engine & Compressor Upgrades

Cooper offers a range of equipment upgrade solutions to reduce
your engine emissions and enhance engine and compressor performance.

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.

Product	Model	HP	Annual Savings*Tons CO2e	Annual Savings*Tonnes CO2e	Annual Equivalency SavingsPassenger Cars**	Annual Equivalency SavingsBbl Oil***	Annual Equivalency SavingsHomes****
Cooper-Bessemer	16W-330	8,000	1,946	1,765	383	4,105	213
Worthington	MLV-20	8,000	1,480	1,342	291	3,121	162
Cooper-Bessemer	16V-250	5,500	1,338	1,214	263	2,822	146
Clark	TCV-16	5,500	1,249	1,133	246	2,635	137
Worthington	ML-12	3,500	545	495	107	1,150	60
Ingersoll Rand	512KVT	3,000	350	318	69	738	38
Ingersoll Rand	412KVSR	2,600	352	319	69	742	38
Cooper-Bessemer	GMW-10	2,500	843	765	166	1,779	92
Cooper-Bessemer	GMVH-10	2,250	482	437	94	1,016	53
Clark	HBA-8	2,050	426	386	83	898	47
Worthington	SUTC-16	2,000	514	466	101	1,083	56
Clark	TLA-6	2,000	454	412	89	958	50
Ingersoll Rand	412KVG	1,320	308	279	60	650	34
AJAX	DPC-2804	800	48	43	9	101	5

* 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.

0.5 g/bhp-hr NOx SOLUTION UPGRADES

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.

Contacts

Vice President, Engineering

Hans Mathews

Mobile	+1 (713) 962-7161
[email protected]

VP, Sales & Marketing

Patrick Gillespie

Mobile	+1 (832) 316-9506
[email protected]

HyperBalance IV™ Upgrades

The HyperBalance IV™ 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 IV™ 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 IV™ upgrade is applicable to Clark, Cooper-Bessemer, Ingersoll Rand, and Worthington engines.

Download HyperBalance^TM Brochure

HyperLogic™ Upgrades

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.

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HyperFuel™ System Upgrades

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.

Download HyperFuel^TM Brochure

EFC™ (Electronic Fuel Control System) Upgrades

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.

Download EFC™ Brochure

Electronic Port Fuel Injector System (ePFI)

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.

Download ePFI Brochure

Electronic Pre-Combustion Chamber (ePCC)

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.

Download ePCC Brochure

Control Panel Upgrades

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.

DOWNLOADS

Brochures

Cooper Machinery Services and its products and services are not sponsored, authorized, or endorsed by Caterpillar, Clark, Ingersoll Rand, Waukesha, or Worthington. All non-O.E.M. product names are property of their respective owners. Any references to trademarked names are solely for informational purposes and do not constitute a claim of ownership by Cooper Machinery Services of CAT, Clark, Ingersoll Rand, Waukesha, or Worthington. CAT is a registered trademark of Caterpillar, Inc. Waukesha is a registered trademark of INNIO Waukesha Gas Engines, Inc. Ingersoll Rand is a registered trademark of Ingersoll Rand, Inc.”

engine & Compressor Upgrades

UPGRADE OFFERING

CLEANBURN PLUSTM uPGRADe
Reduces methane output by up to 40%

CUSTOMIZING UPGRADES BASED ON YOUR INDIVIDUAL NEEDS

SOLUTIONS for ENGINE & COMPRESSOR UPGRADES

0.5 g/bhp-hr NOx SOLUTION UPGRADES