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Equipment Analytics

Cooper offers performance improvement solutions for all makes and models of engines and compressors.

Equipment Analytics Overview

Data collection on a Cooper-Bessemer Engine

Equipment analysis is the routine collection, investigation, and troubleshooting of equipment performance using various tools and technologies to:

  • Detect changes in equipment performance or conditions.
  • Identify corrective actions that will reduce unplanned maintenance costs and improve reliability.
 Cooper’s equipment analytics specialist performs a rigorous analysis by collecting performance data from the machinery while running. Our data collection routes include more than 100 unique points per machine using specialized data collection methods and modern testing apparatuses. We collect crankshaft referenced pressures and vibration measurables (acceleration, velocity, and displacement), as well as temperatures and other key operating data. Data collection requires 2-4 hours for completion.

The collected data is analyzed and interpreted to assess the equipment’s mechanical and performance condition and anomalies. Cooper’s equipment assessment report identifies actionable recommendations for inspection, repair, and correction.
 

Applicability

Cooper offers equipment analytic services for all makes and models of the following engine and compressor brands and categories:

  • Ariel
  • CAT G3600
  • Clark
  • Cooper-Bessemer®
  • Ingersoll Rand
  • Superior®
  • Waukesha VHP
  • Worthington
  • Low speed integral gas engines-compressors
  • High speed gas compressors
  • High speed gas engines
  • Diesel engines
  • Electric drives/motors and/or turboexpanders
  • Gear boxes and couplings

Service Offerings

Onsite and remote service solutions are available to our customers. These services are available on a routine, scheduled basis or as a one-time service for major repairs and overhauls. Add-on services such as emissions testing, equipment tuning, and coupling alignment verification are also available.

Onsite contract analysis occurs four times per year by an expert Cooper analyst at the customer’s location. A standard service contract spans 1-5 years in length. 

Remote contract analysis services are performed four or more times per year by the customer. Customer personnel must be properly trained by Cooper to perform data collection independently. Cooper will provide all necessary test equipment to collect and analyze the data.

Waukesha VHP Engine Analysis 

Clark TCV-10 Engine at a customer site

Stage 1

Earliest interval where the cost for bringing the asset back to serviceable condition has the least cost.

Stage 2

Interval where no action was taken at stage 1 and conditions may have worsened; there may be additional costs associated with returning the asset back to serviceable condition.

Stage 3

Interval where conditions have worsened due to non-actions taken at stages 1 and/or 2; the costs to return the asset back to serviceable condition will be higher than earlier stages.

Stage 4

Major functional failure has occurred due to non-actions taken at stages 1, 2, and/or 3; the costs to return the asset back to serviceable condition are exponentially riskier and higher than earlier stages.

Key Benefits

Cooper’s equipment analytics provide substantial cost improvements, improved reliability, and optimal asset performance to our customers.

Improved Reliability

Equipment analytics augment the standard operation and maintenance philosophy using performance data to successfully detect early signs of wear. Early detection is a preventative measure and best practice among the industry that addresses equipment concerns that prevent failures.

Cost Improvements

Cooper’s diagnostic technologies support early detection of progressive warnings and potential failures. Early detection allows the customer to troubleshoot equipment issues before major damage occurs and the part is unusable. Cooper’s all-encompassing engine and compressor capabilities offer the customer a direct, one-stop shop for all equipment needs following an equipment analysis.

Optimal Performance

Data gathering and analysis has the potential to highlight a variety of equipment performance issues. This proactive approach to equipment maintenance assures that your equipment is running at peak performance with O.E.M. components that are built to last.

Concise Troubleshooting

Cooper’s equipment analysis services allow the customer to quickly and efficiently troubleshoot performance issues. The most common findings include:

  • Suction/discharge valve problems (leaks, component damage, bad selection, etc.)
  • Piston ring leaks
  • Cylinder/liner scoring
  • Packing leaks
  • Crosshead damage
  • Rod load & rod reversal issues
  • Compressor flow balance & general performance
  • Frame & cylinder vibration
  • Torsional vibration & angular velocity
  • Pulsation (acoustical issues)
  • Foundation or grout damage
  • Mechanical looseness
  • Power cylinder issues (piston damage & scuffing liner, wrist pin, etc.)
  • Cylinder head problems (leaks, valve damage, deviation in adjustment, synchronization timing issues, camshaft and roller damage, etc.)
  • Main bearing damage & wear
  • Oil & water pump damage
  • Turbocharger/blower damage
  • Ignition deficiencies (primary & secondary)
  • Coupling & frame misalignment