engine & Compressor Upgrades
your engine emissions and enhance engine and compressor performance.
Cooper has successfully tested a slow-speed integral engine running on a hydrogen (H2)-natural gas fuel blend. The groundbreaking test comes 5 months after the announcement of Cooper’s joint hydrogen research project with a major U.S. gas pipeline company to demonstrate the safe operating range of H2 blends in large-bore internal combustion engines.
“Cooper’s hydrogen development initiative took another large step forward today. We ran an unmodified large-bore, slow-speed integral engine-compressor with an H2 blend of 5% by volume, and we achieved significant reductions of methane in the exhaust. This is the first such run using significant amounts of hydrogen in an engine of this design.” said Cooper CMO, Matt Forcey. “In May, we will be running up to 33% by volume in the same stock engine. Our customers have thousands of similar units running globally, so the potential reduction of methane is substantial.”
The Cooper test for the upgrades was conducted at their slow-speed integral engine test cell at corporate headquarters located in Houston, Texas. The test engine is the current production, NSPS compliant CleanBurn PlusTM AJAX® 2802 with 15″ piston bore, 16″ power stroke, and a speed range of 360-440 RPM. Cooper selected the AJAX engine due to the similarities of its combustion system to that of the large fleet of the other engine brands the company services (Clark, Cooper-Bessemer®, Ingersoll Rand, and Worthington).
The reduction of greenhouse gases, particularly methane, is a key element of Cooper’s emissions reduction technology offering. To improve the environmental impact of engine-compressors operating within our industry, Cooper is pleased to announce CleanBurn Plus™, an emission reduction solution tailored to reduce fuel consumption, fuel slip, methane leakage, and unburned hydrocarbons.
Cooper’s CleanBurn Plus™ upgrade package is a comprehensive solution that can reduce methane output by up to 40% in most of the industry’s integral engine-compressors. For a fleet of engines rated collectively at 100,000 HP, this level of CO2e reduction can equal 20,000 tons/year, equivalent to the elimination of 4,348 standard passenger cars.
Our CleanBurn Plus™ upgrades are offered across our entire integral engine-compressor product line to include AJAX®, Cooper-Bessemer®, Clark, Enterprise®, Ingersoll Rand, Superior®, and Worthington.
* Based on 4,500 operating hours/year, 930BTU/ft3 fuel
** Average passenger car generates 4.60 Tonnes CO2e/year (U.S. EPA)
*** 1 Bbl crude oil generates 0.43 Tonnes CO2e (U.S. EPA)
**** Average U.S. home generates 8.30 Tonnes CO2e/year (U.S. EPA)
For decades, Cooper has been providing technology and engineering services for upgrades for all makes and models of integral and separable engines and compressors. With our advanced technologies, expertise, and project management experience, we offer upgrades to reduce engine emissions, increase horsepower, improve efficiencies and reliability of your equipment, and reduce maintenance costs. Cooper has the products and expertise to upgrade your engine or compressor and meet or exceed the emissions and performance levels you need. Upgrades include, but are not limited to, jet cell conversions, air/fuel ratio improvements, blower/turbocharger upgrades, ignition system upgrades, and electronic control panels.
To further strengthen our upgrade portfolio, Cooper acquired HOERBIGER’s Engines Services (HES) division in 2019. Cooper now offers even more upgrade technologies, including the HyperFuel System™, HyperBalance™, HyperLogic™, ePCC™, and ePFI™. The Engine Services team offers engine emissions reduction and efficiency improvement upgrades, applicable to all types of engines such as slow-speed, high-speed, 2-stroke, and 4-stroke. To date, Engine Services has applied more than 350 engine upgrades to nearly every type of gas compression engine currently in existence.
Cooper’s acquisition of HOERBIGER’s Engine Solutions division has allowed us to become the market leader once again in offering upgrades for your engine automation and emissions reduction. Cooper is very proud to offer a complete engine upgrade solution for 0.5 g/bhp-hr NOx emission that is available for all Clark, Cooper-Bessemer, and Ingersoll Rand slow-speed engine models. This solution has been implemented on numerous engines in field operation and is fully backed by Cooper’s guarantee.
The HyperBalance III™ is a gas engine balancing POWERPC-based platform that enables automatic balancing for two and four stroke engines up to twenty cylinders. It is the most effective and accurate large-bore engine balancing and in-cylinder
monitoring platform in the natural gas compression industry. It uses pressure data from the pressure sensors in conjunction with MPU and AMP signals to continuously assess the state of power cylinder balance and combustion stability.
Key benefits of the HyperBalance III™ platform include peak pressure, pressure ratio, and rate of heat release balance methods for maximized combustion stability within each cylinder. Other benefits include detonation detection with alarms and shutdowns, automatic peak engine performance and protection, and peak pressure updates, giving the end user access to data remotely to make real time decisions. It is the equivalent of having an analyzer on your unit 24 hours a day, 365 days a year.
HyperBalance III™ upgrade is applicable to Clark, Cooper-Bessemer, Ingersoll Rand, and Worthington engines.
Cooper’s HyperLogic™ is an advanced air/fuel ratio control system, using trapped equivalence ratio as the basis for the air/fuel ratio control. The control algorithms are developed for two- and four-stroke, turbocharged, spark-ignited engines.
HyperLogicTM can be used for total unit control, including auxiliaries, or it can be used in modules to retrofit or upgrade existing systems. Each system is exclusively designed to meet customer specifications. Benefits include superior screen arrangement for easy navigation and maximum configurability, minimal equipment downtime with an error messaging system, and continuous monitoring.
HyperLogicTM upgrade is applicable to Clark, Cooper-Bessemer, Ingersoll Rand, Superior, Waukesha, and Worthington engines.
The HyperFuel™ System is a non-hydraulic, electronically operated fuel valve and electronic control system for high-pressure fuel injection in large, natural gas-fueled engines. HyperFuel™ is an innovative and cost-effective solution for enhanced mixing and
emission reduction for direct-injected engines. The advanced fuel valve technology exists in a pressure-balanced, fail safe design. The solenoid actuated pilot valve has switching time less than 1 ms. The benefits of the of the system include NOx reduction up to 95%, as well as up to 9% fuel efficiency improvement.
The HyperFuelTM upgrade is applicable to Clark, Cooper-Bessemer, and Worthington engines.
The EFC™ system is an electronic fuel control system that features a common rail fuel delivery system to mechanical direct-injected engines. It converts the variable pressure governing system to a modern
common rail (constant pressure) pulse width controlled governing system while minimizing new infrastructure. The benefits of EFC™ include improved fuel economy at full loads, maximized fuel savings through “skip fire” routines at part load configurations, and reduced peak pressures variation and stress on engine through improved combustion stability.
EFC™ upgrade is applicable to Clark, Cooper-Bessemer, and Worthington engines.
The Electronic Port Fuel Injector System is a solenoid-operated fuel valve and electronic control system designed for large, four-cycle natural gas engines. This quick response port fuel injector system is an
innovative and cost-effective solution for extending the service life of reciprocating engines. The advanced control technology provides precise control of engine fueling rate throughout start-up and load ranges and replaces governor and fuel control linkages. The benefits of the system include saving up to 9% in fuel consumption, NOx reduction up to 95%, and improved cylinder peak pressure control. The ePFI upgrade is applicable to Enterprise, Superior, and Waukesha engines.
Combustion stability is key for reliable engine performance. Igniting the lean mixture is the main concern from a lean burn engine perspective. Pre-combustion chambers
are a viable approach since the flame propagation into the main combustion chamber provides an order of magnitude higher energy than a spark ignition alone. Fueling in pre-combustion chambers is controlled by mechanical check valves which clog frequently, provide inconsistent fueling, and administer an air/fuel ratio during startup that is too rich and results in fuel slip.
Cooper’s electronically-controlled pre-combustion chamber check valve (ePCC™) precisely controls fuel injection and helps the customer avoid these problems. ePCC™ allows the engine to run consistently smoother and cleaner. Maintenance is significantly reduced, and engine uptime is increased when electronically-controlled check valves are used.
Cooper’s Automation and Control team is made up of experienced engineers who have extensive knowledge of the operation and control of slow-speed and high-speed reciprocating engines and compressors. They
are familiar with all types of control technologies and develop advanced 2-stroke and 4-stroke control systems that work with our clients’ existing technology. Control panel upgrades can be tailored to customer-specific needs and requirements for most makes and models of gas compression and power generation engines. Cooper provides turn-key solutions to your control upgrade projects and can handle all aspects of the project, starting with feasibility studies, design, procurement, installation, and finally, startup/commissioning and training.
To learn about all available upgrades for your assets, click on the link below for each product line.