News and Informa tion from Cook Compression Issue 1 2 015 ... · New High-Speed Compressor Valve...

New High-Speed Compressor Valve Delivers Big Energy Savings

Ring Damped Valve Saves Energy for Gas Gathering Facility

Cook Service Delivers World of Quality

New Tool Makes Valve Installation Safer, Faster

CNG is a Natural for Cook Compression

Dover Pearland Operations Benefits Cook and Customers

In This Issue

New High-SpeedCompressor Valve Delivers Big Energy Savings Read More

Feature Article

CookCertifiedNews and Information from Cook Compression Issue 1 2015

See What’s Happening at Cook Now

North America: +1 877-266-5226Europe: +44 (0) 151 355 [email protected]

Privacy Policy Unsubscribe

Introducing:

Cook Ring Damped

Compressor Valve

mailto:[email protected]

http://www.cookcompression.com/

http://www.cookcompression.com/#

Next Page ‘

Back to topNew High-Speed Compressor ValveDelivers Big Energy Savings

Ring Damped Valve Saves Energy forGas Gathering Facility


New Tool Makes Valve InstallationSafer, Faster


Dover Pearland Operations BenefitsCook and Customers

Visit Cook Compression.com



Save Horsepower With Patented Ring Damped Valves

Imagine a new breed of plate valve that’s so efficient, it cuts energy costs by 10%. That’s the performance operators are reporting with innovative Ring Damped Valves from Cook Compression.

The Ring Damped Valve has a patented design that includes a damping ring, nonmetallic sealing elementand other features that allow it to run at higher lifts, with greater flow area than traditional valves.

EfficiencyOn average, the effective flow area of a Ring Damped Valve is 10% larger than any platevalve of similar size. Increased flow results in a 10% reduction in energy usage by thecompressor. For most applications, these energy savings alone will assure a 100% returnon investment within one year of operation.



Damping Ring Reduces

impact forces, allows

higher lifts.






Next Page ‘












DurabilityUntil now, there’s always been a trade-off betweenefficiency and reliability. Not anymore. Ring DampedValves yield energy savings with durability thatmeets or exceeds the valves they replace. Here’s why.

The Ring DampedValve incorporates a uniquedamping ring to slow the velocity of the sealingelement before it contacts the guard during valveopening. Reducing speed minimizes the impactforces applied on the sealing element, extendingthe useful life of the valve assembly.

Ring Damped Valves also feature a full set of pre-cision-engineered, heavy-duty springs to with-stand high speeds, plus a non-metallic,reinforced-material plate to resist impact fatigue.

ApplicationsThe Ring DampedValve is suitable for (but not limited to) high-speed, short-stroke, lubricated gas com-pressors. Primary applications include transport, production, and storage of natural gas. The valve can alsobe used effectively in a wide variety of processes in refineries, chemical, and petrochemical industries.

















Performance Study #997Ring DampedValves reducetotal valve-related costs by upto 50% on a Joy compressor

orepld Rield R

FF

ing D

omprok Coom Cts fror

alved

essionompr

or High-SpFFor High-Spw! ReN

Report #997essorsompreed Cor High-Sp

evvalVValed amping Dw! R

of unscheduled shutalvt vwith shoralvOEM vwith

essing facilit coA gas pr

Scenario

e Evve EaSing DR

oughly 50% of the J rageerv On awnsdoof unscheduled shute failuralvt vequene and fre lif f alv

..ylinderses in the first stage calv

,xaseTT,angery in La Gessing facilit

y oy y on Jgnere EalvVValved amping D

es must alvy vooughly 50% of the Jer o a high numbe led tves hae failur

oblems ongoing pr,, ongoing prerrvewo H

omprting cacoecipry ro uses J,, uses J

essorsomprey Censesxput Ees Cvves C

es must er

essors ompr

essors,nsess,

k C

e is 4.375 inches in diametalvvomprhe cT2014.

installed in one of the first stage cOEM ve eplacr

ession paromprok CoC

Solution

but also r, tionsaeroped or repaire rb

of unscheduled shut

.ere is 4.375 inches in diametesses 78% methane and opcoessor prompr

ylinders of a Jinstalled in one of the first stage cing Dok Roe Ctivaves with innoalvOEM v

omer ted with the custtneression par

epair ce ressivcxesult in e but also re failuralvV.eary yerved eeplaced or r

oughly 50% of the J r,, rageerv On a.. On awnsdoof unscheduled shut

Epm.. Et 740 res ataeresses 78% methane and opessor in JanuaromprWB-14 cy oylinders of a J

es walvhe vT.esalvVaed amping D

eed to find a solution and agromer t

.ostsepair cegular upt rrertes not only ine failures must alvy vooughly 50% of the J

ach E anuar

e eres w

oeed t

egular es must

osts incured ctestimaomparhe cT

ompry Cowith the Jamping Dthe R

egular int red atolleccepaires of rinstances haalvVValved ampD

er almost a ytffA

tsResul

omery the custed brosts incurestat illustrighison on the rompar

.essoromprtibleompae is fully calvVaed amp

tms thaonfirals cvertegular intae damancorfforer P.. Pepairr.

es ore had no failurves haing Rtion, aerear in oper almost a y

$25,000

$20,000

$15,000

osts of RDC

an reduce tes calvRing damped v

earsYYe, 2 esalvVy . JosV vosts of RD

ealvy VoJ

ealvV VRD

o 50% on Joed costs by up tte-relaalvotal van reduce t

ears

.y compressorso 50% on Jo

lVVed Deplacing JR

e and longer lif fe in nasealing elemenincludes a damping r

o a paed tibutttris aess of the Rhe succT

e used oes aralvVaojecand the pr

ompry coon one J

tial totes has the pinges with Ralvy voeplacing J

.evical gas serture in natsers higher lif fts which off fers higher lif,, which offtt,sealing elemen

ing and nonmetallicincludes a damping rted design thatento a pa

ealvVVed amping Dess of the Ral.vertear ino-ywer a tve used o

edamping Dost if Red ctojecesalvessor with OEM vompr

$10,000

$5,000

0

$8,048$8,048$6,424

16 ssumptions:e AalvVV RD

essorompres/calv stage vst1 16 ssumptions:e AalvVy oJ

ealvew VN

$1,605 $1,800

$6,424 $7,200

4 vear 1 and epairs in ye ralv0 v,essorompres/calv stage vst1 16

ear 2 with a epairs in ye ralv8 v vear 1 and epairs in ye ralv8 v,essor

ostepair CR dohutnscheduled SU

$1,800

$11,453

$21,672

ear 2epairs in ye ralv4 v

wns of $600doost of unscheduled shutcear 2 with a

wnsdo ostotal CTT

essor doomprof cisk of unscheduled shutr

o Jed tomparced etelay-rgener

ed amping DRessors bomprC

elae-ralve veducres has the palvVValved ampD

.timewnessor doostswns and cdoisk of unscheduled shut

tingmitiga while , esalvy voy 2.5%enses bxped e

eeduces will also ralvVValv In addition,o 50%. . In addition,y up tessors b

yoenses on Jxped etelaotial tenotes has the p

ession.com.cookcomprression.com.esentativeprression r repromprr CC

our Ct y o contacapplicationsessors and other y compr ressors and other es in Jo o vves in JoalVVal

ed Ring Damped entabout pat te details and information or mor r FF

e or visit vve or visit ook r C Cook

essors and other ed Ring Damped

e details and information

One N

ession.comomprookCC

olutionsorld of S, a W World of Samee One N

Performance StudiesField Reports from Cook Compression

New! Ring Damped ValveFor High-Speed Compressors

Report#998

One Name, a World of Solutions

CookCompression.com

ScenarioOperators of a gas gathering facility in North Dakota (USA) were searching for ways to

reduce energy costs. The facility operates a Dresser Rand RDS-4 reciprocating compressor

running at 896 rpm to process natural gas. The customer has traditionally used Dresser

Rand PF valves for this application.

SolutionThe quest for greater energy efficiency motivated the customer to replace their

compressor valves with patented Cook Ring Damped Valves. Unique features in the

Ring Damped Valve design allow them to run at higher lifts than traditional plate

valves, resulting in maximum flow area for any given valve size. Increased flow area

significantly reduces the horsepower required to move gas.

Cook designed and manufactured 6.09-inch OD Ring Damped Valves to outfit the two

first-stage cylinders, which operate at 330 psig suction and 810 psig discharge pressures.

A Windrock 6320 PA/VA Portable

Analyzer was used to measure the

performance of the Ring Damped

Valves every 2,000 hours of operation.

ResultsAnalysis of the data revealed substantial

benefits of the Ring Damped Valves

over the PF valves:

▪ 18% higher flow (MMSCFD)▪ 25°F (-3.9°C) lower operating temperature

▪ 11% better economic performance($/MMSCF) due to 14% lower energyusage (HP/MMSCFD)

Figure 1 compares horsepower usage between the Ring Damped Valves and

PF valves. It also displays the financial benefits accrued from reducing horsepower.

The facility’s energy consumption decreased by approximately $2,200 per year for each

Ring Damped Valve installed – a remarkable return on investment with corresponding

environmental benefits from reduced energy usage.

For more details and information about patented Ring Damped Valves, contac t your Cook Compression representative or visit cookcompression.com.

Ring Damped Valve Saves Thousands inEnergy Costs for Gas Gathering Facility

��

IHP/MMSCFD Usage Comparison

Hours of Operation

IHP/M

MSC

FD

51 HP/MMSCFD Average


13% decreasein horsepowerconsumption

Dresser Rand’s PFValve

Cook Compression’sRing Damped Valve

0 4,000 8,000 12,000 16,000

54

52

50

48

46

44

42

40

Energy Savings fromOne (1)

Ring Damped Valve

1 Day $61 Week $421 Month $1801 Year $2,200

Performance Study #998Gas gathering facility decreasesenergy consumption by approxi-mately $2,200 per year for eachRing DampedValve installed

Ring DampedValves are backed by responsive service and technical support from a global networkof Cook Compression engineering, manufacturing and repair resources. To see how they can benefityour operation, contact your Cook Compression representative.

Discover MoreFor more on the economic advantages of Ring DampedValves, see these informative case studies:

http://www.cookcompression.com/files/comm_id_68/CCO_CaseStudy_998_012015.pdf

http://www.cookcompression.com/files/comm_id_68/CCO_Case_Study_997.pdf







Ring DampedValve Saves Energy forGas Gathering Facility








Ring Damped Valve Saves Thousands in Energy Costsfor Gas Gathering Facility

Operators of a gas gathering facility in North Dakota (USA) were searching for ways to cutenergy costs associated with their compressor. The new Cook Ring Damped Valve was themoney-saving solution they were looking for.

The gas gathering facility operates a Dresser Rand RDS-4 reciprocating compressor running at 896rpm to process natural gas. The operator has traditionally used Dresser Rand PF valves for the application.

After reviewing the patented Ring DampedValve design, the customer saw the potential for significant energy savings and decided to replace their PF valves for a trial run.

A Different Breed of ValveUnique features in the Ring DampedValve design allow them to run at higher lifts than traditional plate valves, resulting in maximum flow area for any given valve size. Increased flow area significantly reduces the horsepower required to move gas.

Cook designed and manufactured 6.09-inch OD Ring DampedValves to outfit the two first-stage cylinders, which operate at 330 psig suction and 810 psig discharge pressures. A Windrock 6320 PA/VA Portable Analyzer was used to measure the performanceof the Ring Damped Valves every 2,000 hours of operation.








CookCertified


Less Horsepower, More SavingsAnalysis of the data revealed substantial benefits of the Ring DampedValves over the PF valves:

❙ 18% higher flow (MMSCFD)

❙ 25°F (-3.9°C) lower operating temperature

❙ 11% better economic performance ($/MMSCF) due to 14% lower energy usage (HP/MMSCFD)

Figure 1 compares horsepower usage between Ring DampedValves and PF valves. It also displays thefinancial benefits accrued from reducing horsepower.

The facility’s energy consumption decreased by approximately $2,200 per year for each Ring DampedValve installed – a remarkable return on investment with corresponding environmental benefits from reduced energy usage.

Find Out How Much You’ll saveFor more information about patented Ring DampedValves, contact your Cook Compression representative.

News and Information from Cook Compression Issue 1 2015










IHP/MMSCFD Usage Comparison

Hours of Operation

IHP

/MM

SCFD



13% decreasein horsepowerconsumption

Dresser Rand’s PFValve

Cook Compression’sRing Damped Valve

0 4,000 8,000 12,000 16,000

54

52

50

48

46

44

42

40

Energy Savings fromOne (1)

Ring Damped Valve

1 Day $61 Week $421 Month $1801 Year $2,200

Figure 1





CookCertified




From valve repairs to cylinder overhauls, customershave the same expectations for compressor servicework: quality, consistency, efficiency, and rapid re-sponse. Cook Compression’s World of Quality programexists to make sure that’s exactly what customers get – every time.

World of Quality is a comprehensive effort that touches every aspect of service, from receipt of a part through inspection, disassembly, repair, reassembly and return to the customer. “Our objective,” says Cook VP of North American Service Operations Jeff Huston, “is toprovide an identical level of superior product quality and responsiveness no matter which of Cook’s11 service facilities performs the work.”

Consistent VersatilityAlthough World of Quality became a formalized initiative for Cook in 2014, the vision for the programdates back to 1990, when Huston first saw the need for documenting and enforcing standard operat-ing procedures in the Odessa, TX, facility. The task has grown more challenging (and necessary) overtime, as Cook’s global network of service facilities has increased in number, expanded in capabilitiesand added new personnel at an impressive clip. In recent months, Cook opened a new service centerin Baton Rouge, LA, and relocated its Oklahoma City operations to a new, upgraded facility.

Next Page ‘














CookCertified



“Growth in service resources offers tremendous benefits for Cook andour customers,” adds Huston. “We have the capacity to share workloadsbetween facilities for extremely large orders, shift repair work closer tothe customer for improved responsiveness, and exploit synergy be-tween our operations to handle special customer needs. But the key iswhat we call ‘consistent versatility’ – the ability to deliver the same highlevel of quality and service no matter where the work is done.”

Cook Quality CertifiedThe first phase in implementing the World of Quality program was to determine best practices throughout the organization and then document each of those procedures clearly and accurately. “There is a tremendous amount of institutional knowledge in our organization,” says Huston. “We’ve worked hard to identify the very best of it in order to elevate our performance across the board. Although we have accomplished much along these lines, it’s really an ongoing process.”

The next phase of the program is to put those procedures into practice in each service facility. That involves not only communicating best practices, but making sure they are understood completelyand performed correctly. Huston illustrates it this way: “I can read books about brain surgery, but thatdoesn’t mean I’m ready to operate.”

“Our people are skilled and capable,” says Huston. “But it’s our responsibility to train them in bestpractices. So we have a certification process for each task. A supervisor reviews the proper procedurewith them and works alongside them as they master the skill. Then a Quality Assurance Manager tests










Next Page ‘





CookCertified












them in both the knowledge and skills associated with the task. To be Cook Quality Certified for atask, the only acceptable grade is 100%.

“One example of this process involves repairs for Cook’s Rebecca® fuel gas injector valves. We identi-fied Houston as the center of excellence for these repair procedures and brought in technicians fromCook facilities in La Porte, IN, and Santa Fe Springs, CA, for training. Becoming Cook Quality Certifiedallowed them to provide these services closer to customer locations in the Great Lakes and WestCoast regions, significantly improving response times.”

Remaining Vigilant for QualityAs with any quality assurance program, Cook’s World of Quality is a continuous effort that is rein-forced with internal checks and audits.

“I perform personal inspections in our service facilities – some planned, some unannounced,” saysHuston. “For instance, I’ll walk into a packing ring work cell and ask detailed questions about the ma-terials used, tolerances on grooves and other specifications. Then I observe whether our proceduresare being followed without fail.

“World of Quality is not just about book knowledge. It’s also about translating that knowledge intoactions. Having documented procedures allows technicians to know exactly what is expected and en-ables managers to check compliance for standards that are uniform throughout the world.

“We want our customers to know that we not only have standard operating procedures – we have su-perior operating procedures. And they can have confidence in the quality of the work they receive nomatter where that work is performed.”





CookCertified



New Tool Makes Valve Installation Safer, Faster

Here’s good news for those who manage and perform compressor maintenance. Cook’s V.I.T. (Valve Installation Tool)lets you install and remove valves safely – and in a fraction ofthe time.

Valve installation and removal is a leading cause of injuries in gascompressor operations. Awkward angles, heavy parts, hot, greasy sur-faces and dangerous pinch points combine to increase the risk of seri-ous injury to extremities and cause overexertion from lifting, pushingand holding valves in place.

But now there’s a safer, simpler, more efficient way to get the job done.

The proprietary Cook V.I.T. (Valve Installation Tool) makes it easy to se-curely hold, move and align valves when installing or removing themfrom the cylinder. It allows the procedure to be completed by onlyone worker supported by an overhead crane.

Safety FirstThe V.I.T. is a safer alternative because the full weight of the compres-sor valve is supported by the tool. This is particularly important forvalves in the lower position on the cylinder, where personnel other-wise have to continuously lift and hold valves in position. The V.I.T. also

Next Page ‘














CookCertified



maneuvers the valve into and out of the seat area, keeping worker’shands safely away from tight clearances in the valve port.

Save Time & EffortThe V.I.T. is lightweight and easy to use. Better still, it allows valves tobe installed or removed quickly – typically, in less than 10 minutes.

The installation procedure varies slightly depending upon whetherthe valve is bottom-loaded or top-loaded on the cylinder. In general,however, the process begins by removing the valve cover and bolt-ing the V.I.T. to the cylinder using valve port studs. The valve andcage are placed in the V.I.T. and secured with a coupler. The valve assembly is then moved forward into the seat using a handheld drill.A guide plate aligns the valve and port to make seating the valve effortless.

For valve removal, the procedure is reversed. After removing thevalve cover, the V.I.T. is bolted to the cylinder, the coupler is attachedto the valve assembly, and the valve assembly is backed out of theport. The V.I.T. and secured valve assembly are then lifted away fromthe cylinder using an overhead crane.

Get Your V.I.T.The V.I.T. is available for valves on almost any gas compressor. To improve safety and productivity in your maintenance operations,contact your Cook Compression representative today.










To see video of installation and removal

procedures using the Cook V.I.T., click here.

http://www.cookcompression.com/index.cfm/lev2/2030/Valve.Installation.Tool.(V.I.T.)

http://www.cookcompression.com/index.cfm/lev2/2030/Valve.Installation.Tool.(V.I.T.)





CookCertified



CNG Is A Natural for Cook Compression

Last Summer, Cook Compression Director of OEM Sales John Dunaway took delivery on asparkling new GMC Sierra 2500 pickup – fueled in part by compressed natural gas (CNG).

Why CNG?

“There are several reasons,” explains Dunaway. “For one, it’sa practical expression of Cook’s commitment to our indus-try. Our customers are active in all parts of oil and gas - up-stream, midstream and downstream. The market we serveproduces and transports natural gas, and we’re proud tosupport them in every way possible.”

“There are environmental advantages as well, since naturalgas is a lower-carbon, cleaner-burning fuel.” Compared togasoline and diesel, CNG significantly reduces emissions ofharmful gases like carbon monoxide, carbon dioxide andnitrogen dioxide. It also reduces tailpipe emissions, result-ing in less particulate matter being expelled into the air.

Dollars and SenseCNG is more than just a good idea – it’s a fuel that makes good economic sense. Dunaway’s truck is abi-fuel vehicle, allowing him to easily compare the costs of CNG and gasoline. The numbers point tosolid savings, even with recent reductions in the price per gallon of gasoline.

Next Page ‘














CookCertified



“Mileage is the same for either fuel, so it’s a straight comparison of the fuel cost that matters. At mylast fueling stop, I paid the equivalent of $2.20 cents per gallon. And that’s after a relatively cold win-ter increased natural gas demand. Prior to that, the equivalent price per gallon was less than $2.00. SoI save a couple thousand per year on fuel. With my typical mileage, the bi-fuel option will pay for itselfwithin three to four years.”

Dunaway says that performance is comparable with eitherfuel. “I really can’t tell the difference when I’m driving,” he adds.

Fuel for The Future“Not everyone can make CNG work. Although the infrastruc-ture is growing, you still need to plan trips and be aware offueling station locations. However, fuel availability is noproblem for me. I have a range of 200 miles on CNG aloneand there are convenient stations in my typical driving areain and around Louisville, Cincinnati and Columbus.”

“Cook Compression understands the importance of naturalgas as a fuel of the future. For the United States, natural gasis abundant, stable, predictable and domestically produced.It’s much less sensitive to the global impacts that can driveup diesel and gasoline prices. For the world, it’s another al-ternative to add to the energy mix to meet growing globaldemand.”

Back to top

New High-Speed Compressor ValveDelivers Big Energy Savings













CookCertified



Dover Pearland Operations: Shared Facility Benefits Cook and Customers

Last Spring, the first wave of occupants began moving into the newDover Pearland Operations (DPO) facility near Houston, Texas.

Today, three Dover operating companies have successfully transitioned all employees and equipment into the 150,000 square foot facility: Cook Compression, Midland Manufacturing (part of OPW Fluid Transfer Group), and Waukesha Bearings Plus, Inc.

The DPO facility incorporates a shared services strategy that brings not onlyinternal efficiencies, but also enhanced processes and synergies designed toimprove innovation, quality and service for customers.

A High-Performance EnvironmentThe new, technologically advanced facility includes a host of amenities to help employees perform attheir best, including:

❙ Training room equipped with large video screens and microphones for enhanced audiovisual capability

❙ Digital white boards in every conference room that allow information from the board to be electroni-cally transferred to a computer

❙ Large windows for natural light and extra-bright illumination on the shop floor for maximum visibility

❙ Convenient, digital messaging capabilities throughout the facility

❙ A large cafeteria with a wide variety of food items; employees make purchases using a convenient thumbprint scanner

❙ Locker rooms for all employees, complete with showers Next Page ‘














CookCertified



Exploiting SynergiesThe DPO strategy embodies more than the building andequipment. Operating under a “shared services” concept,employees from all three companies are encouraged to in-terconnect and share best practices.

This shared services culture is encouraged in many ways,including a monthly “All Hands” meeting. On every thirdThursday of the month, employees gather in a largetraining room to hear the latest updates on news andevents. The combined team builds a sense of comraderyas birthdays and anniversaries are celebrated, personal accomplishments are announced,and policies and processes are explained. In the meeting, employees are empowered to sharefeedback and collaborate in a safe and tolerant environment.

More to ComeThe overwhelming success of the DPO concept is evidenced by the facility’s rapid growth. With expansion in almost every area, the combined work force has increased from 180 employees atmove-in to a current head count of 218.

As the building approaches capacity, plans are accelerating for future enlargement. Options include thecompletion of offices on the second story, as well as possible developments on the adjacent property.

As Cook grows its presence worldwide, the company will continue to find innovative ways to expandthe facilities and resources needed to provide industry-leading value for customers.














CookCertified



Cook Certified newsletter is published by Cook Compression for the benefit of its customers and associates.

Your Input Welcome. If you have ideas for future articles or suggestions for making this publication more useful for you, please send a message to [email protected].

Privacy. Cook Certified newsletter will be used to inform you of new and helpful information related to gas compression. Your information will not be sold, rented, leased or otherwise released to any third-party.

Unsubscribe?We respect your privacy. If you prefer not to receive future issues of Cook Certified, please email [email protected] with “Unsubscribe” in the Subject Line.














Date post:	13-Oct-2018
Category:	Documents
Upload:	lenhan
View:	216 times
Download:	0 times

News and Informa tion from Cook Compression Issue 1 2 015 ... · New High-Speed Compressor Valve...

Documents