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Windrock On-Guard™: The Monitoring System of Choice for Multiple Company Locations

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

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Online Monitoring On a Corporate Scale Read More

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CookCertifiedNews and Information from Cook Compression 1st Quarter 2013

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Windrock On-Guard�: The Monitoring System of Choice for Multiple Company Locations

Soon after joining Dover Corporation,Windrock began working withCook Compression to meet the online monitoring needs of a major oiland gas company. Four years later,Windrock systems are the undisputedcorporate-wide solution, optimizing performance for a growing numberof applications and locations. Here’s a look at how Windrock became thesystem of choice.

West Texas. In 2009, a longtime Cook Compression customerwas looking to upgrade the control systems on four integralcompressors and one separable unit at their West Texas facility:

� Three Cooper-Bessemer GMVR-12 integral units with 6 compressor cylinders

� One Cooper-Bessemer GMVH-12 integral unit with 5 compressor cylinders

� One Cooper KM6 electric motor driven unit

Windrock and Cook proposed Windrock On-Guard™onlinecompressor 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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Windrock On-Guard™: The Monitoring System of Choice forMultiple Company Locations

BASF Eliminates Rider Band WearProblems with Free Floating Piston


Offshore Producer More ThanDoubles Compressor Valve Run Times

Solid Ring Technology Seals Better,Lasts Longer

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CookCertifiedNews and Information from Cook Compression 1st Quarter 2013








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Cook Mechanical Field Services personnel (who provide maintenance services at thesite) noted that throughput of the compressors significantly improved with On-Guardmonitoring systems and maintenance costs for the power cylinders have been greatlyreduced with the AutoBalance system.

Middle East. Following this success, the customer’s technicalrepresentatives 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 andWindrock was authorized to provide On-Guard systems for six Ariel-Caterpillar units:

� Four Ariel JGC/6 compressors with Caterpillar 3616 engines� Two Ariel JGC/4 compressors with Caterpillar 3612 engines

The packages were engineered in Calgary, built in Houstonand commissioned on-site in 2011. During initial runs of theunits, 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 somedamage to the crossheads, but the On-Guard system prevented potential catastrophicdamage 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 projectproposed three Neuman & Esser, four-throw compressors that are Caterpillarengine-driven with a first stage screw compressor on the opposite end of theengine from the reciprocating unit. Windrock installed monitoring systems on the reciprocating compressors, along with vibration monitoring for the engines and screw compressors. Commissioningtook place over the summer of 2012.

New Mexico. The next project for the customer began in 2011, whenOn-Guard compressor monitoring systems were added to threeDresser-Rand 4HHE-VL-3, motor-driven units at a CO2 plant in NewMexico. Following this project, the customer ordered monitoring systems for the remaining six Worthington BDC compressors at thesite. These systems are scheduled to be installed by year-end.

California. The most recent (and largest) project was for an expansionat 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 inearly 2013.

A solid record of performance – along with superior technology and turnkeysupport – has enabled the customer to implement the benefits of compressorand engine monitoring on a global, corporate scale.North America: +1 877-266-5226

Europe: +44 (0) 151 355 [email protected]


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BASF Eliminates Rider Band Wear Problems with Free Floating Piston

When process requirements dictate non-lubricatedcompressor 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 riderbands in an Ingersoll-Rand HSE-2-NL non-lube compressorin 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). Suctiontemperature is 33°F (0.56°C), while discharge temperature is 155°F (68°C).

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A Cure for WearCook Compression recommended replacing the conventional compressor pistons with Howden Thomassen Free Floating Pistons.*

The Free Floating Piston is a revolutionary compressor technology that uses acushion of pressurized process gas to float the piston, virtually eliminating rider band wear and dramatically reducing associated maintenance costs anddowntime. Over ten years of operating experience with the technology showsthat 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 gasesand can retrofit to existing compressors.

Free Floating Pistons were installed in both cylinders of the BASF hydrogencompressor in October, 2011.

New Run Time RecordsAn 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 bandwear 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 12months – 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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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-performanceoperation that has taken additional significant strides in 2012 to drive improvement.

The manufacturing center at Odessa (TX) serves the worldwideaftermarket repair industry with premium new compressor rods,pistons, valves and plates. The operation continually strives to exceed customer expectations for customization, speed andquality – all while controlling costs.

Making Processes CLICThe manufacturing center was created several years ago throughthe consolidation of dispersed manufacturing operations inOdessa. To make sure all parties were on the same page andspoke 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 processesand 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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improve the efficiency of production though consignment inventory of material and tooling. In the plant, status boards have been mountedon the shop floor to prominently display production output, 5S, andhealth and safety information. This has proven to communicate more efficiently and effectively than lengthy written reports and emails.

Outfitted for ExcellenceIn addition to organizing the plant for visual monitoring and control ofprocesses, steps were taken to better synchronize the flow of workthroughout 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-artequipment, 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 ExcellenceAt Cook Compression Odessa, excellence continues to build on a firm foundation. As customerneeds change, Cook manufacturing operations will continue to evolve. The combination of leanmethods, continuous improvement, modern technology and highly trained and motivated teammembers will ensure this facility remains a truly world-class manufacturing center.North America: +1 877-266-5226

Europe: +44 (0) 151 355 [email protected]


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Offshore Producer More Than Doubles Compressor Valve Run Times

Gas compressor applications on offshore production platformsand FPSO (Floating Production Storage and Offloading) aretough 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 ProblemsA 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 SolutionCook 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 twosister units that have experienced even more severe problems.

Why It Excels In Harsh ConditionsThe 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 exhibitlow 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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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 thepoint 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 zeroemission/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 generateless frictional heat. As a result, they seal more effectively, especially at higher pressures.

Solid Performance in The FieldApproximately 18 months ago, a Gulf Coast energy company chose SolidRing packing to replace conventional ring sets in 6 Ariel JGT compressorsin natural gas transmission service. These single-stage machines have suction pressures of 800 psig and discharge pressures of 1200 psig. SolidRing packing was installed in a total of 24 cylinders.

Before upgrading, these cylinders experienced static vent leakage ratesfrom 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 after8,000 hours of operation. Even after 12,000 hours, measurements werefrom 0.0 scfm to 0.3 scfm across the 24 cylinders.



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A Cool AlternativeCook Solid Ring technology allows packing assemblies to run cooler, which reduces wear, extendsrun 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 beused. The first ring set does most of the sealing, reducing the pressure applied to subsequentrings. 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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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 fromWaukesha Bearings and Dover Pump Solutions Group. Also inSeptember, Cook representatives were in Düsseldorf for theEFRC International Rotating Equipment Conference. After ashort break, it was off to the Gas Machinery Conference inAustin from September 30-October 3. A highlight of this conference was a technical presentation given jointly by Cookand Ariel Corporation on patented BTUU compressor rings.

In October, Cook Compression was in Odessa for the PermianBasin 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 Exhibitionand Conference (ADIPEC) in November. Representatives reported outstanding crowds at each event and considerableinterest in recent product developments, including new Sentrix™ flow measurement technology and Free Floating Pistons (FFP™).



TurbomachinerySymposium Exhibition,Houston

EFRC InternationalRotating EquipmentConference, Düsseldorf

Gas Machinery Conference, Austin

ADIPEC, Abu Dhabi

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