Cook Ce rti fied News and Information from Cook ... · What’s the true cost of packing case leakage? Here’s an example from an Ingersoll Rand KVSR (3 throw) compressor in gas

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How Do You Accurately MeasureSealing ComponentLeakage?Find The Answer Here.

News and Information from Cook Compression2nd Quarter 2010

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In This Issue

Gas Gauge� Portable Vent Flow Meter

Case In Point: Plugging Profit Leaks

Cook Adds Bob Austin to European Operations Engineering Group

Jeffersonville Plant Hitting On All Cylinders After Move

Strategic Partners Enable Turnkey Approach

Jerry Horton Appointed Regional Manager for Cook-MFS

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Introducing Gas Gauge� Portable Vent Flow Meter

“You can’t manage what you don’t measure.” This time-honored truth of project managementalso applies to compressor packing performance. In other words, if you want to control packingcase emissions, you have to quantify how much gas is leaking into the packing vent.

Fortunately, Cook Compression has the right tool for the job. The new Gas Gaugeportable vent flow meter from Cook Compression gives you a highly accurate, easy-to-use way to quantify packing vent leakage. It has a measurement range of 0.06 - 6.0SCFM, accuracy of 1% +/-0.2% full scale, and is calibrated to measure multiple gases.

Armed with accurate information about packing vent leakage, you’ll be able tounderstand how well your current compressor seals are performing and evaluatethe effectiveness of alternative solutions:

� Accurately assess leakage associated with pressure packing and unloaders

� Develop a family of leak curves that compare the performance of different packing styles

� Quantify the difference in performance between standard packing and Cook engineered packing

� Calculate economic and environmental justification for installing sealing component upgrades

For an example of how precise metrics lead to correct decision-making, see “Case In Point” in this issue. For more on the new Gas Gauge portable vent flow meter, contact your Cook Compression representative.

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New Cook Gas Gauge™Portable Vent Flow Meter

Back to topGas Gauge Portable Flow MeterCase in Point: Plugging Profit LeaksCook Adds Bob AustinJeffersonville Plant Strategic PartnersJerry Horton Visit Cook Compression.com



Case In Point: Plugging Profit Leaks

What’s the true cost of packing case leakage? Here’s an example from an Ingersoll Rand KVSR (3 throw) compressor in gas transmission service.

Using a Cook Compression Gas Gauge™ portablevent flow meter, technicians measured leakage of 25 SCFM in two cylinders. Based on a gas priceof $5/MSCF, that equates to more than $65,000 in lost product per 8,760 run hours. That’s a highcost to the company - and to the environment.

Why Not Do Something About It? Many companies fail to act because they lackhard facts about leakage volumes and costs.After all, until you have an accurate way to quan-tify leakage (see Introducing Gas Gauge™Portable Vent Flow Meter in this issue), it’s impos-sible to compute a return on investment for up-grading sealing technology.

However, a growing number of forward-thinking compressor operators are measuring packing vent leakage.With facts in-hand, it’s a simpler matter to compare the value of an upgraded sealing solution - and thenconfirm its impact after the solution is implemented.

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Figure 1. Costs associated with a leaking packing case.





The Proof Is In The NumbersFor example, take a look at the results of a CookCompression engineered packing solution in agas transmission application. In this evaluation,Cook Low-Emission packing was installed onCylinder 3. Cylinder 1 continued to run standardbronze packing.

The results were dramatic. Standard bronzepacking allowed 1.0 SCFM leakage - a cost of$2,500 in lost product per 8,760 hrs (based on$5/MSCF). In the same application, Cook low-emission packing achieved a leak rate of 0.09SCFM, resulting in only $250 of lost product overthe same period.

The cost difference between the two styles ofpacking is easily recovered by reducing product loss over the life of the packing.

Don’t Overlook Unloaders

Vent leakage measurements are also revealing a surprisingly high volume of product loss through unloaderseals. In one recent investigation, Cook Compression technicians located leaking unloader vents on a plug-style valve unloader in propane service. After upgrading and rebuilding the unloader seals in a Cook Com-pression service center, the customer was able to cut product loss and significantly reduce the amount ofpropane purchased.

For help in measuring packing vent emissions and plugging profit leaks, contact your Cook Compressionrepresentative.

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Figure 2. Standard bronze packing vs Cook low-emission packing.





Cook Compression Adds Bob Austin to European Operations Engineering Group

Bob Austin has joined Cook Compression as Product Support Engineerfor European Operations. Austin augments Cook’s application engineering services, which help customers optimize machine reliabilityand productivity utilizing Cook Compression products and services.Austin is based in the Ellesmere Port (Cheshire, UK) manufacturing and service center and supports customers throughout theCook Compression European Served Area.

Strengthening Technical Support“Bob has more than 35 years of experience in condition monitoring of reciprocat-ing and rotating machinery, including service with leading machinery monitoringequipment manufacturers and a major compressor manufacturer,” said Dean Lewis, Managing Director of Cook Compression European Operations.

“Cook Compression offers extensive technical support to customers through reliability studies and recommendations for improving utilization of their machinery assets. Bob’s expertise is a significant advantage as we expand awareness of these services and deliver practical solutions to our customers.”

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Bob Austin, Product Support Engineer

for Cook Compression European Operations





Windrock Technology

“A key part of the analytical services we provide involves Windrock monitoring and diagnostic equipment for reciprocating machinery,” continued Lewis. “CookCompression European Operations is the exclusive Windrock agent in the UK and provides Windrock products and services throughout the European Served Area.”

In 2007, Windrock became part of Dover Fluid Management, a Dover Corporationmarket segment that also includes Cook Compression.

“Windrock is the premier manufacturer of portable analyzers and online systems for oil, gas, marine andpower generation applications,” said Lewis. “This technology is another important resource available to Bob and other Cook experts as they assess the mechanical condition of machinery and help customers optimize maintenance practices.”

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Jeffersonville Plant Hitting On All Cylinders After Move

After 121 years of continuous operation at the same location, it was finally time for the CookLouisville plant to move on. It was also an opportunity to boost productivity to the next level.

Founding LocationCharles Lee Cook, inventor of floating mechanical packing and namesake for thecompany, began operations at the four-acreLouisville (KY) site in 1888. Since that time, the facility underwent numerous expansionsand upgrades as the industry evolved and the business continued to grow. However,limited space and the aging structure eventually dictated the need to relocate.

The SearchFinding a new location involved more thanfinding a suitable site and building. The new location had to accommodate the needs of Cook’s people. “The knowledge and expertise of our workforce are our most valuable assets,” explains General Manager Ernest McCurdy.“We had to make the transition as smooth as possible for the people we count on.”

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Cook Compression Jeffersonville Facility







As it turned out, the answer was less than ten miles away. A former Dover Corporation facility in nearby Jeffersonville (IN) offered a modern structure, ample space and a reasonable commute for Cook personnel.

Seizing The Moment

“Although moving the machinery and supporting materials of roughly 130,000 square-feet of manufacturingspace is a challenge, it’s also a tremendous opportunity,” continued McCurdy. “So our planning took into account any modifications we could make to maximize efficiency, increase productivity and improve quality.

“As a result, we incorporated process changes and took advantage of the ability to re-position equipmentand work cells for maximum effect. Every aspect of our operation - from the striping on the floor to the flow of materials through the plant - was optimized not only for present needs, but greater flexibility for the future.”

Since completing the move last December, theCook Jeffersonville facility has reaped the rewardsof successful planning: improved service to cus-tomers, increased operational efficiency and the capacity to meet tomorrow’s requirements.

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Strategic Partners Enable Turnkey Approach

Cook Compression is a source for turnkey engineered solutions, providing everything from diagnostics and machine analysis to field services and contracting work. To deliver this comprehensive range of support, we work closely with a global network of highly specialized compression technology experts.

Following is a brief look at some of these strategic partners and their core expertise.

Adhesive Services CompanyAdhesive Services Company is a specialist in performing engineered foundation re-pairs/rebuilds and grouting services. An extensive service history and excellent safetyand performance record make Adhesive Services Company the industry leader infoundation repair.

Adhesive Services Company goes beyond machinery grouting, offering comprehensivesolutions to complex foundation issues. Services include complete foundation and anchor bolt repairs with the machine in place, post-tensioning, vertical pinning, epoxy pressure injection and application of high performance industrial coatings for concrete and steel structures. A complete foundation repair by Adhesive Services Company leaves an existing foundation in ‘better-than-new’ condition and should last the economic life of the equipment.

In business since 1975, Adhesive Services Company has performed foundation repairs throughout the United States and around the world. Their team includes engineers, professional support staff, highly experienced field superintendents, and grout technicians.

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Down Time Services

Down Time Services (DTS) provides specialized field machining and metrology services,including large flange resurfacing, boring bar work, milling of baseplates and keyways,heavy drilling and tapping, stud tensioning and torquing.

DTS has served onshore and offshore oil and gas production, petrochemical plants andother industries worldwide since 1985. DTS employs highly trained and skilled technicians andoperates complete machine shops to support its operations. Their large inventory of field machining equipment includes boring bars, flange facers, mills, drills, lathes, optical precision measuring equipment, hydraulic tensioners and more.

Downtime Services has partnered with Cook-MFS to provide services such as:

� Align boring of engine/compressor frames, pumps and turbines

� Compressor cylinder relining, boring and honing

� Milling of compressor bases and pump bases

� Optical alignment of cylinders, bearing housings and main bearing bores

T.F. Hudgins Lubrication Products

The Lubrication Products Division of T.F. Hudgins Incorporated designs, fabricates, installs and services a wide range of custom lubrication systems and associated control systems for compressors, engines, pumps and machineapplications. T.F. Hudgins lubrication systems are built to meet any specifica-tion or operating condition.

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T.F. Hudgins inspects, repairs and rebuilds lubrication system pumps, gear boxes, check valves, divider valves and other components for virtually all types of force feed and centralized automatic lubrication systems. The company provides 24-hour emergency repairs and periodic preventive maintenance programs, as well as system performance upgrades and lubrication system training.

T. F. Hudgins is the industry leader in high-pressure lubricationdelivery, with custom-designed systems that use proprietarytechnologies. T. F. Hudgins performs Hyper System upgradesand is the nation’s only factory-approved high-pressure repaircenter, with test capabilities to 60,000 psig.

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Jerry Horton Appointed Region Manager for Cook-MFS

Jerry Horton was recently named Eastern Region Manager for Cook-MFS.As part of the services group for Cook Compression, Cook-MFS providesturnkey repair, maintenance and overhaul services for compressors, en-gines, pumps, turbines and other reciprocating and rotating equipment.

Horton is a 32-year veteran of the mechanical service industry, with extensive experience in maintaining both reciprocal and centrifugal compressors. He previously worked for Cooper Compression and successfully managed projects worldwide. In his role with Cook-MFS, Horton oversees mechanical service operations for the Eastern United States.

“We continue to see robust demand for our mechanical services,” explains Frank Wierengo, Vice Presidentand General Manager of Cook Services. “Jerry’s knowledge and experience play a key role as we strengthenand expand our U.S. services group.

“Working closely with sales personnel and our regional and satellite service centers, Jerry helps leverage our resources to deliver the responsiveness and value our customers need in maintaining and optimizingtheir machinery.”

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Jerry Horton, Cook-MFS EasternRegion Manager





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Cook Ce rti fied News and Information from Cook ... · What’s the true cost of packing case leakage? Here’s an example from an Ingersoll Rand KVSR (3 throw) compressor in gas