Author: Krista Betts

Dover Precision Components Supplies Reliability and Efficiency for Rotating and Reciprocating Machinery

May 31, 2018

Dover Precision ComponentsTo leverage their collective strength and heritage, Cook Compression, Inpro/Seal, Waukesha Bearings and Bearings Plus have formed the newly named Dover Precision Components operating company. As the umbrella for these key brands, Dover Precision Components is an integrated provider of performance-critical solutions for rotating and reciprocating machinery and features a diverse portfolio of products and services.

Here is a closer look at the brands that form Dover Precision Components: Cook Compression delivers custom-engineered valves, sealing technologies, pistons and rods, as well as expert repair and reconditioning services and advanced technical support, for reciprocating compressors. Inpro/Seal, the inventor of the Bearing Isolator, designs and manufactures bearing protection and shaft seals to increase the reliability of rotating equipment. Waukesha Bearings is a global leader in engineered hydrodynamic fluid film bearings and brush seals for high-performing turbomachinery and, under the Waukesha Magnetic Bearings brand, produces the most robust active magnetic bearing systems available. Bearings Plus specializes in the repair, replacement and upgrade of fluid film bearings and seals to get turbomachinery back up and running, better than before.

The brands were originally brought together in November 2015 to broaden product offerings, expand global resources and apply operational efficiencies to better serve customers in the energy and industrial markets. Since then, synergies between the brands have extended engineering and materials expertise, opened new avenues for innovation, promoted best practices in manufacturing, and advanced quality and continuous improvement efforts.

“The introduction of the Dover Precision Components name supports our strategic partnerships with OEMs and end users and will improve the visibility of our broad capabilities to improve performance of rotating and reciprocating assets,” commented Dover Precision Components President Marcell Ulrichs. “The name will also provide a common identity for our customers and employees across the globe.”

Headquartered in Houston, Dover Precision Components maintains facilities in North America, Europe, Asia and the Middle East. It has more than 1,400 employees worldwide.

“We take great pride in the legacies of our brands,” said Ulrichs, “and we aim to further strengthen those brands under the umbrella of Dover Precision Components.”

About Dover Precision Components
Dover Precision Components delivers performance-critical solutions for rotating and reciprocating machinery across the oil & gas, power generation, marine, industrial, chemical and general processing markets. Comprising the Waukesha Bearings, Bearings Plus, Inpro/Seal and Cook Compression brands, our portfolio includes hydrodynamic bearings, active magnetic bearings, system and bearing protection, and reciprocating compressor valves, sealing technologies, pistons, rods and more. Each solution is custom-engineered to provide optimum efficiency, reliability and productivity, and backed by comprehensive aftermarket services. Dover Precision Components serves its global customer base through facilities in North America, Europe, Asia and the Middle East, as well as technical sales representatives around the world. Dover Precision Components is part of Dover Corporation’s Fluids segment.

Cooled Packing Cases: Where Turbulence Is An Advantage

Read our article in the April 2018 issue of Gas Compression Magazine.

May 9, 2018

For reciprocating compressors, high pressures and high speeds, as required for refining or enhanced oil recovery processes, for example, are becoming the norm, and original equipment manufacturers (OEMs) are increasingly building to American Petroleum Institute (API) limits on piston rod linear speeds.

These high pressures and speeds threaten the structural integrity, sealing performance and longevity of compressor packing cases – risks that can be mitigated with the use of cooled packing cases. API 618, now in its 5th edition, requires a cooling system for lubricated cases with non-metallic rings that have a maximum allowable working pressure (MAWP) above 500 psi (35 bar), lubricated cases with any ring material that have a MAWP above 1500 psi (103 bar), and all non-lubricated cases, regardless of pressure. Beyond the API requirement, cooled packing cases are proven to reduce rod temperatures as well as packing case temperatures, extending component life and improving sealing.

Read “Cooled Packing Cases: Where Turbulence Is an Advantage,” in the April 2018 issue of Gas Compression Magazine, to learn about one cooling system solution that is compliant with the most recent API 618 edition and is celebrating close to 20 years on the market. Discover the benefits that make the Vortex Cooling® packing case efficient for design or retrofit.

READ THE ARTICLE >>

Cook Compression U.K. Facility Surpasses 1,000 Days Without a Recordable Injury or Illness

19 March 2018

The Cook Compression Ellesmere Port, U.K., facility is proud to celebrate 1,075 consecutive days without a recordable incident, and 1,353 consecutive days without a lost time accident. Over the course of 151,431 exposure hours in 2017, the facility also went without any first aid cases.

Phil Avis, HSE and CI Manager for the facility, attributes this safety record to the development of a robust safety culture that combines acute awareness of risks and hazards with continued training and investment in the proper protections.

Safety awareness has been cultivated among employees with the use of qualitative risk assessments and safety behavioural observation (SBO) audits. A preventive tool that identifies risks and engages the workforce, SBO audits have produced greater understanding and discussion of safety matters since their introduction at the facility in 2016. One hundred twenty-seven audits were recorded in 2017, highlighting training gaps, identifying work area concerns, and presenting opportunities for safety coaching and reflection. Steps are in place to ensure that identified improvements are implemented in a timely fashion.

Areas of focus in 2017 also included manual handling, review and consultation with employees on the glove policy, and re-evaluation of all machine guarding. Risk assessments of work area layouts, repetitive work, and work related upper limb disorders were reviewed. Outcomes of the assessments included the introduction of newer lifting equipment, rotation of work involving repetitive motion (among related areas), and ergonomic improvements for staff using any form of computer.

An exercise was also undertaken to review all machines that fell under Provision and Use of Work Equipment Regulations (PUWER), with remedial actions noted and implemented. All machinery is compliant with machine guarding regulations, greatly reducing risk to personnel.

New employees have a safety induction of up to two days, which includes presentations, videos and hazard interaction activities. In 2017, with the inclusion of external and on-site trainings, the facility logged a total 450 hours in safety training.

Through these measures, and reinforcement by Cook Compression leadership, every employee knows that safety is paramount and that it requires a proactive approach. Each individual is encouraged to perform a 30-second risk assessment before starting any task and to come forward with safety ideas. “They know we’re looking out for them,” says Phil Avis, “and they’re looking out for each other. Everyone is focused on safety. I’m proud to work here, and proud of every individual.”

ISO 9001:2015 Quality Management System Certification for Houston Facility

February 28, 2018

Cook Compression® and Bearings Plus® (BPI®) are proud to announce that their quality management system at Dover Pearland Operations (DPO) has received ISO 9001:2015 certification.

Cook Compression and Bearings Plus share the 150,000 square foot DPO facility along with fellow Dover company OPW. The shared services strategy exemplified at DPO provides internal efficiencies, enhanced processes and synergies to improve quality, innovation and customer service. The quality management system certification recognizes the combined efforts and integrated processes of Cook and BPI, covering the design, manufacture, service and repair of compressor valves, fuel gas injection valves, engineered plastics, fluid film bearings, seals, components for turbomachinery, and sealing systems.

Both  Cook  Compression and Bearings Plus are committed to continuous improvement of systems, processes, services, and products, and achieving ISO 9001:2015 certification is a reflection of that focus. “The Plan-Do-Check-Act (PDCA) cycle that is foundational to ISO 9001:2015 is part of the CI culture of Dover and its operating companies. Our achievement of this latest edition of the standard is a natural progression of the work we do every day,” said Nicole Miles, Quality Manager at DPO.

“Our customers have come to expect the highest quality and consistency from us,” commented Omar Amezcua, DPO Plant Manager, “and that means that we have to continually evaluate our processes and keep up with best practices. I’m proud of the engagement we have seen throughout our DPO team in applying these quality management and continuous improvement principles.”

Cook Projects Group Drives Customer Savings

Since 2001, the Cook Compression Projects Group has helped customers define efficiencies, improve reliability, advance safety, and realize OPEX and CAPEX savings. The group’s expertise lies in long-term, multi-functional projects that require comprehensive understanding of both equipment and processes – and that significantly affect the customer’s bottom line.

From the group’s more than 420 projects to date, here is just one example:

Piston and rod manufactureAchieving Capacity Increases with Existing Equipment
Late in 2016 the Cook Compression Projects Group was challenged with the task of identifying practical opportunities for an end user to free up one or more compressors in its fleet of 15+ identical operating compressors located across several sites. The compressor operators had noted that the units were at their capacity and mechanical limitations. Having spare or standby equipment would provide flexibility to plan and perform compressor maintenance without halting production, significantly improving up-time and operational reliability and reducing operating expenses for the plants.

The compressor OEM offered two options: add a new complete compressor train to each site or bore the cylinders oversized to increase the flow of each compressor. A technical review by Cook Compression identified a third solution: upgrade the existing compressors’ pistons, rods, valves and wear parts. The upgrade would leave the cylinder bore size the same, preserving the cylinder’s maximum allowable working pressure (MAWP). It would also eliminate the need to remove the cylinder for boring, saving valuable runtime.

Late in 2017, Cook Mechanical Field Services applied the upgrades to the first compressor. The two-day turnaround included installation of new piston and rod assemblies, new Manley® valves with suction unloaders, and rebuilt packing and wiper cases, as well as modifications to the compressor heads.

The customer’s equipment analyst has confirmed that the predicted ~2mmscfd (10%) increase in flow has been achieved, without exceeding the mechanical limits of the driver and compressor frame rod load limits. This 10% increase in flow per unit is enough for the end user to place one compressor at each site on standby and still meet the plants’ flow requirements.

Projects Group Introduces Effective Emissions Solutions

Another recent project on the U.S. West Coast addressed emissions reductions and engaged a continuum of customer contacts from the corporate Environmental Team leaders to the field processing plant personnel.

The Projects Group handled the installation of low-leak packing, as well as the documentation of compliance with current California EPA regulations and the training of on-site personnel.

Read About the Performance of the Low-Leak Packing

New Ellesmere Port, UK, facility for Cook Compression

February 1, 2018

We are pleased to announce that Cook Compression Ellesmere Port will be relocating to a brand-new facility, purpose-built for us. The move is scheduled to begin in March and be fully completed by mid-April. We will continue to call Ellesmere Port our home, as we are moving just a short distance to:

Cook Compression Ltd.
Helix Business Park
New Bridge Road
Ellesmere Port
CH65 4LR
United Kingdom

Our new location will allow us to continue to provide superior service to our customers and grow with your needs. Much consideration has been given to maximizing efficiency in the 26,000 sq. foot (8,000 sq. meter) space and ensuring that production is state-of-the-art. Below are a few things to know about the move itself.

Continuity of Service
Our aim is to provide seamless service to our customers throughout the transition. Any delivery dates you have been given – or that you receive for future orders – already account for the move. Our production team is meeting daily to discuss scheduling and to ensure that orders are met.

New orders will continue to be accepted throughout the transition period, and deliveries can still be made to the current, Burnell Road location until further notice.

How to Reach Us
If you need additional flexibility or have questions about the move, please contact your sales representative. You can still reach us through your normal channels, including email, mobile phones, and our main line for the Ellesmere Port facility: +44 (0) 151 355 5937.

You can also submit your inquiries through our online contact form.

Featured Field Report: #111 – Condition Monitoring

Condition Monitoring Leads to Valve Solutions

Alley BOP234 compressors in boil-off gas serviceAn aboveground LNG storage site in the UK had a number of compressors in boil-off gas service. The Alley BOP234 machines were high-speed, short-stroke units installed in the late 1960’s and early 1970’s.

Compressor Valve Engineering (CVE) – one of the original operating units that became Cook Compression in 2007 – had a long history with this customer and these machines, including a polymer conversion on the plate valves. The procedure had been an unqualified success, with valve life growing from 2,000 to 17,000 hours.

Years later, the story took a dramatic turn. Seemingly without explanation, the compressors began to experience a spate of valve failures after short run times. The customer turned to Cook Compression for help.

Solution
Cook Compression immediately began to investigate, using proprietary valve design software that had been radically improved since the original valve conversion. Although a few design specifications could be “tweaked” for better performance, the basic conversion was sound.

The next step was to conduct condition monitoring and analysis. Data was captured using a portable performance analyzer. The discharge valves were equipped with Cook Compression valve indicator ports, which simplified the job of acquiring data.

Analysis of the data showed that the valves were “noisy” (leaking) and the most probable cause was contamination in the gas stream.

Results
The design study and the condition monitoring analysis were presented to the customer, who conducted an internal investigation for the cause of the contamination.

As it turns out, operators were using boil-off gas to dry items they had been washing. The gas was then being put back into the system – along with debris from the items which had been washed and dried.

Stopping that practice and replacing the valve internals restored the valves to their normal, extended service intervals.

Stringent Emission Requirements? Not a Problem

In 2013, a customer on the West Coast of the U.S. approached Cook Compression to discuss how they could comply with the increasing emission regulations in the region. This was a critical issue to the customer, directly affecting their bottom line. Discussions between Cook representatives and the customer’s corporate office went on for years. During the final two years, the customer engaged its plant facility managers in identifying – and proposing solutions to – emission-related issues. At the center of the discussions were packing cases, which are typically the primary source of leakage in reciprocating compressors.

In order to determine the best solution, the customer designed an experiment: Three packing cases from three different vendors, including Cook, would be placed head to head on three identical cylinders operating under identical parameters. Under Cook’s recommendation, flowmeters would be installed to quantify the emissions out of each cylinder.

Cook Compression’s approach was to provide low-leak packing specifically designed for low-emission applications. After a detailed review of the operating conditions and gas composition, the proper sealing elements were selected to ensure that no excess heat would be generated. This coupled with proper material selection allowed for an effective and reliable seal.

The three packing cases, along with the suggested flowmeters, were installed side by side in March 2017. Cook’s custom-engineered packing case proved to be a superior solution, exhibiting a much lower leakage rate than the competitor solutions. Emissions from the Cook Compression packing case was 5 times lower than that of the next best performer.

In July 2017, a Cook Compression representative was at the customer’s site and examined the flowmeter readings for cumulative gas emissions. The Cook packing case was still, by far, the superior solution. Due to the success, the customer has requested Cook packing cases not only for this facility but for others as well.Packing Cases

> Read more about Cook Compression emissions solutions.

> Read more about Cook Compression packing cases.

Cook Compression Launches Authorised Service Partner Program in Europe

December 19, 2017

Partners to Provide Quality, Local Valve and Packing Case Repairs for Reciprocating Compressors

Cook Compression is proud to announce its certification of three Authorised Service Partners for valve and packing case repairs: Kompresory Veselý, in the Czech Republic; Rudos Ruzomberok, in the Slovak Republic; and Runtime Engineering AB, in Sweden. These companies are the first such partners for Cook Compression in Europe.

Cook Compression applies its technical expertise, application knowledge and state-of-the-art product and material capabilities to improve reciprocating compressor performance around the globe. Through Authorised Service Partners, Cook Compression aims to make its expertise and quality service more readily available to reciprocating compressor end users throughout Europe.

Authorised Service Partners have passed a rigorous audit of their processes and equipment, are held to strict quality standards, and guarantee their work for warranty periods as established by Cook Compression. Service capabilities apply to any brand compressor valve or packing case. Further, each valve that leaves the partners’ facilities will be quality tested using a specially designed Cook Compression valve air test bench.

Kompresory Veselý has 25 years of compressor experience and a reputation for exceptional customer service. A major service provider for PET compressors in the Czech Republic and neighboring countries, Kompresory Veselý is also expanding its service into petrochemical and other industries. The company’s highly skilled, local staff provides high-quality service, emergency response, and turnkey management to keep compressors running at peak performance.

Rudos was established in 1996 in the field of railway brake compressor repair and today continues to provide comprehensive solutions to that market as well as biogas applications. Rudos combines the most up-to-date technologies with a skilled team to be a leader in the field of compressed air, alternative energy, treatment plant technology, and rolling stock. With 18 technicians working from three locations, the company provides flexible, reliable service to more than 500 clients in Slovakia.

Runtime Engineering is a newly formed unit of the Erinova Group dedicated to reciprocating compressor and industrial fan spare parts and services in the Scandinavian market. Runtime Engineering draws on the expertise of its sister companies, the Sweden-based Protoma and MLT. Protoma, founded in 1994, specializes in industrial sealing solutions such as mechanical seals, packings, gaskets, compensators and hydraulic seals. MLT, founded in 1988, focuses on industrial measurement technology, including condition monitoring, laser alignment, balancing and 3D scanning. Altogether, Erinova Group has 60 employees providing trusted products, service and customer training.

“By putting Cook Compression’s long experience in providing OEM-quality reciprocating compressor components behind the trusted regional positions of these partners, we can offer reciprocating compressor end users a higher standard of service,” said Dean Lewis, Cook Compression VP Aftermarket, Europe & Russia. “This mutually supportive relationship takes the best of our companies and puts it to work for our customers.”

Featured Field Report: #108 – Piston and Rider Ring Upgrades

Beverage Producer Taps into Cook Upgrade to Extend Piston Ring and Rider Life

When a large beverage producer in the Philippines needed more durable compressor components than its OEM supplier could offer, Cook Compression was ready to respond.

The customer wanted to increase the service life of piston and rider rings in a Broomwade VMD 1500 2-stage, 377 hp, non-lubricated, utility air compressor with final delivery pressure of 100 psig. The first stage cylinder bore is 203 ⁄ 8 inches and the second stage bore is 121 ⁄ 4 inches. The OEM rings they had been using were manufactured from glass-filled PTFE and needed replacement every eight to 12 months.

Non-lubricated utility air compressor Non-lubricated utility air compressor

Solution
Seeking increased reliability and improved technical support, the customer contacted Azeri Industrial Sales, a Cook Compression representative for the Philippines. The Cook representative compiled dimensional specifications from used pistons, as well as detailed operating parameters for the unit.

Cook engineers recommended rings produced with TruTech™ 3210, a special polymer alloy that has demonstrated outstanding performance in a variety of lubricated and non-lubricated applications. TruTech 3210 has provided exceptional wear behavior with air, methane, propane, LNG and bone dry gases.

The customer installed the Cook rings in the first stage cylinder to test their service life with OEM rings in the second stage.

Results
The Cook rings were inspected after six months of operation and the customer found no significant wear. A second inspection five months later revealed equally impressive results. At this time, the Cook rings with 11 months of operation were compared to the OEM rings from the second stage with only eight months of operation. Despite being in use three months longer, the Cook piston and rider rings had at least ¼ inch more radial thickness than the OEM rings.

Based on these results, the customer installed Cook rings in the second cylinder and has achieved its goals of extended run times, reduced costs and increased productivity.