AJAX Engine compressors

Ajax integral engine-compressors are gas compressors with built-in two cycle
natural gas engine. The slow speed (440 rpm max), simplistic design make this
compressor highly reliable, low maintenance and easy to operate. Ajax is the
compressor of choice in its power range (105-600 KW) and it is common to see
several Ajax machines in one compressor station. Standard features include:

1. Hydraulic fuel control system: for optimum fuel efficiency.

2. Babbitt sleeve and/or Double-row tapered roller
bearings: for maximum loading in extreme application conditions.
3. Power cylinders: two-cycle, low-BMEP, chrome-plated, with fewer
parts for less maintenance. Require no gas control valves.
4. Crosshead guides: absorb (relieve) crank stresses on the cylinder
and prevent contamination of lube oil in crankcase.
5. Splash lubrication system: no oil pump, filter or cooler required
for main and connecting rod bearings. Oil-bath lubrication system is
sealed from combustion process in the cylinders.
6. Reliable ignition: solid-state, time-based ignition system without
distributor.
7. Efficient lubrication: force-fed lubrication system for power and
compression cylinders, with lube point injection and divider block.
 8. Crosshead structure with Babbitt facing at both the power and the
compressor ends.
9. Crankshaft and Connecting rods: closed-die forged in precision dies.
10. Crankcase: ribbed, cast iron construction for durability.
11. Distant piece (intermediate casing): API-Type II extra-
length design for easy rod packing maintenance.
12. High rod load and cylinder working pressure: full-load
operation through a variety of compression ratios up to 6:1 per stage.
13. Compressor cylinders: large gas passages and valve flow
areas for high efficiency.
14. High-quality differential poppet valves.
15. Cylinder clearance/loading regulation: manual, hand-wheel
type, variable-volume extra clearance pocket with indicator allows the
cylinder unloading without de-pressurizing.

The model line of Ajax compressors includes four basic models (according to the
number of power cylinders: DPC 2801, DPC 2802, DPC 2803, DPC 2804).
Maximum shaft power for the largest compressor DPC 2804 is about 600 kW.

Ajax integral reciprocating engine-compressor set consists of:

1. Integral reciprocating engine-compressor for gas compression
comprising reciprocating compressor and reciprocating gas-fueled engine
drive.
2. Integral compressor frame mount (skid). The steel skid is mounted
and secured on a foundation plate fabricated according to the
manufacturers drawings. The steel skid is built for heavy-duty service and
designed to carry reciprocating compressor with gas engine drive
including auxiliary systems and process equipment.
3. Separators (scrubbers) one set at the inlet to compression stage and
another set at the outlet from aftercooler section provide 95% efficiency
for separation of liquid droplets larger than 5 m. Each separator is
equipped with a pressure-relief valve which is mounted directly on the
separator or on the connecting piping, automatic drain valve, and
condensate level gauges for the automatic high-level emergency tripping
system.
4. Suction and discharge surge tanks are provided at the inlet and
discharge connections. Gas flow pulsations occurring during the operation
of reciprocating compressor are dampened in surge tanks and supply
pipelines which are designed and intended to suppress pressure
fluctuations up to +\-5% of the peak ratio 2.5:1 under standard gas
conditions. Discharge surge tanks are fitted with suitable connections for
drain lines, pressure and temperature gauges.
5. Oil lubrication system for compressor and engine crankcase and
power and compression cylinders comprising the following:

Lube oil crankcase for lubrication of crankshaft, bearings and

crossheads
Lube oil storage tank for lubrication of cylinder faces and gland
seals of compressor and drive rods
Main lubricator driven by crankshaft for oil supply to the cylinders
Instrumentation for lube oil system performance monitoring
Lube oil piping set
Hand pump for pre-lubrication of main bearings, connecting rod
bearings and crossheads
Pre-lubrication and lube oil pre-heating system with oil supply to
crankshaft, bearings and crossheads
Thermostatic valve
Oil level regulator and low-level switch
Pressure-relief device (safety valve)

6. ALTRONIC III Ignition System comprising the following:

Shielded, contactless, synchronized ALTRONIC III ignition system
Ignition coil
Electric wiring. All wires enclosed in protective sheath to prevent
mechanical damage
Electronic speed governor
24 V generator actuated by power transmission from the crankshaft.
7. Compressor monitoring and control system comprising the
following:
Shielded wiring, normally-open
Supervisory and indicating instrumentation
Centurion controller and a digital display of Murphy make for
monitoring (and emergency tripping) of the following parameters:
Exhaust temperature in each cylinder
Suction and discharge pressure, intermediate pressure at each
compression stage
Water temperature in compressor and engine cooling jacket
Temperature of crankshaft main bearings
Compressor discharge temperature and pressure
Liquid level in scrubbers
Failure of lube oil supply to compressor and engine cylinders
Oil level in drip pan
Crankshaft rotation speed
Starting counter
 Vibration of engine drive and air cooler.
8. Compressor drive pneumatic starting system comprising the
following:
Pneumatic motor
Set of supply piping
Ball valve
Pressure-relief valve.

9. Compressor and power drive cooling system comprising the

following:
Crankshaft-driven cooling water pump.

10. Gas air cooler of prefabricated, modular design comprising

the following:
Liquid cooler section for compressor and engine cylinders cooling
system
Compressed gas cooling section (according to the number of
compression stages)
Fan with V-belt motor drive
Set of piping and flange connections to the main lines
Casing with skid (frame) for housing all equipment above listed

11. Fuel gas injection system.

Patented, cam gear-actuated hydraulic fuel injection system
provides optimum fuel efficiency. Fuel preparation technology based
on internal carburation system makes it completely unnecessary
to employ any additional devices for reduction of hazardous
emissions. Dual ignition (with antechamber) is designed to ensure
complete fuel combustion resulting in less generation of NOx.
Air cooler located outside the main compressor skid on a separate
foundation.
12. Drive exhaust system comprising the following:
One silencer for power drive exhaust system (vertically mounted on
the common skid) with pipe connections to cylinder exhaust
manifolds.
13. Compressor piping system comprising the following:
Complete set of interstage piping for connection of compressor gas
path elements from the suction drum inlet flange to the discharge
stage outlet flanges
Complete set of control and shutoff valves
Bypass (crossover) pipeline complete with shutoff and control
valves
 Complete set of gas pressure-relief valves installed on separators or
directly on the connecting piping of compressor unit
Fuel gas pipeline complete with pressure regulator, pressure-relief
valve, fuel filter, fuel valve and pressure gauge.

Ajax 2803 for assosoated gas gathering system

Ajax 2802 compressor end view

Ajax 2802: compressor end, local control panel

Ajax 2802 local control panel on a base of Murfy controller (easy and reliable)
Ajax 2802: power end view

Ajax 2802: power end, fuel system

Ajax 2802: power end low emission application (double ignition system)
Ajax 2802 belt driven combined cooler: manual louvers for gas section (easy
and reliable)

Ajax 2802: pneumatical starter working pressure 6 barg (gas or air)

Ajax 2802 compressor cylinders with Variable Volume Pockets

Ajax 2802 in conteiner: transport application. Cooler is hydraulic driven

Ajax 2802 during assembling work at the job site small gas extraxtion area

Ajax 2802 mobile design

Ajax 2802 in stationary bloc-box. Block box has all eng system: ventilation, gas
analisysing system, firefighting system

Red Mountain Energy 2010