» Refining: For over a DECADE, CE has been providing solutions for customers in the oil refining industry by providing the appropriate high-quality designed and manufactured products and services needed to keep reciprocating compressors free of damaging elements and maximizing operational value.
» Chemical: CE designs and manufactures a full range of high performance compressor valves, packings, rings, purge and emission control systems and also monitoring systems; all of which are necessary in order to properly pressurize processed (gasses) GASES in a reciprocating compressor, such as one used in a Chemical plant.
» Gas Transmission: Natural gas needs to be highly pressurized before it can be transmitted through pipelines. CE designs and manufactures a full range of products specifically for compressing, filtering and monitoring natural gas so that the gas can properly and safely be transmitted.
» Gas Gathering: CE designs and manufactures the appropriate compressor parts needed in order to gather, process and transmit natural gases from one plant to the next.
» Air Separation: CE products are used for reciprocating compressors in the air separation industry to separate atmospheric air into its two main components, nitrogen and oxygen.
» PET: CE designs and manufactures compressor parts for the PET bottle making industries. These compressor parts are crucial in order for the compressors to pressurize air which is what blows the plastic bottles.
» Plant Air: CE serves customers in the power plant industries by providing them with the proper reciprocating compressor products needed to filter out toxins in plant air.
» OEM: CE works with OEMs to provide customers with quality compressor products which increase reliability.
» Pulp and Paper: CE supplies customers in the pulp and paper industry with the proper products and services needed for their reciprocating compressors to effectively create pulp and paper products.
» Mining: CE serves customers in the mining industry by providing the reciprocating compressor products needed in order to consolidate materials and extract the desired compounds from the minerals at present.
» Pharmaceutical Systems: CE provides customers in the Pharmaceutical industry with the products they need to effectively develop glass and plastic products for health care providers.
THE EFFICIENT RING VALVE FOR HEAVY GASES
»High reliability
»Special spring protection
»High efficiency and long service life
The COMPETENCE INDIA CE valve is optimally suited for applications in the chemical and process industries, in refineries, and in the energy sector. The operation in heavy gases such as carbon dioxide, carbon monoxide or propylene is also optimized in the best possible manner. The valve offers reliability and efficiency even under difficult conditions.
EFFICIENT RING VALVE FOR HIGH-PRESSURE APPLICATIONS
»Carbon-reinforced rings guided with zero backlash, with low mass inertia
»Profiled guard with anti-adhesive design
»Spring nest with optimized spring geometry
The COMPETENCE INDIA CM valve is suitable for use in typical high-pressure applications, especially for the compression of natural gas in gas reservoirs or for gas lift and re-injection systems. The typical field of use of the valve also includes applications with highly pressurized, heavy gases such as LDPE.
LOW-MAINTENANCE AND ENERGY-SAVING COMPRESSOR OPERATION
»Use in oxygen and low-temperature applications
»Optimized aerodynamics
»Plastic valve plates
The COMPETENCE INDIA CP valve is the latest innovation among the COMPETENCE INDIA valves. Fields of application include the chemical, petrochemical, pharmaceutical industries, the medical field, the energy sensor as well as the electronics and packaging industries. Whenever it comes to the compression of industrial gases, the CP valve is the right choice. Additional fields include liquefaction systems for LNG, ethylene, propylene or propane as well as air compressors for the production of PET bottles. The CP valve is marked by maximum efficiency and strength. When used to retrofit older compressors, the CP valve increases the economic efficiency of the system.
FOR HYDROGEN COMPRESSION
»Anti-stiction design
»Advanced non-metallic sealing elements for a very long service life
»Robust springs
The CX valve is specially designed for the demands when compressing hydrogen in refineries and in the petrochemical and chemical industries. The range of uses encompasses hydro cracking, hydrodesulfurization (HDS), residue destigmatization (RDS), continuous catalytic reforming (CCR), and coke oven gas applications.
FOR MAXIMUM PRESSURES AND DIFFICULT CONDITIONS
»Low flow losses
»Non-metallic valve ring with superior damping properties
»Temperature resistant up to 300ºC (572ºF)
The COMPETENCE INDIA HPV valve is specifically designed for use under difficult conditions. Whether the use involves chlorine, hydrocarbons, hydrogen, noble gases or methane the HPV valves satisfy virtually all the requirements of the natural gas, chemical, petrochemical and pharmaceutical industries as well as of the food and electronics industries. The wide range of uses includes reciprocating and diaphragm compressors as well as cooling equipment, for example for cooling the gas of turbo-generators or for mixing gases.
FOR HEAVY GASES AND HIGH PRESSURES
»Double damped plate valve plate design
»Delicate port design
»Metal or non-metallic valve plates
The COMPETENCE INDIA HDS valve is suitable for high-pressure applications in the chemical, petrochemical and natural gas industries. Primary fields of use include hydro treating, urea production, polyethylene production, and natural gas storage.
FOR LUBRICATED AND NON-LUBRICATED HIGH-SPEED AIR, REFRIGERATION AND GAS COMPRESSORS
»Frictionless guided valve plates
»Suitable for dry-running and lubricated systems
»Maintenance-free reliable operation
Due to its metallic sealing elements, the R valve is especially suited for use in small, high-speed industrial air compressors. These compressors are used to economically generate compressed air for PET bottle manufacturing, or brake and instrument air. The valve also assures trouble-free compressor operation when handling technical gases and in the generation of cooling energy.
FOR LUBRICATED AND DRY-RUNNING COMPRESSORS
»Smallest possible clearance volume, therefore maximum delivery volume
»Low flow resistance
»Compact, space-saving design
Concentric valves are a space-saving alternative to conventional inlet/outlet valves. They are suitable for all types of compressors in the lower power range.
FOR HIGH EFFICIENCY AT LOW TO MEDIUM PRESSURE LEVELS
»High efficiency
»Long service life, simple maintenance and installation
»Wide flow ducts to prevent clogging
The CS valve is the classical non-metallic plate valve suitable for use in compressors in the petrochemical and chemical industries for the reliable compression of natural gas, hydrogen or technical gases.
FOR USE IN SHORT-STROKE COMPRESSORS AT HIGH ROTATIONAL SPEEDS
»High efficiency and long service life
»Resistant to gas impurities and oil stiction
»High operating temperatures
The COMPETENCE INDIA CT valve is suitable for virtually all applications that employ short-stroke, high-speed gas compressors. Primary fields of operation include the transport, production and storage of natural gas. The valves also operate reliably and efficiently in a wide variety of processes in refineries and in the chemical and petrochemical industries.
CPI combines a wide range of metallic and non-metallic materials and a variety of designs to meet with many typical packing requirements and also the more specific and problematic ones.
The range of materials that CPI utilizes are available across the broad range of packing rings designed for unidirectional and bidirectional sealing, low pressure vent and gas purge sealing. This also includes high-speed and high pressure rings, as well as sandwich and triple circle designs.
Basic Packing Ring Designs:
»Single acting seal rings/pairs
»Double acting seal rings/pairs
»Backup rings
»Pressure breakers
»Pressure breaker with relief slots
CPI oil wiper rings are designed to effectively provide positive containment of lubricants within the crankcase. The CPI scraper is designed specifically for those applications where total oil control is necessary. Most reciprocating compressors use oil control or wiper rings to prevent crankcase oil from passing into the cylinder and in some instances to prevent condensate and cylinder and packing lubricant from entering the crankcase.
Segmented wiper rings may be either radially or tangentially cut. They are garter spring actuated. The scraper edges in contact with the piston rod are proportioned to give a bearing load sufficient to break the surface tension of the oil film on the rod and wipe it away. While there are many variations and innovations of wipers, there are basically two types. Normally two or three wipers are used in an oil seal and as previously indicated may be used as a part of or in conjunction with a pressure packing.
The CPI scraper is designed specifically for those applications where total oil control is necessary. Available in both cast iron and bronze, the unique design and operation of these rings provide extremely effective containment of lubricants in their intended area as well as long trouble free service.
The unique design and operation of these rings provides extremely effective containment of lubricants and long trouble-free service.
Basic Wiper Ring Designs:
»Tangent cut unidirectional
»Tangent cut bidirectional
»Radial cut wiper rings
Packing and Wiper Ring Materials:
»CPI Special Polymer Alloys
»PTFE
»Thermoplastics
»Bronze
»Cast iron
CPI designs and manufactures a full line of compressor packing cases, intermediate partition packing cases and wiper cases for your reciprocating compressor’s piston rod sealing system.
»Precision machined from cast iron, bronze alloy steel or stainless steel
»All packing and wiper cases are designed to be easily reconditioned when needed to maximize service life
»Available in cooled or non-cooled for use in both oil-free and lubricated applications to satisfy the full spectrum of temperatures, pressures and corrosive conditions
»Designed to meet all environmental concerns and regulations including available vent and purge designed assemblies for fugitive emissions reductions
The packing case assembly is critical to the proper operation of the piston rod packing and the sealing of the cylinder. The CPI packing case has several important features that help to maximize your compressor’s performance:
»Cylinder-end gasket to prevent process gas from bypassing the packing rings
»Precision-machined mating and sealing surfaces to prevent leakage
»Provides passages for lubrication, vent, coolant and buffer gas as required
»Flange with adequate bolting to maintain gasket seating and seal between cups at operating pressure
»Recess in each cup to contain free floating seal rings
With the ever increasing concern for the effects upon the global environment, systems to control emissions are becoming even more important. As part of its commitment to its customers and the environment, CPI has a range of purge control systems that maintain buffer pressure and monitor gas flow and packing condition to eliminate emissions from packing cases used in reciprocating compressors. The purge-gas system prevents your process gas from escaping through the packing case by introducing an inert buffer gas into the assembly.
Application-engineered piston and rider rings are available, specifically designed to meet your operating parameters. On-site blending and compression or injection molding enables CPI to maintain total control throughout the manufacturing process.
»Provide excellent sealing capabilities
»Piston support
»Available in a variety of designs and materials to best suit your application requirements
A range of piston rings, rider rings and rider bands fulfill the varied sealing and piston support requirements for reciprocating compressors, using a range of CPI Special Polymer Alloys, standard and special materials. Many successful field applications, using the unique range of CPI materials, have transformed both oil-free and lubricated compressor reliability, resulting in better sealing, less wear and longer running life.
CPI’s commitment to the manufacture of quality components is vitally important. Each facility adheres to meticulous and stringent procedures to maintain quality assurance to ISO 9001 standards.
The CPI manufacturing process benefits from total control and traceability of materials, within-house blending and moulding facilities through to the manufacturing and distribution of our precision engineered and quality components. All CPI’s manufacturing facilities are equipped with cutting edge production technologies of precision, automated and CNC machinery, operated by a highly skilled, experienced and dedicated work force.
CPI manufactures to the highest quality standards a full range of pistons and piston rods in stainless or alloy steels, aluminum and cast iron, for a broad range of applications and operating conditions. Experienced technical knowledge of compressor design and operation ensures that the optimum materials, surface treatments and sealing components are selected for each application. FEA analysis is used to ensure the design meets all of the highest CPI engineered standards to guarantee product integrity and quality.
All pistons and rods are inspected to assess how to proceed with reconditioning and to ensure their suitability for re-use. Piston reconditioning may include re-machining of grooves and re-anodizing. Rod reconditioning may include machining, grinding, polishing and the application of specialized spray coatings. Finally, all parts are re-assembled including CPI piston and rider rings.
»Piston manufacturing
»Piston rod manufacturing
»Specialized thermal spray and plasma coatings
»Rolled or cut threads
»Piston and rod repair and reconditioning
»Manufacturing of piston and rider rings
»Tungsten carbide coating and five alloy coating available