The device manual describes the Ajax Compressor DPC 2804 LE / Non-LE, an engine-compressor unit designed for oil and gas applications. This comprehensive manual covers installation, operation, and maintenance procedures for the Ajax series compressor frames, emphasizing safety, performance, and longevity.
Function Description:
The Ajax Compressor DPC 2804 LE / Non-LE is a reciprocating engine-compressor unit primarily used in the oil and gas industry. It functions by compressing natural gas, a critical process in gas production, transmission, and storage. The unit integrates an engine and a compressor, operating on a two-cycle principle. The engine provides the power to drive the compressor cylinders, which then increase the pressure of the gas. The manual details the basic design, including the engine and frame, piston, power cylinder, jet cell, compressor cylinder, lubrication system, piston rods, and fuel system. The two-cycle principle of operation involves distinct phases: compression, power, and scavenging, which are fundamental to its gas compression capabilities. The unit is designed for both LE (Low Emissions) and Non-LE configurations, catering to different environmental and operational requirements.
Important Technical Specifications:
The manual provides a wealth of technical data, including general specifications, power and RPMs, basic engine specifications, compressor specifications, and auxiliary systems.
- Engine Type: Two-cycle engine, integrated with the compressor.
- Model: DPC 2804 LE / Non-LE.
- Power and RPMs: Specific tables (Table 5-2) detail the power output and operating RPMs, which are crucial for performance matching and operational efficiency.
- Dimensional & Clearance Data: Tables 5-7 and 5-8 provide critical dimensional and clearance data for engine and compressor components, respectively. This includes specifications for the crankcase, main bearing journal group, power cylinder group, power piston, crosshead, connecting rod group, and compressor crosshead and connection rod group. These clearances are vital for proper assembly, operation, and wear assessment.
- Torque Specifications: The manual includes detailed torque tables for critical Ajax fasteners (Table 5-9) and general fasteners (Table 5-10). Adhering to these torque values is essential for the structural integrity and safe operation of the unit.
- Noise Data: Ajax Engine Compressor Noise Data is provided, including Sound Pressure Levels for the 2804LE model (Table 5-11) and Sound Pressure Levels Vs. Frequencies (Table 5-12). This information is important for compliance with noise regulations and for ensuring a safe working environment.
- Lubrication System: The unit features a crankcase lubrication system with oil level control and an oil control baffle. It also includes an SMX Divider Valve and a DNFT - LED Digital No-Flow Timer for precise lubrication management. Power cylinder lubrication rates are specified in Table 8-5 for DPC-2804 & LE models.
- Fuel System: A plunger-type, spill-port gas injection system is described, with details on hydraulic fluid, fluid supply tank, pump assembly, flow control valve, injection valve assembly, and bleeder cock. Gas pressure requirements and fuel injection valve adjustments are also covered.
- Cooling System: The cooling system includes specifications for engine coolant temperature and compressor cylinder cooling.
- Ignition System: The unit utilizes an Altronic III Ignition system for DPC-2804LE models, with installation instructions for the engine, rotation, flange-mount unit, and primary wiring (Table 13-1).
Usage Features:
The Ajax Compressor is designed for robust and reliable operation in demanding environments.
- Installation Flexibility: The manual details installation procedures for both permanent Ajax compressor packages and inertia-base units, including foundation preparation, grouting instructions, and setting the engine compressor.
- Keyless Flywheel Installation: Specific instructions are provided for the keyless flywheel installation and ignition timing, including finding TDC (Top Dead Center) and timing degree marks.
- Air Starting System: The unit incorporates an air starting system, with general information, product identification, and starter motor pressure ratings (Table 6-5).
- Hazardous Location Sealing: Instructions for sealing electrical fittings in hazardous locations using CHICO A Sealing Compound are included, ensuring safety and compliance in potentially explosive atmospheres.
- Start-Up Procedures: Detailed start-up procedures are outlined for both configurations (with and without bypass), covering power cylinder and compressor cylinder pre-start-up servicing and compressor purging.
- Fuel Injection Timing: Instructions for checking and adjusting gas injection timing on the DPC-2804LE engine are provided, crucial for optimal engine performance.
- Ajax Jet Cell Operation: The manual includes information on the operation and maintenance of the Ajax Jet Cell, a component likely related to combustion or emissions control.
- Low Emissions Retrofit Conversions: Procedures for Ajax Low Emissions Retrofit Conversions for specific bore sizes (13-1/4 inch and 15 inch) are included, highlighting the unit's adaptability to environmental regulations.
Maintenance Features:
The manual places a strong emphasis on preventive maintenance and troubleshooting to ensure the long-term reliability and performance of the compressor.
- Revision History: A detailed revision history (Table on page 3) tracks updates to the manual, including contact information, lubrication system details, content additions, and sealing compound instructions, ensuring users have the most current information.
- Safety Decals: The importance of visible, readable, and attached safety decals (Danger, Caution, Note) is stressed, along with instructions for replacement if damaged or worn.
- Crankcase Oil Maintenance: Procedures for crankcase oil maintenance, including oil level control and baffle maintenance, are detailed.
- Lubrication System Components: Maintenance of lubrication system components such as SMX Divider Valves and DNFT - LED Digital No-Flow Timers is covered.
- Oil Recommendations: Lubricating oil recommendations for Ajax Engine-Compressors (Ajax ES-1006) are provided, including general specifications, quality and performance criteria, ash level, viscosity requirements, and physical properties of recommended oil (Table 8-6).
- Low Temperature Operation: Procedures for low temperature operation, including a starting chart (Table 8-7), are included to ensure reliable performance in cold climates.
- Fuel System Maintenance: Maintenance instructions for the fuel system, including bleeding air before starting and adjusting fuel injection valves, are provided.
- Cooling System Maintenance: Cooler operation and maintenance, fan and drive lubrication, tube cleaning, and leak detection (plug and tube leaks) are detailed.
- Power Cylinder Assembly: Maintenance aspects of the power cylinder assembly, including power cylinder wear, air intake check valves, and piston and piston rings (with installation instructions for tapered face rings), are described.
- Piston Rod Stuffing Box: Installation procedures for both engine and compressor piston rod stuffing boxes and packing rings are covered.
- Main Bearing & Crankshaft Installation: Detailed instructions for main bearing and crankshaft installation, including lowering the crankshaft into the frame and main/thrust bearing installation, are provided. Bearing clearances and crankshaft web deflection measurements (using Plastigage®) are also included.
- Compressor Cylinder Assembly: Maintenance of compressor cylinder bodies, cylinder groups, slip liners, shrink liners, pistons, piston rings (with clearance specifications in Table 12-1), piston rods, pressure packing, and valves is thoroughly explained.
- Compressor Lubrication: Specific guidelines for compressor cylinder and pressure packing lubrication, including lubrication quantities and fire-resistant lubricants, are provided.
- Preventive Maintenance Program: A dedicated section (Section 16) outlines a comprehensive preventive maintenance program.
- Servicing for Extended Storage: Instructions for preparing the unit for extended storage and servicing it after such periods are included (Section 15).
- Technical Documentation: References to engineering standards (ES 1002, ES 1006, ES 4025) and technical information bulletins (TIB 061013, TIB-AJ-1003) are provided, offering additional resources for maintenance and specific procedures like catalytic converter installation and power piston crown height adjustment.
The manual emphasizes the importance of proper training for personnel operating and maintaining the equipment, recommending GE Oil & Gas Compression Systems LLC's AJAX Reciprocating Compressor Training. It also highlights the confidential and proprietary nature of the information contained within, intended solely for the use and maintenance of Ajax series compressor frames.
Need help?
General
To Next Page
