to achieve progress with regard to developing new synchronizer system designs through the excellent cooperation with HOERBIGER,” states Professor Fang Weirong “HOERBIGER is a company that not only continually enhances its products, but is also able to respond to the cost pressure we are faced with in competition.”

“We hope to be able to make our products competitive in the future by continuing the close cooperation with such a competitive company as HOERBIGER. HOERBIGER not only has a strong position in terms of product quality, but also the capability to manufacture locally. For us, it’s not only the cost advantage which comes from producing in China that counts, but also the proximity to our suppliers,” adds Professor Fang Weirong.

Bottom: In addition to

the transmissions for

the Roewe 750, in the

future the transmissions

for the Roewe 350, MG

5 and MG 6 (picture)

will be produced in

Shanghai.

www.hoerbiger.com

042

043

HOERBIGER Compression Technology, Latin America

Argentina has been producing oil and gas for almost a century. Oil and gas producers face the challenge of economically extracting what residual amounts of resources are left from the fi elds that are largely depleted. This has created a new business opportunity for HOERBIGER, a new business model.TexT: Michaela Stollberg · Ludwig Schönefeld · PHOTOs: Ralf Baumgarten · Manfred Klimek

SERVICE EXCELLENCE IN LATIN AMERICA

THE WELLHEAD COMPRESSION PROJECT

044

045

T o HOERBIGER Compression Tech-nology, Service Excellence means re-liably performing maintenance work, which increases the useful life and efficiency of rotary equipment and

provides customers with added value in the long term by optimizing their capital investment.

In developed markets, also referred to as mature markets, this is achieved by service products that clearly go beyond the performance spec-trum of the competitors, especially when it comes to upgrading and revamping classic re-ciprocating compressors.

Service Excellence, however, may also take on an entirely different shape, as in Latin America.

Here, HOERBIGER successfully developed a new service product that is tailored to the regional market: wellhead compression. HOERBIGER supplies the customers with fully equipped gas engine compressor units as part of a leasing contract. These gas compressors can be used to economically extract residual quantities of natural gas and oil from largely ex-hausted fields. HOERBIGER operates and main-tains the gas engines and compressors, which

greatly benefits the customer with comparative-ly little expenditure.

Daniel Vazquez—Visionary in theWellhead Compression ProjectDaniel Vazquez manages business development of HOERBIGER Compression Technology in Latin America—and is in charge of the Wellhead Compression Project.

After frequent customer visits and discussions about ways for HOERBIGER to improve their oil and gas production operations, Daniel Vazquez initiated the contact between HOERBIGER in Latin America and a manufacturer of small re-ciprocating compressors in the U.S. who was looking for new distribution channels for his units in the Latin American market.

The concept of using mobile gas compressor packages to allow residual amounts to be ex-tracted from fields that are largely depleted was already proven throughout the USA. Daniel Vazquez ensured that this business model is now also a valuable asset in Argentina and other South American countries: “We discovered this attractive market niche in Latin America and created an attractive opportunity for ourselves

at just the right time.” HOERBIGER sells or leases these mobile gas compressors to oil and natural gas producers in Latin America to artifi-cially stimulate the flow from the reservoir. This significantly increases the production of natural gas, oil and valuable condensates.

“The production increase is significant,” raves Daniel Vazquez. “By using our compressors, it is possible to increase the delivery of oil and con-densates by 60 to 80 or more barrels per day at wells that technically were no longer profitable.” The natural gas output also improves between 25,000 up to 85,000 cubic meters per day. Wells that were once considered dry can be brought back into production.

The dedication of Daniel Vazquez (picture on right)

and his team has paid off. An idea became a new

business model.

“We bring mature oil and natural gas wells back to life.”

Daniel Vazquez,

HOERBIGER

The service teams assure the

reliable operation of the

equipment. This also includes

regular maintenance in the

workshop and at the site.

PHOT

O: M

anfre

d K

limek

046

047

Operation, Service and Maintenance— Reliably from one SourceHOERBIGER leases the compressor equipment to the customer and ensures the reliable and uninterrupted operation by also providing the necessary maintenance services. The customer enjoys the benefits of considerably increased production at a very low capital investment.

“We typically repair reciprocating compressors in our repair shop,” relates Vazquez. “Now that we’ve become operators, we equip our service team to go into the field to provide customers with on-site support.”

The service teams are able to adapt the equip-ment to improve reliability when field conditions become extreme; for example when ambient temperatures reach up to 50 degrees Celsius (122 degrees Fahrenheit), or when there is salt, sand, carbon dioxide and/or hydrogen sulfide in the gas stream.

More than 150 Units in Operation—Regional Demand is on the RiseThe extensive know-how in compression tech-nology allows HOERBIGER to defy these chal-lenges and offer compressor units that can han-dle these problems as well as large volumes of contaminated gas and condensate.

Presently more than 150 compressor units are operating in Latin America as part of the Well-head Compression Project. As more fields across the region mature, the potential for more business will develop.

The Executive Board of HOERBIGER was in favor of the project from the start. The success has proven Daniel Vazquez and his team right. “The enormous growth potential and the profit-ability of the Wellhead Compression Project have made the investments well worth it,” adds Daniel Vazquez.

The team’s responsibilities are

diverse. The gas compressors used

are checked on-site on a regular

basis and serviced in the workshop.

Service teams assure that the equip-

ment functions flawlessly, even under

extreme conditions. Ambient temper-

atures in the reservoirs can climb as

high as 50 degrees Celsius (122 de-

grees Fahrenheit).

Visit our new Website:www.hoerbiger.com

More Information?Use the QR code to access the film

“Service Excellence” about the

Wellhead Compression Project at

the HOERBIGER website.

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HOERBIGER is again an innovation driver when it comes to the stepless control of reciprocating compressors: eHydroCOM was the fi rst purely electrical capacity control system ever to be successfully tested in a rough, highly demanding industrial setting. In the future, the eHydroCOM system will offer full functionality without the need for hydraulics and promises lower installation, maintenance and operating costs to customers from the oil, gas, and process industries. The new concept benefi ts from the extensive experience that HOERBIGER has gathered with the electrohydraulic HydroCOM control system since the late 1990s. TexT: Simon Schmid · PHOTOs: Ralf Baumgarten · HOERBIGER

HOERBIGER eHydroCOM—A GROUNDBREAKING CONTROL SYSTEM UNDERGOING FIELD TESTING

Research and Development News:

A t this year’s symposium of the European Forum for Reciprocating Compressors (EFRC), which is held in Düsseldorf on

September 27 and 28, 2012, the HOERBIGER Group will showcase the development status of the eHydroCOM, which is the evolutionary advancement of its successful HydroCOM step-less capacity control system for reciprocating compressors.

The eHydroCOM pilot series is present under-going endurance testing on a commercially operated compressor in a demanding natural gas application. In the future, the system will provide operators and OEMs with another step-less capacity control system, in addition to the HydroCOM. The application areas for stepless reverse flow control can therefore be expanded and their advantages will be available to an even greater clientele.

The actuator of the new control system is oper-ated solely electrically and unlike its predeces-sor requires no hydraulic system. It nonetheless offers all the advantages of hydraulic actuation: high load-bearing capacity with load spikes of up to 15,000 newtons, compressor speeds of up to 1,200 revolutions per minute, and extremely fast valve closing times with optimized impact speed of the valve sealing element to increase the service life. In an effort to find the most appropriate electrical actuator principle among those presently utilized in the market, HOERBIGER analyzed eight different operating principles for their suitability and decided in fa-vor of a unique hybrid solution.

Energy-saving ControlMany applications of reciprocating compressors require efficient capacity control. Like the HydroCOM system installed in as many as 900 reciprocating compressors around the globe, eHydroCOM employs the reverse flow capacity control principle. This allows fast and precise control almost without power loss—and unlike with bypass or stepped controls, in general only the required amount of gas is compressed. This makes the HOERBIGER stepless capacity control systems the world leader in terms of technology and efficiency and they offer clear

cost advantages over a compressor equipped with stepped control or a bypass for recirculating compressed gas.

Optimized DesignFor operators and OEMs, the great added value of the eHydroCOM system will come from its low installation and maintenance expenditure. To a large extent, it utilizes the system structure and bus architecture of existing installations, making it easy to retrofit. The technical design has been tailored to the present needs of the oil, gas, and process industries. Yet it also satisfies future ex-pectations of the industry with regard to lower installation and maintenance complexity and a longer service life. Despite the elimination of hydraulic fluid as the cooling medium, eHydroCOM dispenses with the need for an external cooling unit—such as a fan.

Future-oriented ConceptDuring the entire pre-development phase, a test bench that was developed in-house and can simulate a variety of operating parameters of compressors, has proven to be a valuable tool: Allowing for initial functional tests of the actuator and power electronics all the way to long-term endurance testing of the overall system, HOERBIGER successfully tested the eHydroCOM system before installing it in active compressors for trial applications.

eHydroCOMBASE SPECIFICATIONS • Current development status:

field testing stage• Compressor speeds up to 1,200

revolutions per minute• Maximum unloader forces during valve

unloading of up to 8,000 newtons• Load spikes during operation of up to

15,000 newtons• Valve closing times of less than four

milliseconds• No external cooling unit required• Resistance to vibrations• Up to 24,000 operating hours without

need for maintenance• No mechanical adjustments on the

actuator required• Completely oil-free design• Versatile usability of the actuator for all

applications in refineries, process chemis-try and natural gas uses

• Plug-and-play design: easy installation and service, even in remote locations

• EX-certified for hydrogen applications• Temperature expansion and wear

compensation on the sealing element • Full control of the suction valve and

unloader movements to maintain their speeds in predefined boundaries, regard-less of compressor load and speed

Cylinder of a reciprocating

compressor, equipped

with the new eHydroCOM

control system.

050

051

1

2 2

1

LESS WEAR, LONG SERVICE LIFE, LOWER EMISSIONS

Figure 2: The leakage measurement shows zero Nm3/h (below the measuring range of the previously used device)—even in the pressurized shutdown state

of the natural gas compressor.

Figure 1: BCD ring segments—HOERBIGER design

for pressure balancing and sealing effi ciency.

“Cap segments” ensure sealing in the axial and

radial directions. “Primary segments” provide

sealing around the piston rod and form a gap to

compensate for wear.

Figure 3: Comparison between conventional tangential/radial sealing rings

(blue) and BCD sealing elements made of different materials (orange,

green): The tangential/radial sealing rings exhibit increased leakage as the

pressure rises, while the BCD ring leakage remains constant at a low level.

12

new seal is approximately two times greater than before. Problems due to overheating during no-load operation, multiple start-ups or leaks while shut down are eliminated. The slim design of the BCD ring allows for easy retrofitting of existing systems. The cut design allows the ring to be inserted without complex disassembly of the rod. The special configuration requires no pins, which have been customary with cut rings. Together with the lower gas leakage during operation and pres-surized shutdown times, the environmental impact of the compressor is significantly improved.

Most Frequent Cause of Failure: valve and Packing ProblemsA look at the causes of failures of reciprocating compressors in the field leads to astonishing findings: approximately 70 percent of all failures are due to only eight causes. Playing a role in over 35 percent of cases, valve failure ranks at the top. Packing problems then follow in second place, accounting for approximately 18 percent of all failures. All of the remaining causes contribute only approximately 8 percent to the failure rate. These statistics show that the failure rate can be enormously decreased simply by replacing the packing rings with the robust BCD rings designed specifically for the respective conditions. This is also confirmed by the operating data of already retrofitted reciprocating

In the oil, gas and process industries, reciprocating compressors are indispensable. If they fail or do not deliver the required performance, all downstream production steps are negatively impacted. The seals that are selected are frequently the cause of the compressor’s lack of durability. The piston rod seal in particular often causes problems. The integration of a special sealing ring, which is exactly tailored to the conditions of the sealing area, corrects this problem.TExT: Andreas Zeiff · PHOTOs: HOERBIGER

BCD RINGS EFFECTIVELY SEAL PISTON RODS

temperature profiles on the piston rod to be simulated, and the exact pressure curve, surface pressures as well as the frictional heat that develops to be calculated in advance on the computer. Based on the new findings gained through simulation, the HOERBIGER specialists developed an installation-friendly, cut sealing ring. Its special geometry takes all the pressure influences from static and dynamic loads into account. Intensive testing conducted on the test bench has confirmed the theoretical results regarding sealing action, pressure distribution and frictional characteristics. The special design of the BCD rings significantly increases the reliability and sealing efficiency. The four segments are divided into primary and cap segments, each performing different functions. While the cap segments provide sealing action in the axial and radial directions, the primary segments surround the piston rod and form a gap to compensate for wear. The cleverly devised design assures pressure balancing and guarantees high sealing efficiency over the entire service life (figure 1). Manufacturers and operators of reciprocating compressors have confirmed the benefits of the BCD ring in applications and tests. Howden Thomassen Compres-sion, for example, showed as much as 70 percent lower leakage as compared to conventional sealing solutions in independent test series which were conducted for the components selected for their compres-sors. Contrary to existing sealing solutions, the leakage rate remains at a minimum level as the pressure rises, and the frictional heat which must be dissipated is also far below the usual level (figure 2).

Fundamental Advantages Due to Special PropertiesIn addition to pressure balancing and sealing efficiency, the specific construction of the BCD ring offers fundamental advantages. The favorable pressure distribution between the rings and rod also reduces the contact pressure, and consequently friction and heat development at the ring. This significantly reduces wear and contributes to a longer life expectancy with consistently high sealing efficiency. The life of the

compressors. The new BCD rings score well especially with natural gas: the trend in natural gas compressors is increasingly toward non-lubricated designs. In conventional solutions, this results in higher wear. In practical experience, HOERBIGER has demonstrated time and again that the life expectancy and reliability of the equipment increase considerably after the valves and sealing packings are replaced with modern components. In one natural gas compressor station, the pack-ing elements regularly failed after 2,000 hours in the nonlubricated first and second compression stages. By using continuous control with the HydroCOM system and replacing the packings with BCD rings, life-times of more than 12,000 hours are now possible without leakage. This saves not only maintenance costs, but also reduces the emissions of climate-damaging methane (figure 3).

long Service life in the Process Gas IndustryThe modern ring design also offers advantages in the process gas industry. One refinery, for example, was able to drastically improve the operating times of the hydrogen compressor. Hydrogen containing traces of methane is compressed to 66 bar in two stages, and the tem-peratures are approximately 100 degrees Celsius (212 degrees Fahren-heit). The existing water-cooled seals ran unlubricated at a piston rod speed of approximately 2.6 m/s. The BCD rings were fitted in the exist-ing, cooled packing housing. The material of the rings is customized to the special requirements of extremely dry conditions. In continuous operation, the life expectancy was increased to more than 22,000 hours (approximately 2.5 years) with the new sealing rings. This allowed the regular maintenance of the compressor to be extended and coordi-nated with other equipment components, reducing the operating costs of the plant as a whole. The new sealing rings are optimally tailored to the conditions in the compressor because of the mathematical calcu-lation of the actual local factors. Despite the slimmer, cut design, the sealing action and service life are extremely high, and the temperature of the piston rod is considerably lower. As an easy-to-retrofit compo-nent, the BCD ring is therefore suitable for all applications in which sealing the rod previously required short maintenance intervals.

M ore than twice as long as conventional seals HOERBIGER BCD rings last. The emission of leak-ing gases is drastically reduced. The easy-to-retrofit sealing element solves even the most difficult of problems, without necessitating high investments

in new equipment components. In new equipment, the considerably slimmer sealing elements save valuable space in the compressor. Reciprocating compressors are used to compress gases. The design of piston compressors is increasingly trending toward non-lubricated construction. The seal around the piston rod quite frequently constitutes a weak point and results in comparatively short maintenance intervals. As a reciprocating compressor specialist, HOERBIGER offers an option in these instances which safeguards the operation of the equipment with comparatively low expenditure. The BCD piston rod seals, which are modern sealing elements computed according to the finite-element method, considerably increase equipment reliability, even under more difficult conditions.

Reciprocating Compressors have high RequirementsModern reciprocating compressors are robust and designed to be durable and efficient. However, depending on the model and ambient conditions, some components wear more quickly. These components are the “hot spots” when it comes to maintenance and negatively impact the overall economical operation of the compressors. The seal around the piston rod is one of these critical areas. Until relatively recently, it was not possible to determine the exact thermophysical processes on the sealing ring. The development of the seals was entirely based on empirical evidence, which often times was impossible to translate into new applications. HOERBIGER developed a mathemati-cal model which allows the gas pressure profile between the sealing ring and rod—the “foot print” of a ring design—to be predicted for every compressor type, the percussion force over the packing and the

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vítezslav Straka is Operations Manager at MnD Gas Storage in uhrice. Straka and his team of ten technicians are in charge of assuring the smooth and safe operation of the underground natural gas storage facility. His equipment runs around the clock, 24 hours a day, 365 days a year. TexT: Georg Frick · PHOTOs: Manfred KlimekGaS24 HOuRS a DaY,

365 DaYS a YEaR nO BREaK fOR COMPRESSORS

On Site at MnD Gas Storage in uhrice

www.mnd.cz

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B efore Vítězslav Straka shows us his compressors, he explains the busi-ness model of MND Gas Storage: “MND Gas Storage stores natural gas for a variety of customers. Our

clients purchase storage capacity on the Energy Exchange and enter into long- or short-term contracts with MND Gas Storage. The gas is then stored in accordance with the customers’ requirements, but does not belong to MND Gas Storage.” Uhřice is located in the gently rolling countryside of Litenčice Hills, southeast of Br-no. The landscape is shaped by agriculture and isolated pockets of viticulture. It is not a place where one would suspect any noteworthy indus-trial activity. What is special about this area is the oil and gas fields located approximately two kilometers below the Earth’s surface. The un-derground storage facility in Uhřice is also a for-mer natural gas field. It has been used to store natural gas after gas production ceased there. The total capacity of the underground facility is 280 million cubic meters. Directly adjacent to the compartments utilized exclusively for storing natural gas, in Uhřice South, residual amounts of crude oil are still being extracted from an oil/gas field. At the same time, the site is already being used to store gas.

Ideal Conditions for Storing GasThe Uhřice reservoir is located at a depth of approximately 1,800 meters (5,900 feet). The natural gas compartment is surrounded by absolutely impermeable sandstone and clay formations. This geological formation offers ideal conditions for storing gas. MND Gas Storage primarily stores natural gas from Russia, which is delivered via pipelines to Lanžhot in the Czech Republic, in the tripoint with Austria and Slovakia, from where it is transported under-ground to Uhřice. There, it is received in one of two enormous compressor halls. Vítězslav Straka

first takes us through the newer hall, which was just completed in 2012. Together with Pavel Hafner, Service Manager at HOERBIGER Žandov s.r.o., he explains the technical details of the two 16-cylinder Caterpillar gas engines and the two-stage Ariel compressors driven by them. The compressors are used to compress the gas which is transported to Uhřice for underground storage. The gas is precompressed to a pres-sure of 12 MPa in a first stage. In a second stage, secondary compression up to a maxi-mum pressure of 21 MPa is carried out, where-upon the gas is ultimately pumped underground through wells. The gas is compressed incre-mentally, because it heats up significantly under pressure. The two-stage compression allows the gas to be cooled in an intercooler.

Everything is largely automated:Thanks to HOERBIGER SystemsDuring regular operation, everything is largely automated. A HOERBIGER RecipCOM system monitors the compressors around the clock—an indispensable step for a facility that operates without interruption. A key function of the moni-toring system is to quickly detect sudden com-pressor damage and wear.

A HOERBIGER HydroCOM system meanwhile controls the first compressor stage. The timing and flow of gas volume are exactly tailored to the demand. Because the gas volume that is com-pressed is always only the exact amount that is required, the dynamic HydroCOM control unit produces significant cost savings for MND Gas Storage compared to conventional control by way of the rotational speed of the compressor drive. Vítězslav Straka takes us to the second hall. This building, which was built in 2006, also houses two gas engines and two compressors. While the output of the gas engines installed in 2012 is 3,500 kW, the output of the engines

Pictures 1 to 4: Gas-powered engines

drive the compressors which compress

the natural gas transported to Uhřice for

underground storage. The HOERBIGER

HydroCOM system (picture 3) allows the

gas volume required to be exactly tailored

to the demand.

Picture 5: This is the above-ground portion

of the kilometers of wells which deliver

the compressed gas to the reservoirs

located deep down.

Pictures 6 to 7: All important data merge

in the central operations and monitoring

room—including the readings from the

installed HOERBIGER HydroCOM and

HOERBIGER RecipCOM systems.

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here is lower at 2,500 kW. The compressors are produced by Gemini, but like the Ariel compres-sors next door are also equipped with a HydroCOM control unit and a RecipCOM moni-toring system.All four compressors of MND Gas Storage handle an average of 5.4 million cubic meters of gas a day at full utilization of the facil-ity. Vítězslav Straka stresses that it is quite possi-ble to exceed this number if the gas reservoir is emptied completely. It was critical to always maintain a pressure of 80 bar in the reservoir because this was the only way to preserve the geological structure. Before being passed on to the customers, the natural gas stored in the underground facility undergoes a quality control step. Because the facility two kilometers below ground is of natural origin, admixtures may occur in the reservoir. MND Gas Storage there-fore removes such impurities.

Lower Complexity–Higher Reliability After visiting the halls, Vítězslav Straka takes us to the central monitoring and operations room of the facility. Through the windows, we can see the above-ground portion of the kilometers of wells which deliver the compressed gas to the underground reservoir. The boreholes of the wells are not necessarily vertical, but rather are deliberately geared toward the underground shape of the reservoir and therefore often times are horizontal. The gas flow of the individual wells is regulated by a pressure control system. From the center, an operator has control over the network of wells and their safety valves. The readings and data of the HydroCOM control units and of the HOERBIGER RecipCOM sys-tems which are installed on the compressors

merge here, in the central monitoring and oper-ations room. MND Gas Storage has relied on HOERBIGER technology since 2006. The units form an integral part of the facility and ensure that it operates efficiently and safely: lower com-plexity equates to higher reliability. HOERBIGER is also a service partner when it comes to main-taining the systems and compressors. Mainte-nance is performed at service intervals of one to two years—depending on the number of hours the machines have been running. In addition, the service team of HOERBIGER Žandov s.r.o. can be on-site at any time as needed. “Just yes-terday we needed service from HOERBIGER on short notice,” Vitězslav Straka reports. And why did MND Gas Storage opt for such a close part-nership with HOERBIGER? Vítězslav Straka does not have to give this much thought: “HOERBIGER came out ahead in an invitation to bid. The objective was to regulate the machine performance without lowering the rotational speed. Out of the various systems that are avail-able in the market, the HOERBIGER HydroCOM control unit and the HOERBIGER RecipCOM monitoring system were those that met our needs the best.”

The employees of MND Gas Storage in Uhřice value HOERBIGER as an extremely reliable and flexible partner who tries to accommodate all their requests. A major advantage is HOERBIGER’s branch in the Czech Republic, HOERBIGER Žandov s.r.o. Sharing the language and having knowledge of the local regulations make it much easier to work together. Vítězslav Straka laughs and adds that he is not trying to flatter Service Manager Pavel Hafner: “The cooperation with HOERBIGER is really outstanding.”

“After the Czech Republic opened to foreign in-vestors, establishing our company was arguably one of the fastest privatizations,” Dr. Libor Zeman recalls, who accompanied the founding of HOERBIGER Žandov s.r.o. as Managing Director from the very start. At the beginning of the nine-ties, the predecessor enterprise, CKD Žandov, was looking for an investor. HOERBIGER quick-ly recognized the opportunity that an investment in one of Eastern Europe’s largest valve manu-facturers at the time would entail—in particular because the company was able to look back on a history of more than one hundred years.

In 1993, HOERBIGER finally acquired the valve production operation ofČCKD Žandov and swiftly developed the new location into HOERBIGER Žandov s.r.o. Using state-of-the-art machines, today the site primarily manufactures smaller valves, air valves and various key components. HOERBIGER continues to build on the prede-cessor’s great tradition. Every year, HOERBIGER produces as many as 200,000 valves and more than 200,000 components in Žandov.

Expanding the PortfolioToday, after approximately 20 years, HOERBIGER Žandov s.r.o. has also become established as a service location—with a branch in Bratislava in Slovakia. The service area has undergone continual expansion since 1996. In 2012, HOERBIGER Žandov s.r.o. is one of the leading providers of services for anything compressor-related, both in the Czech Republic and in Slovakia. The portfolio ranges from repairs and service to the maintenance and optimization of compres-sors. Like MND Gas Storage (see customer feature on pages 52 to 55), numerous long-standing cus-tomers trust in HOERBIGER’s know-how.

For more than 15 years, HOERBIGER Žandov s.r.o. has also performed maintenance on the compressors used in the huge, underground natural gas storage facilities of RWE Gas Storage s.r.o. in the Czech Republic. These compressors

were equipped and optimized with state-of-the-art HOERBIGER components, in particular with RecipCOM, the online monitoring system.

HOERBIGER services allow even older-model compressors, such as those built by CKD and used at RWE Gas Storage in Dolní Dunajovice, to be upgraded. This significantly increases the re-liability. In light of the immense costs associated with investments in new purchases, the reliabil-ity argument also meets with interest among other customers from the oil, gas, and process industries. The services not only increase the overall efficiency and reliability of compressors, but also make a contribution to protecting the environment through the use of modern compo-nents and monitoring systems. Protecting the environment is also increasingly gaining in importance.

Positive Development“HOERBIGER Žandov s.r.o. recognized the po-tential in the service field early on and geared its service range to the customers’ needs in the Czech Republic and Slovakia,” Dr. Zeman ex-plained. “We offer our customers tailor-made solutions, which explains our accordingly high market share.”

The positive development is also reflected in the company’s figures. “We started with 70 employ-ees in 1993 and generated sales of approxi-mately 1 million euros,” Dr. Zeman said. “Since then, HOERBIGER Žandov s.r.o. has grown to 130 employees with annual sales of approxi-mately 13.5 million euros.”

With its service department, HOERBIGER Žandov s.r.o. is part of a global network of service locations. For more than 40 years, HOERBIGER has offered service solutions for reciprocating compressors, engines and turbomachines and has an extensive presence in all regions in which the oil, gas, and process industries operate.

20 YEaRS Of HOERBIGER ZanDOv S.R.O.PRODuCTIOn faCILITY anD SERvICE BRanCH

Just a few more months–then HOERBIGER Zandov s.r.o. can celebrate a milestone anniversary. In 2013, it will be exactly 20 years that HOERBIGER founded the branch in Zandov, Czech Republic. While initially it was purely a production site for valves and compressor components, today HOERBIGER Zandov s.r.o. is one of the leading service providers for compressors in the Czech Republic and Slovakia. TexT: Tim Wohlfarth · PHOTOs: Martin Špelda

HOERBIGER Žandov s.r.o. produces

valves and compressor components

and offers comprehensive all-inclusive

compressor services. Its valve service

(picture above), for example, assures

optimal use of this important component.

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Authors and Photographers1 Ralf Baumgarten (52) lives and works in Cologne. Over the years, the graduate designer has made a name for himself as a photographer. His works have won multiple awards. For his book “UhrMenschen,” for example, he received the prestigious Red Dot Design Award in 2005, and in 2010 he garnered the IF Design Award for the book “12 Faces of Time—Horological Virtuosos.” His clients include inter-national magazines, publishers, and companies.

2 Ingo Bulla (55), has been a professional photographer for 32 years. He learned his trade at a daily newspaper. Today, he lives and works both in Göttingen, Germany, and Beijing, China. His strengths are por-traits and artistically composed features. Photographs by Ingo Bulla are published in a wide variety of media and magazines. Exhibits, both domestically and abroad, round out his activities.

3 Nikolaus Fecht (58) is the recipient of numerous public relations prizes and has made a name for himself with trade articles, satires, editorials, commentaries and fairy tales on technical topics of all kinds. The regular clientele for his articles includes renowned Ger-man-speaking trade media such as Fluid, technica, Produktion and VDI-Nachrichten.

4 Alessandra Fraschini (44) has worked as a journalist since 1995 and can draw on experience in the mechanics and refrigeration fields. Her work includes interviews and articles, which have been published in key Italian technical journals. After twenty years as an editor and manager, she now works as a freelance journalist in Milan and Treviso.

5 Georg Frick (26) is an editor at Mensalia Unternehmensberatung in Vienna. He studied economics and political science in Spain, England and Vienna and in addition to economic reports, he primarily writes about technical topics relating to energy and the environment.

6 Gerd Golbach (58) has lived in China for more than 19 years. The sociologist and sinologist works for various bilateral and international development aid organizations. As a consultant or project director, he assumes various managerial tasks and has also organized and supported a variety of projects by providing documentation and pub-lic relations. He has published several articles in specialty books and publications of development aid organizations.

7 Manfred Klimek (48) has made a name for himself over the years as a photographer and cameraman. He works for international maga-zines such as Zeit Magazin and Stern as well as numerous television stations. His specialty is documentaries. His photographs, generally taken with an open aperture, provide an additional dimension to the format of industrial features in HOERBIGER@MOTION : The text does not have to explain the image. Instead, the text and picture comple-ment each other to give a common impression of the company por-trayed.

8 Simon Schmid (28) works in HOERBIGER’s Corporate Communica-tions department. As the Editor Online Communications, he is in charge of the Group’s electronic media. Simon Schmid started his professional career as a copywriter and author for the automotive and automotive supply industries. He holds a degree in social studies and economics from Tübingen.

9 Ludwig Schönefeld (47) is the Head of HOERBIGER’s Corporate Communications. Besides strategic tasks, he has retained the lati -tude to return to his journalistic roots through industry features for HOERBIGER@MOTION.

10 Martin Spelda (45) has been a photographer for 20 years. He learned his trade at a private photography school and lives and works in the Czech Republic. His work encompasses films and theater, as well as still photography. His portfolio includes pictures of people and architecture as well as food and technical photography for a number of companies and agencies.

11 Michaela Stollberg (44) changed careers to work in the creative field after studying business administration at the University of Cologne and an internship in TV production. From 1995 to 1998, Michaela Stollberg was the head of the editorial department and film director at facts+fiction in Cologne, Germany. She has worked as a freelance and independent author, editor and film director since 1998.

12 Andreas Zeiff (50) is a graduate chemist. After studying at Karlsruhe University (today KIT), Andreas Zeiff switched to specialist journalism. As an employee of the Stutensee editorial agency, he authors articles for numerous trade magazines in the oil, gas and process industries.

Published byHOERBIGER Holding AGBaarerstrasse 186304 Zug, Switzerland

Internet: www.hoerbiger.comE-mail: info@hoerbiger.com

Executive BoardDr. Martin Komischke (Chairman)Charles FriessNorbert GaußJohann Hipfl Dr. Siegmar SchlagauGerhard Wagner

Commercial Register NumberCH-270.3.003.156-2Commercial register of the Canton of Zug, Switzerland

Value-added tax number194 609

Edited byHOERBIGER Holding AGCorporate CommunicationsBaarerstrasse 186304 Zug, Switzerland

Ludwig Schönefeld (Director)Phone: + 41 / 41 / 560-75 79ludwig.schoenefeld@hoerbiger.com

Jens GeiselPhone: + 41 / 41 / 560-10 19jens.geisel@hoerbiger.com

Daniela Garsch (Editorial Assistance)Phone: + 49 / 8861 / 25 66-21 88daniela.garsch@hoerbiger.com

We would like to thank the following institu-tions and individuals—to the extent they are not mentioned as authors or photographers in connection with the articles—for their participation:Offi cine Mario Dorin S.p.A: Mauro Dallai, Dr. Giovanni Dorin, Giacomo Pisano. Shanghai Automotive (Group) Corporation: Prof. Fang Weirong, Qian Xiangyang. KSB Group: Christophe Amagat, Christophe Bouffi n, Antoine Casteleyn, Eric Leblais, Frederique Koch, Michel Oddoux, Christoph P. Pauly. Brigitte Beyer. Vittorio Lucchetti.

HOERBIGER Antriebstechnik: Leo Feng, Michael Haberl, Franz Soffa, Grace Wang. HOERBIGER Automatisierungstechnik: Katja Ebenhoch, Marcus Grödl, Remy Hoerdt, Thomas Ulbrich. HOERBIGER Kompressortechnik: Kathy Boutin, Jiri Brabec, Carlos Carratu, Roland Cesak, Thomas Christl, Terence Chuah, Keith Farnham, Franz Gruber, Pavel Hafner, Lothar Kern, Lutz Kranz, Martin Lachmann, Florian Neumann, Christian Prinz, Leonel Salinas, Don York, Libor Zeman.

TranslationsKerstin RolandMaintal Translations Inc.Virginia Beach, VA 23452, USA

Andrea Hartmann97074 Würzburg, Germany

LayoutCP/COMPARTNERAgentur für Kommunikation GmbH45127 Essen, Germany

Guido Schweiß-Gerwin, Tim Wohlfarth, Carsten Cimander

Cover picture: A stock of crankcases awaiting the next steps at Dorin.

Photo: Ralf Baumgarten

Printed byIm intermedia GmbH44866 Bochum, Germany

Alfred Aumaier GmbH82008 Unterhaching, Germany

Circulation: 25,000Distribution: 42 countries worldwideLanguages: German, English

The contents of the articles, in particular quotes, opinions and estimates on markets and technologies, do not always refl ect the opinions of the publisher.

Copyright: HOERBIGER Holding AG, 2012

LIBEREC— INDUSTRIAL REGION WITH CHARMFor centuries, textile manufacturing shaped the economic development in the area surrounding Liberec in the Czech Republic. Today, the region bordering Germany and Poland relies on strengths of a different nature. The town of Žandov, for example, has a long tradition of mechanical engineering. TexT: Tim Wohlfarth · PHOTOs: Martin Špelda · fotolia

Ž andov is located in the Liberec Region in the north of the Czech Republic, not far from the border with Germany and approxi-mately 70 kilometers (44 miles) away from the capital of Prague. The town on the Ploucnice River is home to approximately 2,000 people and framed by the forested hills of the Bohemian

Uplands. The town's history dates back to the 13th century and was once dominated by nobilities such as the Berks from Dubá or the House of Wartenberg. Even today, countless fortresses, castles and ruins of the Liberec Region are evidence of the legacy of the noble families.

Featuring the Church of Saint Bartholomew, the fountain from 1853, the statue of Saint Sebastian and the “Krone” vacation home, Žandov itself offers only few historic attractions that point to the past. Today, the town is influenced by industry. After all, Žandov can look back on over one hundred years of mechanical engineering tradition.

The range of production of the companies situated in Žandov initially was comprised of the production of textile weaving machines and casting machines as well as reciprocating compressors, which to this day are still produced locally.

Since the nineties, foreign investors are increasingly utilizing the in-depth mechanical engineering know-how and operate in Žandov and the sur-rounding area. This also includes HOERBIGER. Since 1993, HOERBIGER Žandov s.r.o. has offered a comprehensive portfolio of products and services, ranging from compressor valves to other key components to service solutions for reciprocating compressors.

Traditional StrengthsŽandov is not alone in relying on its industrial tradition; the entire Liberec Region is shaped by industry. While it measures only about 3,163 square kilometers (1,221 square miles) and is the smallest region in the Czech Republic, the proportion of people employed in industry is comparatively high. For good reasons: because the generally mountainous and rugged terrain is not suited for agriculture, the locals have always turned artisanry into their main source of income. The region is famous, for example, for its glassworks as well as for the production of jewelry. Bohemian crystal is well known all over the world. In contrast, textile manufacturing, another traditional sector, is increasingly becoming less important. In many places, only the former villas of textile manufacturers attest to the affluence that the textile industry once generated for many cities in the region.

Especially the capital bearing the same name as the region, Liberec, still offers many historical monuments, such as the Town Hall constructed in 1893—a symbol of the economic boom of those days. The textile boom benefited the town more than any other city in the region. During its heyday, approximately 50 textile factories were being operated there. But those days are long gone. Even one of the most famous enterprises, Textilana, fell victim to the fiercely competitive conditions and declared bankruptcy in 2011.

Supporting PillarsMechanical engineering, polymer processing and the automotive industry today form the central pillars of the economic development in the Liberec Region. Uranium mining, another key economic sector of the past, has also meanwhile been abandoned. The significance of industry is also reflected in the course offerings available at the Technical University of Liberec: the spectrum ranges from mechanical engineering technology to design of machine elements and mechanisms, applied mechanics, automatic controls and mechatronics to technical cybernetics, just to mention a few examples. But textile technology, clothing technology or chemical textile technology can also be found here. And so it appears that there is no closure with the past just yet. At least the know-how is still being cultivated.

The fact the region, despite its industrialization, has not lost its charm benefits another important economic sector: the tourism industry. Apart from the plethora of fortresses, castles and other historic monuments, Liberec attracts countless visitors every year with its scenic attractions. Approximately 40 percent of the region is covered with forests. The Lusatian Mountains, Jizera Mountains and Giant Mountains offer hikers, nature enthusiasts, mountain climbers and winter sports aficionados numerous worthwhile destinations.

Even today, the magnifi cent Town Hall in District Capital of Liberec (left) is remi-

niscent of the prosperity that was once primarily created by the textile industry.

In addition to the numerous attractions, which also include the fountain and the

statue of Saint Sebastian in Žandov (two smaller pictures on the right), the

mountainous scenery attracts countless tourists to the region.

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OFFICINE MARIO DORIN S.P.A.:REFRIGERATION AND AIR-CONDITIONING TECH NOLOGY SINCE 100 YEARS Page 20

HOERBIGER COMPRESSION TECHNOLOGY:SERVICE EXCELLENCE IN LATIN AMERICA Page 42

MND GAS STORAGE:NO BREAK FOR COMPRESSORS Page 52