Cook Certified - Cook Compression

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Cook Certified
News and Information from Cook Compression
1st Quarter 2013
Feature Article
Online
Monitoring
On a Corporate
Scale
Read More
In This Issue
Windrock On-Guard™: The Monitoring System of Choice for
Multiple Company Locations
See What’s Happening at Cook Now
BASF Eliminates Rider Band Wear Problems with Free Floating Piston
Odessa Manufacturing Center Drives Excellence
North America: +1 877-266-5226
Europe: +44 (0) 151 355 5937
www.cookcompression.com
editor@cookcompression.com
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Offshore Producer More Than Doubles Compressor Valve Run Times
Solid Ring Technology Seals Better, Lasts Longer
Cook Shows Off
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Windrock On-Guard™: The
Monitoring System of Choice for
BASF Eliminates Rider Band Wear
Problems with Free Floating Piston
Odessa Manufacturing Center
Drives Excellence
Offshore Producer More Than
Doubles Compressor Valve Run Times
Solid Ring Technology Seals Better,
Lasts Longer
Cook Shows Off
Visit Cook Compression.com
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1st Quarter 2013
Windrock On-Guard姠: The Monitoring System
of Choice for Multiple Company Locations
Soon after joining Dover Corporation, Windrock began working with
Cook Compression to meet the online monitoring needs of a major oil
and gas company. Four years later, Windrock systems are the undisputed
corporate-wide solution, optimizing performance for a growing number
of applications and locations. Here’s a look at how Windrock became the
system of choice.
West Texas. In 2009, a longtime Cook Compression customer
was looking to upgrade the control systems on four integral
compressors and one separable unit at their West Texas facility:
ᔢ Three Cooper-Bessemer GMVR-12 integral units
with 6 compressor cylinders
ᔢ One Cooper-Bessemer GMVH-12 integral unit
with 5 compressor cylinders
ᔢ One Cooper KM6 electric motor driven unit
Windrock and Cook proposed Windrock On-Guard™ online
compressor monitoring for the compression process and a
Windrock AutoBalance™ fuel control system for the engine.
The customer agreed to the plan and completed installation/
commissioning in 2010.
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Cook Mechanical Field Services personnel (who provide maintenance services at the
site) noted that throughput of the compressors significantly improved with On-Guard
monitoring systems and maintenance costs for the power cylinders have been greatly
reduced with the AutoBalance system.
Middle East. Following this success, the customer’s technical
representatives recommended Windrock compressor
monitoring systems for six new compressor packages
proposed for an expansion project at one of their overseas
facilities. In 2010, the project was awarded to a packager and
Windrock was authorized to provide On-Guard systems for
six Ariel-Caterpillar units:
ᔢ Four Ariel JGC/6 compressors with Caterpillar 3616 engines
ᔢ Two Ariel JGC/4 compressors with Caterpillar 3612 engines
The packages were engineered in Calgary, built in Houston
and commissioned on-site in 2011. During initial runs of the
units, Windrock commissioning personnel identified significant rod run out on
two of the six new units. Further examination determined that one of the crosshead
lubrication lines had not been properly connected on both units. This resulted in some
damage to the crossheads, but the On-Guard system prevented potential catastrophic
damage to the compressors and crankshafts.
South Texas. In 2010, Windrock received RFQs from several packagers for three units
to be installed at the customer’s gas plant in South Texas. All of the RFQs specified
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Windrock On-Guard monitoring systems. The packager receiving the project
proposed three Neuman & Esser, four-throw compressors that are Caterpillar
engine-driven with a first stage screw compressor on the opposite end of the
engine from the reciprocating unit. Windrock installed monitoring
systems on the reciprocating compressors, along with vibration
monitoring for the engines and screw compressors. Commissioning
took place over the summer of 2012.
New Mexico. The next project for the customer began in 2011, when
On-Guard compressor monitoring systems were added to three
Dresser-Rand 4HHE-VL-3, motor-driven units at a CO2 plant in New
Mexico. Following this project, the customer ordered monitoring
systems for the remaining six Worthington BDC compressors at the
site. These systems are scheduled to be installed by year-end.
California. The most recent (and largest) project was for an expansion
at one of the customer’s gas plants in California. These On-Guard
monitoring systems are to be installed on nine Ariel six-throw compressors
(KBZ & JGD frames). Installation and commissioning should take place in
early 2013.
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A solid record of performance – along with superior technology and turnkey
support – has enabled the customer to implement the benefits of compressor
and engine monitoring on a global, corporate scale.
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BASF Eliminates Rider Band Wear Problems with
Free Floating Piston
When process requirements dictate non-lubricated
compressor cylinders, operators face an ongoing
battle with accelerated wear and decreased run times.
Even the best rider band designs cannot eliminate
the friction that erodes components, increases
maintenance costs and causes downtime.
The solution? A cushion of air.
Operators at the BASF Corporation facility in Freeport (TX)
were searching for ways to increase the service life of rider
bands in an Ingersoll-Rand HSE-2-NL non-lube compressor
in hydrogen service. The rider bands were typically worn
out after 5 to 6 months of operation. On several occasions,
accelerated rider band wear had allowed the piston to
contact the liner, resulting in significant damage, cost
and delays.
The single-stage compressor has 19-inch and 14-inch cylinders and operates at 514 rpm.
Suction pressure is 7 psig (0.48 bar) and discharge pressure is 40 psig (2.76 bar). Suction
temperature is 33°F (0.56°C), while discharge temperature is 155°F (68°C).
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A Cure for Wear
Cook Compression recommended replacing the conventional compressor
pistons with Howden Thomassen Free Floating Pistons.*
The Free Floating Piston is a revolutionary compressor technology that uses a
cushion of pressurized process gas to float the piston, virtually eliminating
rider band wear and dramatically reducing associated maintenance costs and
downtime. Over ten years of operating experience with the technology shows
that rider band wear is reduced to practically zero, repairs are minimal and
reliability is excellent. The Free Floating Piston is designed for use only in
non-lubricated compressor applications. It is compatible with all process gases
and can retrofit to existing compressors.
Free Floating Pistons were installed in both cylinders of the BASF hydrogen
compressor in October, 2011.
New Run Time Records
An inspection was performed in February, 2012. After approximately four months of continuous run time,
maximum rider band wear was 0.009 inch. A second inspection in August, 2012, revealed maximum rider band
wear had increased only 0.005 inch to a total of 0.014 inch after approximately 11 months of operation.
With Free Floating Pistons, rider band service life has now increased from a maximum of 6 months to 12
months – and counting.
To learn more about Free Floating Pistons, click here or contact your Cook Compression representative.
* Free Floating Piston (FFP™) technology is the property of Howden Thomassen Compressors.
Cook Compression is the exclusive provider of Free Floating Piston technology in North America.
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Odessa Manufacturing Center Drives Excellence
For Cook Compression manufacturing centers, excellence isn’t a destination to be reached
– it’s an ongoing journey to further heights of quality, productivity and responsiveness.
One example of this concept is Cook’s Odessa Manufacturing Center – a high-performance
operation that has taken additional significant strides in 2012 to drive improvement.
The manufacturing center at Odessa (TX) serves the worldwide
aftermarket repair industry with premium new compressor rods,
pistons, valves and plates. The operation continually strives to
exceed customer expectations for customization, speed and
quality – all while controlling costs.
Making Processes CLIC
The manufacturing center was created several years ago through
the consolidation of dispersed manufacturing operations in
Odessa. To make sure all parties were on the same page and
spoke the same language regarding continuous improvement and lean practices, the center
first adopted CLIC (Cook Lean Improvement Culture) – a series of tools to help business processes
and supporting operations become more stable and responsive to change, with a focus on
delivering value to customers.
Manufacturing center team members have since worked to implement the visual factory
component of 5S, as well as some Kanban (or “pull”) features. Certain internal processes are
running with visual factory and the process has been expanded to some local suppliers to
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1st Quarter 2013
improve the efficiency of production though consignment inventory
of material and tooling. In the plant, status boards have been mounted
on the shop floor to prominently display production output, 5S, and
health and safety information. This has proven to communicate more
efficiently and effectively than lengthy written reports and emails.
Outfitted for Excellence
In addition to organizing the plant for visual monitoring and control of
processes, steps were taken to better synchronize the flow of work
throughout the facility. Machines and stations have been re-positioned
into more effective cells, resulting in improved efficiency and increased
output per employee.
Significant investments have also been made to improve facilities and machinery,
including upgraded lighting in work areas and the acquisition of state-of the-art
equipment, such as a Mazak CNC turning center and an induction hardening
machine capable of heat treating pieces up to 120 inches in length.
The Evolution of Excellence
At Cook Compression Odessa, excellence continues to build on a firm foundation. As customer
needs change, Cook manufacturing operations will continue to evolve. The combination of lean
methods, continuous improvement, modern technology and highly trained and motivated team
members will ensure this facility remains a truly world-class manufacturing center.
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1st Quarter 2013
Offshore Producer More Than Doubles
Compressor Valve Run Times
Gas compressor applications on offshore production platforms
and FPSO (Floating Production Storage and Offloading) are
tough on compressor valves. The gas composition from the
well and associated processes typically includes heavy
hydrocarbons, hydrogen sulfide and water. What’s more, the
gas composition changes frequently during operations,
making it difficult to optimize a valve design for all conditions.
Fortunately, Cook Compression offers a proven solution.
Major Problems
A major multinational oil company was battling compressor valve failures on an
offshore platform. Their Cooper Superior W-76 four-stage unit was compressing dirty
natural gas and experiencing a maximum of six months run time before having to replace
their plate valves. The compressor operates at 900 rpm. First stage suction pressure is
70 psig and the third stage discharge pressure is 599 psig.
With the high costs of downtime and lost production offshore, the operator needed a
valve capable of withstanding harsh conditions and delivering longer service life.
MOPPET ® Valve Solution
Cook Compression recommended replacing plate valves in stages 1-3 with
patented MOPPET valves.
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After more than a year of operation, the MOPPET valves are still operating reliably today.
The operator is so pleased with the durability of the valves, they are upgrading two
sister units that have experienced even more severe problems.
Why It Excels In Harsh Conditions
The MOPPET valve design is unlike any other valve. It consists of a series of small,
identical, radiused-disc elements that operate independently of each other.
Each element is made of durable, lightweight thermoplastic material. The element
design provides outstanding resistance to damage and wear from entrained
debris. The low mass of the thermoplastic disc reduces impact velocities, while
the radiused sealing surface deflects solid matter.
MOPPET elements are thick (0.35 inch/8.89 mm) and have a centerline diameter
of only one inch (25.4 mm), making them extremely stiff and resilient. They exhibit
low bending stresses and withstand high impact forces caused by extreme pressure,
gas mole weight, driver speed, or the presence of incompressible matter in the gas.
Another advantage is that springs and spring pockets in MOPPET valves are designed for durability
in dirty service. Spring pockets have generous vent holes to eliminate the build-up of incompressible
materials that can damage springs. High lifts and more space between the spring coils also allow debris
to pass freely through the valve. In addition, spring stresses are lower than in typical plate valve springs.
MOPPET springs have significantly taller free length, allowing for large wire diameter that reduces
torsional stress. Larger wire also makes springs more resistant to damage from debris.
Offshore – and in any other demanding application – MOPPET compressor valves deliver
unmatched durability.
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1st Quarter 2013
Solid Ring Technology Seals Better, Lasts Longer
U.S. EPA Greenhouse Gas (GHG) Reporting requirements highlight not only the need for
better measurement solutions, but also the need for improved control of gas leakage at the
point where most of it occurs – reciprocating compressor packing cases. Earlier this year,
Cook Compression responded with Sentrix™ flow measurement technology
(click here for details). Now, Cook addresses the need for zero
emission/low leak packing with patented Solid Ring technology.
Cook Solid Ring technology replaces conventional segmented back-up
rings with uncut rings. These uncut rings eliminate leak paths and generate
less frictional heat. As a result, they seal more effectively, especially at
higher pressures.
Solid Performance in The Field
Approximately 18 months ago, a Gulf Coast energy company chose Solid
Ring packing to replace conventional ring sets in 6 Ariel JGT compressors
in natural gas transmission service. These single-stage machines have
suction pressures of 800 psig and discharge pressures of 1200 psig. Solid
Ring packing was installed in a total of 24 cylinders.
Before upgrading, these cylinders experienced static vent leakage rates
from 0.8 scfm up to 2.1 scfm. After installing Solid Ring packing, vent
leakage was reduced to near zero scfm. The same results were seen after
8,000 hours of operation. Even after 12,000 hours, measurements were
from 0.0 scfm to 0.3 scfm across the 24 cylinders.
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A Cool Alternative
Cook Solid Ring technology allows packing assemblies to run cooler, which reduces wear, extends
run times and decreases maintenance costs.
Each ring set includes multiple seal rings that load and unload sequentially based on pressure.
This reduces friction by minimizing the number of rings in contact with the rod at any time.
In addition, the increased sealing capacity of each ring set allows fewer cups (and rings) to be
used. The first ring set does most of the sealing, reducing the pressure applied to subsequent
rings. As a result, the overall frictional heat load is greatly reduced.
To learn more about how Cook Solid Ring technology can improve sealing effectiveness
and extend run-times, contact your Cook Compression representative.
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Cook Shows Off
Fall 2012 was a busy trade show season for
Cook Compression. Here’s a recap of events.
It began in September at the 41st annual Turbomachinery
Symposium Exhibition in Houston. Cook Compression was
part of the Dover Energy booth that also featured exhibits from
Waukesha Bearings and Dover Pump Solutions Group. Also in
September, Cook representatives were in Düsseldorf for the
EFRC International Rotating Equipment Conference. After a
short break, it was off to the Gas Machinery Conference in
Austin from September 30- October 3. A highlight of this
conference was a technical presentation given jointly by Cook
and Ariel Corporation on patented BTUU compressor rings.
In October, Cook Compression was in Odessa for the Permian
Basin Oil Show. The final show for the year was in Abu Dhabi
as Cook Compression visited with current and prospective
customers at the Abu Dhabi International Petroleum Exhibition
and Conference (ADIPEC) in November. Representatives
reported outstanding crowds at each event and considerable
interest in recent product developments, including new
Sentrix™ flow measurement technology and Free
Floating Pistons (FFP™).
Turbomachinery
Symposium
Exhibition,
Houston
EFRC International
Rotating Equipment
Conference, Düsseldorf
Gas Machinery
Conference, Austin
ADIPEC, Abu Dhabi
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Cook Certified - Cook Compression

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