Cameron Remanufacturing Two 16-Cylinder Cooper-Bessemer Engines in Houston Plant

Cameron has taken on a project to remanufacture two 16-cylinder Cooper-Bessemer V-250s and upgrade them to W-330s. The units will replace 14,400 horsepower of Cooper-Bessemer Type 26 horizontal units originally installed in 1920s and 1930s. After 80 years of dependable service and support from these units, the customer has chosen Cooper-Bessemer units again. In addition to OEM support, the customer has chosen the Cooper-Bessemer units because they are unmatched in maintenance cost, compressor efficiencies, life cycle and reliability – all while still meeting today’s strict emissions standards.

The units will be “zero-houred” and assigned news serial numbers. The base, block, crankshaft, master rod, power rods and a few other items will be remanufactured to new condition; most components will be brand new, many with new designs. Several new component designs were created using Cameron’s state-of-the-art engine design and simulation software. The software program gives Cameron engineers the ability to simultaneously dial in multiple configurations to reach the optimal performance, emissions, efficiency, combustion and noise levels. The heads have been redesigned to allow for leaner combustion while also increasing combustion stability. Air to the engine will be delivered via two new ET24 turbochargers that were designed, manufactured and tested in Cameron’s Salina, Kansas TSI plant. A new control package with parametric emissions monitoring will allow the engine to run at tighter margins of emissions compliance. Additional performance and reliability components include electronic fuel injection, pre-chambers with electronic check valves, and improved intake and exhaust system. Once complete, the engines will be rated 8000 HP at 100-degree ambient temperature and can be up-rated to 9200 HP at 40-degree ambient temperature. The engines will each be matched with four Cooper-Bessemer CEGTA-20 gas transmission compressor cylinders. These 21.5-inch-diameter, air-cooled, high efficiency cylinders have a flow rate of 331 MMSCFD and compression ratio of 1.6:1. They will be tested to 1950 psig and will have a working pressure of 1300 psig. Each cylinder, weighing in at 43,000 lbs, will also be equipped with the latest sealing components to mitigate fugitive emissions.

The desire for improved performance and fuel consumption, in conjunction with clean air needs, has created a lot of interest in remanufacturing and upgrading old engines. Following years of upgrade experience and continued research and development, Cameron is prepared to meet the demands of their customers.

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Cooper-Bessemer® Gas Engines and Compressors

Integral Gas Engine-Compressors
Cooper-Bessemer® introduced the world to the first intergral gas engine-compressor in 1909. Over 100 years later Cooper-Bessmer® engine-compressors are among the most reliable and efficient methods for gas compression. The wide operating range of the Cooper-Bessemer® integrals have made them a perfect choice for services where there are severe variations in operating pressures and flow rates.

Power Engines
Cooper-Bessemer® power engines have been installed around the world for use in electric power generation, mechanical drive, nuclear standby and cogeneration applications. The Cooper-Bessemer® power engines range in horsepower from 1,500 to 8,700 hp and have been supplied for use with variety of fuels such as diesel, gas and dual-fuel. Where emissions are critical, the units have been furnished or converted to CleanBurn™ technology, which is used for lowering the emissions of the engines and was ioneered by Cooper-Bessemer®.

Separable Compressors
The Cooper-Bessemer® M-Line compressors are slow to medium speed horizontal units utilizing a balanced opposed cylinder design and range in horsepower from 1,000 to 30,000 hp. The compressors have been custom designed to meet a wide range of operating conditions and for virtually any gas application.


Maintenance and Service Solutions
-  Genuine OEM Parts
-  Machine Shop Repair Services
-  Overhaul and Retrofit Services
-  Exchange, Reconditioned and Used Parts
-  Preventive Maintenance Programs
-  Maintenance and Operating Contracts

Engineering Solutions
-  Emissions Reduction
-  Horsepower Upgrades
-  Re-application of Equipment
-  Engine and Compressor Control Systems and Upgrades
-  Performance Analysis and Optimization
- Failure Analysis

Remanufactured Cooper-Bessemer® Engines, Compressor Frames and Cylinders

CAMSERV's world wide, OEM resources are committed to keeping Cooper Bessemer® equipment operating like new by offering the following services to our Cooper-Bessemer® customers.

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An Emissions Solution On Two-Stroke Lean-Burn Engine

PIPELINE AND GAS JOURNAL
 
The internal combustion engine (ICE), fueled by natural gas has moved in the direction of efficiency and environmental friendliness with lean-burn technology.  Cameron's AJAX LE uses CleanBurn prechamber type of combustion that allows for operation with very stable combustion at lean air fuel mixtures.  The lean air fuel mixture reduces the formation of NOx.  The lean mixture also provides a more complete combustion process resulting in reduced CO and hydrocarbon levels in the exhaust.  [more]
 
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Environmentally-Responsible Compressor Package Now Available

Environmentally-Responsible Compressor Package Now Available; Tri-Star Compression, Texas Power Offer Efficient Package to Gas Industry

Arlington, TX—Tristar Compression LP and Texas Power are now packaging a state-of-the-art Ajax compressor unit with electric power and services to provide natural gas companies a one stop option that is environmentally-responsible.

Recognizing the growing need for electric compression, company officials through this unique collaboration are addressing emissions and noise concerns of residents in the highly-populated areas of the Barnett Shale. Compression is used to boost wellhead flowing pressure to pipeline intake pressure.

“The current EPA air regulatory issues could completely dismantle the practice of using gas-operated compressors in the ozone non-attainment regions of states like Texas,” said Jim Simmons, Texas Power’s director of commercial sales. “Our collaboration over the past several months determined that it would be up to vendors like us to support gas producers by giving them workable options in communities where people are complaining about their presence.”

This option assists companies in their ability to streamline operations and increase efficiency. The union allows interested companies to obtain a high quality Cameron AJAX C-202 compressor, and at the same time, receive complete service provided by Tristar Compression and Texas Power.

Among the most attractive attributes of the new unit is that it is no longer relies on burning natural gas, but rather an electric motor. The electric motor still offers plenty of power, as it comes with either a 250 or a 600 hp motor, depending on the crankshaft and bearing selection. The switch to an electric motor also lends itself to a quieter production. “It’s so quiet you can carry on a conversation standing right next to it and never have to raise your voice,” said Simmons.

“Even with all the upgrades you’ll see, the best part is there are only four new parts in the entire compressor,” said Russ Holzhausen, Project Manager AJAX New Products, Cameron’s Compression Systems group. By maintaining the existing design, Cameron was able to rely on the quality features of the existing design while minimizing the amount of new parts needed on the C-202.

“We figure why tinker too much with a good thing,” Holzhausen said. “This allows great synergy between the gas and electric AJAX product lines as most other parts in both are compatible.”

About Cameron:
Cameron (NYSE: CAM) is a leading provider of flow equipment products, systems and services to worldwide oil, gas and process industries.

About Texas Power:
Texas Power is a Texas-owned and operated Retail Electric Provider located in the heart of the DFW Metroplex. Texas Power is committed to excellence in service and product, offering both residential and commercial electricity. For more information, visit http://www.texaspoweronline.com/ or call 1-866-SHINE-ON.

For more information about our services, please visit our website at:
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Shop Repairs

Proven Repair Leadership

CAMSERV is an industry-recognized leader in providing high quality machining and repair services. At Cameron's Compression Systems, our primary goal is to provide timely, cost-effective repair solutions for our customers. We operate numerous service locations worldwide, each staffed by experienced personnel and properly equipped to restore most makes of equipment to OEM or aftermarket specifications.

Reconditioning. CAMSERV can recondition or remanufacture any make of reciprocating engine, compressor or turbocharger, offering an attractive, economical solution based on your particular situation. Reconditioning restores equipment to like-new condition, in accordance with OEM and aftermarket specifications. Remanufacturing involves restoring equipment to a given set of specifications, based on a particular application.

Retrofits

CAMSERV provides retrofit services to enhance engine performance and meet new emission requirements. Available for CleanBurn™ and other engine emission technologies, retrofits can be specified to meet minimum, moderate or maximum NOx and CO reduction. Current technology provides a new Ajax catalytic converter, low-pressure electronic fuel injection, high-performance turbocharging, as well as LE kits and HCR pistons for Ajax units.

Upgrades

Engine efficiency upgrades can also be performed to help improve fuel efficiency, engine performance, and reliability. Upgrades can include Jet Cell™ conversions, air/fuel ratio improvements, blower/turbocharger and ignition system upgrades, and electronic control panels.

One Stop Shopping Solution

At Cameron's Compression Systems, we are your single source provider for all your repair needs. We possess a wide range of capabilites in each of our shop departments.

Valve Department. Cameron's Compression Systems valve department can repair or recondition any valve in the market. Services include:

• Packing and wiper cases
• Fuel and air starting valves
• Manufacture gas compressor rings and riders up to 45" diameter

Pump Department. At CAMSERV, we can repair or manufacture parts for all types of pumps, including:

• Split case horizontal
• Vertical
• Bearing overhung
• Inline
• Positive displacement
• Gear pumps

In addition to the services above, CAMSERV's pump department can repair gearboxes, small air compressors, vane compressors, screw compressors, and blowers.
Metalizing Department. When corrosion protection is of utmost concern and equipment must last an extended period of time through demanding environments, call CAMSERV for help. At Cameron's Compression Systems, we can provide durable, cost effective corrosion protection services that meet your requirements. Using the latest coating processes such as detonation gun thermal spray and high velocity oxygen fuel (HVOF) spray, we can apply a wide range of coatings such as ceramic, nickel, chrome, and tungsten carbide. Some parts that we can provide metalizing services for include:

• Compressor piston ring and rider band grooves
• Compressor rods
• Pump shafts
• Pump lungers
• Mud motor parts
• Crossheads
• And much more

Welding Department. CAMSERV offers quality welding services of all types to meet our customer requirements. Our expert licensed welders continually produce quality workmanship and keep abreast with the new technologies emerging in the welding industry. The welding department works hand in hand with the machine and fabrication works, combining to produce high quality work and competitive prices. Cameron's Compression Systems can weld:

• Cast iron (nickel rod, or brazing)
• Mild steel
• Aluminum
• Stainless steel
• Bronze
• Aluminum
• Bronze
• Stellite hard facing

Put CAMSERV To Work For You
For more information on our shop capabilities or to receive a quote for needed services, contact your nearest Cameron's Compression Systems sales office or consult your local sales representative today.

For more information about our services, please visit our website at:
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Compression Systems - A Legacy of Quality

RECIPROCATING AND CENTRIFUGAL COMPRESSORS:
SINCE 1833

2008 marked a monumental milestone for Cameron. We’re celebrated 175 years in business. That’s right, nearly two centuries! To put this in perspective, our roots stretch back over 25 years before Abraham Lincoln was the President of the United States.

Cameron’s legacy started in 1833 when two entrepreneurs, Charles and Elias Cooper, established a foundry in Mount Vernon, Ohio, USA.  Through the mid and late 1800s, the Cooper foundry was the licensed producer of the famous Corliss steam engines and, at the turn of the century, ventured into the production of natural gas internal combustion engines. Cooper-Bessemer®, one of Cameron’s oldest and most recognized product brands, was the result of a merger between the Cooper foundry and the Bessemer Gas Engine Company in 1929.

In the 1940’s, Cooper ramped up its production to support the war effort and produced diesel engines for military vessels of all kinds and also increased production of locomotive engines. At the peak of its wartime production, Cooper-Bessemer had 4,337 employees working in round-the-clock shifts. In 1944, Cooper was listed for the first time on the New York Stock Exchange and opened its first international offices in Venezuela and the Soviet Union.

The famous GMV engine would be developed and sold before the turn of the decade. Throughout the 20th century, several acquisitions were made by Cooper that expanded the company’s reciprocating compressor scope. Cooper purchased three companies between 1960 and 1976, including the AJAX Engine Company, Pennsylvania Process Compressor and White Superior. Stemming from the success of this growth, additional acquisitions were made between 1987 to 2001 including the Enterprise Power Engine aftermarket business, Nickles Industrial Manufacturing and Turbine Specialties.

 
In 1955, the Joy Manufacturing Company was formed in Buffalo, NY and quickly grew into a complete manufacturing company, producing integrally geared, oil-free centrifugal air compressors. The 1970s saw Joy™ grow world wide with much focus on engineered custom compressors for refineries and air separation applications. In 1987, Cooper acquired the Joy™ product line in an effort to expand its product focus from primarily reciprocating gas compressors to include industrial centrifugal compressors. 
 

With a product lineup inclusive of integrally geared centrifugal air and process gas compressors, reciprocating gas compressors, integral gas engine compressors, turbochargers and a host of aftermarket parts and services to support our equipment, Cameron is looking forward to the next 175 years of success.

For more information about our services, please visit our website at:
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50 Years of Excellence: Cameron Centrifugal Compressors

Centrifugal Products History (1955-Today)

In 1955, Joy Manufacturing Co. consisted of only four engineers. Their office, located above a hardware store in Western New York, was the scene where they drafted designs of various types of turbo-machinery. In short time, the company purchased land in Cheektowaga, NY which became the site of their Research and Development facility. From 1955-1960, the four engineers designed, developed and experimented with gas turbines, steam turbines, axial flow compressors, in-line centrifugal compressors and integral gear centrifugal compressors.

After five years of experimentation, Joy Manufacturing Co. narrowed its focus on the design and manufacturing of an integral gear centrifugal compressor, and the MSG (multi-staged gear) models were introduced to the market. These models were primarily sold for plant air applications. Throughout the 1970’s, the company experienced a significant amount of growth domestically. During this time, Joy Manufacturing discovered a market niche and began to engineer custom compressors for refinery applications and the air separation industry.

The 1980’s signaled rapid changes and new development for Joy Manufacturing. These changes included the development and introduction of a low cost plant air compressor, the utilization of computer-based design software and a substantial manufacturing facility expansion.

In 1987, Joy Manufacturing Co. was acquired by Cooper Industries, and the Cooper Turbo-Compressor division was formed. This acquisition marked the end of the JOY name and kicked off an era of extensive new product development. As a result of substantial investments, new manufacturing tools were purchased, test facilities were enhanced, and computer equipment was upgraded. These improvements gave way to the creation of the TurboAir 2000 plant air compressor and new high-performance MSG compressors for the air separation industry.

Over 50 Years, Over 12,000 Compressors

Cameron, formerly the Joy Manufacturing Company and Cooper Turbocompressor, has been a leading global manufacturer of centrifugal compressors since 1955, when the Joy Manufacturing Company began operations in, Buffalo New York. Our Turbo-Air (TA) compressor line operates up to 12,000 hp and 1,000 psig and is designed to fulfill your standard plantair needs that reside in the 600 CFM to 35,000 CFM range. Our MSG (Multi-Stage Geared) compressors are appication engineered and operate up to 20,000 hp and 1,000 psig and are designed for a wide flow range, 600 - 90,000 CFM. Our centrifugal products aftermarket team completes our product offering and is geared toward providing parts and services fo all your compressors, not just Joy compressors or those produced by Cameron.

For more information about our services, please visit our website at:
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