DPC-28021 LE Compressor Package Service Manual Contract 10330 Unit#1528 Engine Compressor Cylinders Model Serial Number Model Serial number DPC-2802LE $5081 Ts YKIIG 14033 TOS" 515" VEDAEAT 14081 Contents Vendor Bulletin No. OR ‘Ajax PartNo. Tab 1 Supplementary Documentation A) Warranty Ajax Mathematical Conversion Table TDI ANO3-147 BB) Engineering Standards Lube Oil & Low Temp Starting Recommendation Ajax ES 1006 ©) Service Bulletins ‘Trimming for Sour Gas Applications Ajax ES 13 Installation of Sheave and Flywhee} Ajax ESS-F-961 Flywheel Installation and Ignition Timing Ajax ESS-F-963, Jet Cell Operation & Maintenance ‘Ajax ESS-L-981 Jet Cell System Installation Ajax ESS-L-983 General PM Schedule Ajax IB 020326 ‘Component Wear Limits ‘Ajax ‘THB 020718 12 Ge Load vs Engine Coolant Temperature ‘jax TIB 030910 Hydraulic Fuel Injection System Purging Ajax TIB 031104 Lubrication Rates ‘Ajax ‘TIB 040910 Engine Operation with Fuel Containing H,S ‘Ajax TIB 050610 ‘Tab2 Package Drawings General Arrangement Ajax 02-00-T050-343, Tab3- Engine 'A) Operation & Maintenance Manual - Integral Engine-Compressors B) Parts Lists & Iustrations Ajax DPC.2802LE C) Ignition System Service Manual Altronic ALSM 1-94 Ignition System Installation Alltronie ‘ALIL03-02 Ignition Coil, 591 010 ‘Altronic 591 010 Ignition System Wiring Schematic Allronie 109022 ‘Tab4 Fuel Gas Supply System A) Fuel Filter/Separator Section Fuel Filter Drawing Ajax ‘TP 02-22-T05A.002 rev 2 Fuel Gas Vent Piping ‘Ajax TP 02-22-TO7A-001 Instrument Gas Pressure Regulator, 67CFR-225 Fisher Form 5469 Differential Pressure Gauge, 120-AA-00-00-30 Mid-West IM120/03 Drain Trap, 22.LD Armstrong LD-39 Level Controller, L1200 FWMurphy 2005 9124 Operation and Parts Bulletin FWMurphy 00-02-0175 Dump Valve, DVUISO 2003 6222 ‘0 &M Instructions Murphy (0-02-0483‘Tab4 Fuel Gas Supply System (cont) B) Main Fuel Section Fuel Gas Piping Drawing Regulator, Main Fuel, O & M Instructions, Type 627 Fuel Shutoff Valve, M2582, 1", O & M Instructions ©) Precombustion Chamber (LE) Fuel Section Pressure Regulator, Precombustion Chamber Fuel Operation & Maintenance Instructions, Type 64 Shut Off Valve, Precombustion Chamber Fuel Operation & Maintenance Instructions, Type 119 D) Start System TDI Literature Installation & Operation Manual Service Manual Performance Curve, Natural Gas ‘Tab 5 Cooling System Coolant System Drawing Compressor Cylinder Cootant System (Throw #1) Pump Mounting Assembly Drawing F1 820AM Pump, Iilustrated Parts List (8” Impeller) Pump Maintenance Bulletin Pump Lubrication Guide ‘Thermostatic Control Valve Bulletin Butterfly Valve, 2", Operation & Maintenance Bulletin Tab6 Cooler & Drive Cooler Drive Components Cooler Drawing, C72B Cooler Spec Sheet Parts List ‘Suggested Startup Procedure Operation and Maintenance Instructions Fan O & M Bulletin ‘V-Belt Drives, Installation & Maintenance Tab7 Compressor Performance Request Form Ilustrated Parts List, 15” cylinde Ilustrated Parts List, 10.5” x 5.75” cylinder Ilustrated Parts List, YVD/YVS-30-10 Rod Packing Manual ‘Tab 8 Process Gas Equipment Process Control Tubing Schematic Level Controller, L1200 Operation and Parts Bulletin, Dump Valve Assembly, DVU-175 ‘Dump Valve Operations Manual Relief Valve Vent Piping Relief Valves and Fittings Bypass Piping ‘Valve O & M Instructions Ajax Fisher FwWMurphy Fisher Fisher I TDI TDI Ajax ‘Ajax ‘Ajax Peerless Peerless DEMCO Ajax ACE ACE ACE ACE ACE Moore ‘TBWoods Ajax Ajax Ajax ‘Ajax C.Lee Cook Ajax EWMurphy FWMurphy Ajax Murphy Ajax Ajnx Ajax WKM ‘TP 02-22-TOIC-001-150 5252 M-7980N, 1245 5204 TI-702, rev TI-701 ‘ANO00-642 8/00 TP 02-04-TO1A-001 rl 02-04-T02A-001 TP 02-04-T03A-001 4845749 4852918 Te1s12 02-03-T020-301 05158-C 3087A, 051580107 ‘TMC-704 VBDIM G-0000 DAEAT-0000 TPB TU (02-18-T020-318 2005 9124 00-02-0175 ‘TP 00.06-T01A-001 rev 2 (00-02-0483 ‘TP 02-48-T010-333 02-17-T020-332 TP 02-50-T010-318 TC-1473Tab9 Control Panel & Instrumentation ‘A) Conduit & Sensor Assembly Vibration Switch & Conduit Liquid Level Switch O & M Bulletin B) Instrument and Control Panel ‘Annunciator, TTDI-IGN-T ‘Temperature Scanner, TDX6-BFK Pressure Swichgage, OPL. Pulsation Dampener Differential Pressure Swichgage Pressure Regulator, Model 67CR-206, ©) Safety Control Panel Troubleshooting Techniques ‘Tab 10 Lubrication System Drain Piping Lube Oil Supply from Off Frame Reservoir Lube Op System Schematic Lubrication Monitor, Operation & Wiring Bulletin SMX Divider Valve Bulletin Proximity Switch, Bulletin Rupture Disc Drawing. Lubricator Pump, Model P-SSUR, "4" Lubricator Pump, Model P-SSUR, %" Crankcase Oil Level Controller & Switch, O&M Bulletin Tab 11 IGTB RPM Control IGTB Operation & Problem Diagnostics VI System Junction Box Assembly VI System Junction Box Wiring Schematic V1 System Panel Mounting. Alternator Output vs Engine RPM w/5.33:1 Ratio Alternator Installation Instructions ‘Alternator Service Instructions " Used with permission Ajax ‘Ajax Murphy Murphy Murphy Murphy Murphy Murphy Murphy Fisher ‘Murphy Ajax Ajax Progressive Progressive Progressive Deliron Ajax © 2000! FWMurphy Ajax ‘Ajax ‘Ajax ‘Ajax ‘Ajax Altronic Alltronic ‘TP 02-32-TOIC-003, TP 02-32-TO2A-001 14 00.02.0175 50-30-4718 TTDI-99062N TDX-9110N 00-02-0161 PD-95145B -95033N 5469) TP 02-23-T01A-001 r0 ‘TP 00-24-TO1A-001 10 2802-G-DAEAT-NO DLM926-PM 169LIT D-PRXSW BM-21138 BM-21136-1 BM-21137-1 LM-92164N ‘TP 1300-000 r2 ‘TP YAE-5583 12 TP BM-21161-C 13i 02-19-TOLA-001 12 11-24-03 ALTIT2-01 A24 SI2-01Section 1WARRANTY ‘Warranties To Original Purchaser (Non-Transferable). 8) "Material and Workmanship Warranty”: The Seller warrants to the Purchaser that the Equipment of Seller’s own manufacture 10 bee supplied hereunder will be complete in all its parts, and, for the Warranty Period - The warranty period shall extend for 12 months from date of start-up, but shall not exceed 18 months from date of shipment from factory. Warranty Period specified will be free from defects in material or workmanship caused by the Seller and arising under normal and proper operating conditions; and that such Equipment will be delivered free from any lawful security interest or other lien or encumbrance known to the Seller, except security interests or other liens or encumbrances arising hereunder. The obligation of the Seller and the Purchaser's sole and exclusive remedy hereunder shall be limited atthe Seller's option: 1) To replacement or repair of any Equipment or parts thereof which are retumed to the Seller's works within the Warranty Period, transportation charges prepaid, 2) Should the Equipment or parts thereof be determined by the Seller to be so defective, however, as to preclude the remedying of warranty defects by replacement or repair, the Purchaser's sole and exclusive remedy shall then be a refund of the purchase price, less a reasonable charge for any utilization of the Equipment by Purchaser. 3) Nothwithstanding the foregoing, the Seller shall have no obligation as a result of improper storage, installation, repairs or modifications not made by the Seller, or as a result ‘of removal, improper use, or misapplication of the Equipment after it has been delivered to the Purchaser. 4) Purchaser shall pay freight charges in connection with the return ot replacement of the defective Equipment or parts. b) "Performance Warranty"; The Seller warrants that the Equipment of its own manufacture, when shipped and/or installed, will operate within any performance characteristics which are expressly specified herein as a performance ‘guarantee. Any performance characteristics indicated herein which are mot expressly stated as guarantees are expected, but not guaranteed". When factory testing is conducted for ‘measuring any performance guarantee of the Equipment purchased, then certified test results verifying any such ‘guarantees shall be considered both by the Purchaser and the Seller as conclusive. The Purchaser may have a representative present when such factory tests are conducted,9 if requested at the time an order is placed. Should Purchaser desire to conduct a field performance test to verify any performance guarantee, such test must be conducted by Purchaser, at his expense, within thirty (30) days from the date of inital start-up of the Equipment, and in accordance with the appropriate ASME Power Test Code, except as ‘otherwise agreed in writing by Seller. Seller shall be entitled to have a representative or representatives present to witness such test and Purchaser shall reimburse Seller for the time ‘and expense of such representatives at the Seller's service tates then in effect at the time of the test. Purchaser shall, sive Seller fifteen (15) days written notice prior to the date Purchaser intends to commence such test. If the ficld performance test is not conducted within the aforesaid period all performance guarantees shall be deemed to have been ‘met. In the event any Equipment performance guarantee which is to be verified by the field performance test is not successfully demonstrated within thirty (30) days from the ‘commencement of such test, the obligation of the Seller and the Purchaser's sole and exclusive remedy hereunder shall be that set forth in paragraph (a) above. "OSHA" Warranty": The Seller warrants for installations within the United States that Equipment of its own ‘manufacture, when shipped, will be in compliance with the Occupational Safety and Health Act, and any and all amendments thereto and regulations promulgated thereunder that may be in effect as of the date of the Seller's quotation insofar as said law and regulations may pertain to the physical characteristics of the Equipment “provided however", the Seller does not warrant such compliance with respect to the circumstances of use of said Equipment and “provided further’, the Seller makes no warranty with respect to the noise level of said Equipment, when put into operation, since such noise levels will be influenced by and dependent upon the environment into which the Equipment may be placed. The Seller's obligation and the Purchaser's sole remedy with respect to this warranty shall be providing notice of any such non-compliance is given within one year from the date of delivery of said Equipment to Purchaser, 10 repair or replace any part of said Equipment that is proven to Seller's satisfaction not to have been in compliance with the ‘Act as amended and regulations thereto in effect as of the date of quotation or, if it be determined by Seller that the Equipment or parts thereof cannot be repaired or replaced in such a manner as to put the Equipment in compliance, Purchaser's sole and exclusive remedy shall then be a refund of the purchase price less a reasonable charge for any utilization of the Equipment by Purchaser. Purchaser shall pay freight charges in connection with the retum or replacement of any Equipment or parts that are found not to be in compliance.a ° DAMAGES. "IN NO EVENT SHALL SELLER BE LIABLE FOR SPECIAL, CONSEQUENTIAL OR INCIDENTAL DAMAGES, NOR FOR LOSS OF ANTICIPATED PROFITS NOR FOR LOSS OF USE OF ANY EQUIPMENT, INSTALLATION SYSTEM, OPERATION OR SERVICE INTO WHICH THE GOODS OR PARTS MAY BE PUT, OR WITH RESPECT TO WHICH ANY SERVICES MAY BE PERFORMED BY SELLER". "THIS LIMITATION ON Notwithstanding the foregoing, the Seller shall have no obligation under this warranty as a result of installation, repairs or modifications not made by the Seller, or as a result of removal, improper use, improper operation, or mis- application of the Equipment after it has been delivered to the Purchaser. “Warranty As To Equipment Not Made By The Seller’ Equipment parts and accessories made by other manufacturers and supplied hereunder by the Seller are warranted only to the extent of the original manufacturer's warranty to the Seller. “EXCEPT AS SET FORTH HEREIN, AND EXCEPT AS TO TITLE IT IS EXPRESSLY AGREED "THAT THERE IS NO IMPLIED WARRANTY OF MERCHANTABILITY, NOT OTHER WARRANTY, EXPRESS, IMPLIED, OR STATUTORY, NOR ANY AFFIRMATION OF FACT, OR PROMISE BY THE SELLER WITH REFERENCE TO THE EQUIPMENT OR PARTS THEREOF, OR OTHERWISE, WHICH EXTENDS BEYOND THE DESCRIPTION OF THE EQUIPMENT AS SET FORTH HEREIN, AND (2) THAT THE PURCHASER ACKNOWLEDGES THAT IT IS PURCHASING THE EQUIPMENT SOLELY ON THE BASIS OF THE COMMITMENTS OF THE SELLER EXPRESSLY SET FORTH HEREIN". SELLER'S LIABILITY SHALL APPLY TO ANY LIABILITY FOR DEFAULT UNDER OR IN CONNECTION WITH THE GOODS, PARTS OF UNIT SALES OR SERVICESDELIVERED HEREUNDER, WHETHER BASED ON WARRANTY, FAILURE OF OR DELAY IN DELIVERY OR OTHERWISE". "ANY ACTION FOR BREACH OF CONTRACT HEREUNDER MUST BE COMMENCED WITHIN ONE YEAR AFTER THE CAUSE OF ACTION HAS ACCRUED".TDI TuRBOTWIN™ Engine Air Starters IDI MATHEMATICAL CONVERSION TABLE UNITS | TO CONVERT INTO MULTIPLY BY P R | Bars PSIG 14.5 E | Kilograms/Sq. Centimeter PSIG. 14.22 S| Kilopascals PSIG 0.145 s_ |PsiG Bars 0.069 U_ |PSIG Kilograms/Sq Centimeter (Kg/em) | 0.070 R_ {PSIG Kilopascals (Kpa) 6.895 E Liters Cubic Inches (in®) 61.023 Vv | Gallons Cubic Inches (in°) 232.56 © | Gallons Cubic Feet ft") 0.135 | Cubic Centimeters Cubic Inches (in*) 0.061 U_—_| Cubic Inches Liters (L) 0.0164 M_ | Cubic Inches Gallons (Gal) 0.0043 E | Cubic Feet Gallons (Gal) 7.413 Cubic Inches Cubic Centimeters (cm*) 16.39 T __| Newton Meters Foot Pounds (Ft-Ib) 0.7376 0 | Kilogram Meters Foot Pounds (Ft-Ib) 7.233 R__| Foot Pounds Newton Meters (N-m) 1.356 Q__| Foot Pounds Kilogram Meters (K-gm) 0.1383 U Kilogram Meters Newton Meters (K-gm) 9.807 E F __| Standard Cubic Feet per Minute | Cubic Meters/Hr (mm/h) 1.70 + Cubic Meters/Hr ‘Standard Cubic Feet per Minute 0.588 © | Standard Cubic Feet per Minute (SCFM) 0.0750 w Pounds per Minute (Lb/Min.) Pp © | Horsepower Kilowatts (KW) 0.746 W | Horsepower Ftbsp/Second 550.0 E | Kilowatts Horsepower (HP) 1.340 R ‘ANO3-147 9/97‘Cooper Cameron Corporation Ajax Superior Cooper-Bassemar Reciprocating Products Division Engineeting Standerde 10 20 3.0 LUBRICATING OIL RECOMMENDATIONS FOR AJAX ENGINES - COMPRESSORS GENERAL 1.1 The lubrication of Ajax equipment requires the use of premium quality lubricating oils designed specifically for natural gas 2-cycle engine - compressor service, This standard describes oils which have proven successful in field use, 1.2 Customers operating engines with exhaust catalyst systems, fuels with high sulfur contents, landfill ‘gas, unusual fuels or non-traditional applications should contact Ajax Engineering for lubricant and ‘maintenance recommendations. 1.3. Recommendations for compressor cylinders and piston rod packing are found in Engineering Standard ES-1002. QUALITY AND PERFORMANCE 2.1 Satisfactory oil quality is the responsibility of the refiner, blender or rebrander. Only reputable ‘companies with proper service organizations should be used as suppliers. 2.2 Cooper Energy Services does not guarantee the quality or performance of lubricating oils. 2.3 Cooper Energy Services does not endorse particular brands of oil. For customers convenience, {information on oils by brand name is maintained by Cooper Energy Services. Customers are invited to advise Ajax Engineering or service representatives what brands of oils ate preferred. Cooper Energy Services can then cite the oils which have given satisfactory service in similar applications. GENERAL SPECIFICATION: 3.1. A general description of oils suitable for use in Ajax equipment is an ashless oil specifically formulated for 2-cyele natural gas engines with the following properties: 3.2 Physical Properties: ‘Viscosity Index: 70 Minimum ‘ASTM D2270 Flash Point: | 400°F (204°C) Minimum | ASTM D92 Pour Point: 10°F (12°C) Maximum | ASTM D97 3.3. Ash Level: Ashless oils with a sulfated ash content of up to 0.1% maximum by ASTM D 874 are preferred. Oils with ash levels up to 0.8% may be used, but they may cause combustion chamber deposits, especially if they contain more than 0.04% by weight zinc. ES 1006. newApex Superior Cooper-Bestemer Reciprocating Products Division Engineering Standards 3.4. Viscosity Requirements: @ Ajax equipment uses a splash lubrication system to lubricate the compressor crosshead. Lubricating oil must be sufficiently fluid at the ambient temperature in order to lubricate the crosshead properly. Multigrade oils may be used to provide proper lubrication at low temperatures. The following chart should be used to select the proper viscosity grade for the lowest ambient temperature expected. Oil Selection tor Ambient Temperature Prectidatentcttlehitl acaba ed eansiereaab [__ SAE 30 (Preferred) SAE 40 SAE 15W-40_ 0 20 40. 60 80 100 120 Lowest Expected Temperature (F) 4.0 LOW TEMPERATURE OPERATION oe 4.1. If frequent cold weather starts are necessary, contact your local Aftermarket sales office for information about heated prelube systems for your engine. 4.2. The following procedures are recommended to warm the engine and oil in cold weather to prevent damage due to insufficient oil flow. Starting the engine and allowing it to run with the oil too cold to flow will result in severe engine damage. 4.2.1 Units Down Less Than 5 Hours: 4.2.1.1 For units that have been down less than 5 hours and the ambient temperatures have been above 40°F, idle (minimum 300 RPM) the unit for 20 minutes, then run 15 minutes with a light load before fully loading the unit 4.2.1.2 For units that have been down less than 5 hours and the ambient temperatures have been 40°F or below, idle (minimum 300 RPM) the unit for 30 minutes, then run 30 minutes with a light load before fully loading the unit. 4.2.2 Units Down More Than 5 Hours: 4.2.2.1 The following procedure is for a unit that has been down more than five hours. This procedure will allow the unit time for thermal expansion in order to maintain sufficient Tunning clearances. Ba Deca Tasaea by sores | ot vee ar 72/1‘Cooper Cameron Corporation Alex-Superionr Cooper-Bessemer Reciprocating Products Division Engineering Stendarde e@ 4.2.2.2 To properly warm the unit, find the overnight low ambient temperature in the first column of chart below. Start and idle the unit at 300 RPM for the number of minutes required for the overnight low ambient temperature. Then shut the unit down the number of ‘minutes required. Repeat this sequence the number of times listed. Continue in this ordec until you have met the requirements for that temperature range. This procedure will allow ‘components such as the crossheads, pins, bushings and bearings sufficient time for expansion to maintain proper running clearances. 90 to 70°F (32 to 21°C) [69 t0'5OPF (20.t0.10.°C) | ‘49 to 40°F (9 to 5°C) 31 to 18°F (1 to-7°C) 47. = 2 3 No Load +1 to -20°F (-18 to -28°C) e a No boats Refer vo Paragraphs Mans Rater to Pare 16 15. 3 No Load 30. 1 No Load 60 o 1 45AJAX-SUPERIOR Cooper Energy Services ENGINEERING STANDARDS e TRIMMING SUPERIOR AND AJAX COMPRESSORS FOR SOUR GAS APPLICATIONS IN LUBRICATED SERVICE 1.0 PURPOSE 1.1 Todefine and clarify the compressor design criteria to be used in applying compressors in sour gas service to prevent the occurrence of sulfide stress corrosion cracking and untimely failure of compressor components, 1.2 To establish compressor design criteria that follows the guidelines of API 11P and NACE ‘MRO175 for sour gas service. 1.3. Toestablish Ajax and Superior Packaging design criteria that follows the giridelines of API 1P and NACE MRO175. 1.4 To establish and define different levels of protection depending upon the customer's requirements. 14.1 The standard protection level will be per guidelines established by API 11P and described in Section 4.0. 1.42 For more rigid protection requirements the guidelines used will be NACE MRO175 ‘and described in Section 5.0. This stricter protection may be needed to comply with stricter regulatory controls or customer requirements. 143 Since the customer knows the application details of his process much more thoroughly than Ajax-Superior, the customer may determine that higher levels of HSS trim are required and opt to buy those. Ajax-Superior will make every effort to accommodate those special requirements. 20 APPLICATION 21 These guidelines apply only to lubricated compressor units; requirements will be different on a non-lube compressor and will be decided on an individual basis. 2.2 Section 4.0 designates the trim requirement when units are designed to the guidelines of API uP. + Section 4.1 for H.S concentrations up to and including 2% by volume and apply to Ajax and Superior model compressors including RAM and JOY. + Section 4.2 for ELS concentrations between 2 - 5% (Level 1-11P) and apply only to Ajax and Superior model compressors including RAM. + Section 4.3 for H,S concentrations greater than 5% (Level 2-11P) and apply only to Ajax and Superior model compressors including RAM. eq = om 5. eA ‘WN ace WissenCooper Energy Services 30 AJAX-SUPERIOR ENGINEERING STANDARDS 23. Section 5.0 designates the trim requirements when units are designed to more nearly meet the guidelines of NACE MRO175 and apply only to Ajax and Superior model compressors including RAM. 24 Section 6.0 designates the trim requirements for Ajax Packaging when it is designed to meet the guidelines of API11P. 25 — Section 7.0 designates the trim requirements for Ajax Packaging when it is designed to more nearly meet the guidelines of NACE MRO175 and more stringent customer requirements. 2.6 When CO, concentrations greater than 5% are present with an HS concentration greater than 2%, the units should be trimmed per the Level 2-11P requirements in Section 4.3 as a ‘minimum. In addition, the requirements in Section 7.0 of CO, trim standard (E514) will be required. RESPONSIBILITIES 3.1 Marketing's responsibilities are: 3.14 To acquire reliable gas analysis; and to identify, to both engineering and the ‘customer, all sour gas applications as early as possible (hopefully in the pre-quotation stage). 3.1.2 Tobe familiar with the various requirements set herein. 31.3. Toprice all sour gas units appropriately. 3.14 Toeducate the involved customers and end-users on theit responsibilities concerning the maintenance and operational procedures to be used for sour gas compressors. 32 Engineering's responsbbilities are: 321 To define and specify properly designed components in accordance with the guidelines set herein. 3.2.2 Toreview all sour applications forwarded by Marketing and assist them as required in tailoring individual applications to requirements. 323. Toset the standards for design and proper maintenance and keep them updated as the “state-of-the-art” advances. 3.24 To assure that copies of this standard as well as Engineering Standard BS1002 for Superior products and ESS-L-811 and ESS-L-168 for Ajax products are properly distributed in instruction manuals for sour gas units. Dai ES13 [22 Srv — Ta ‘Gavan Papel WN ShaeAJAX-SUPERIOR Cooper Energy Services ENGINEERING STANDARDS @ 33 Responsibilities of the customer: 33.1 To advise Ajax-Superior Sales and Marketing when the recommended trim requirements in this specification are not considered adequate and to negotiate what is required prior to order release. 33.2 To maintain the sour gas compressors in accordance with the standards set herein and to adhere to the particular minimum lubrication recommendations specified. 33.3 To assure that maintenance and operating procedures are well understood and followed and that all required safety training and safety procedures for handling sour gas have been addressed. Those safety procedures must be enforced for all persons working at or visiting the unit site. 40 STANDARD TRIM REQUIREMENTS: Unless otherwise required by specific customer requirements, sour gas units will be trimmed using the guidelines of the latest edition of API 11P. Exceptions to this can occur on an individual basis when either high H,S levels exist or other constituents are present which affect the trim. 4.1 Hydrogen sulfide (H,S) concentrations up to and including 2% by volume. 4.1.1 For any concentration of HS below .005% (50 ppm) no special requirements are necessary relative to the trimming of the equipment. e 4.1.2 For any concentration of H,S from .005% (50 ppm) up to and including 2% by volume in lubricated service special trim will not be required. Standard material is acceptable and special lubrication practices are recommended. 4.13 The frame lubricant used must have a total base number (TBN) of 15 or higher to help prevent the lubricant from turning acid and damaging bearings and bushings. This alkalinity must be maintained during operation in the machine by appropriate timely makeup or complete oll changes. At no time should the lubricant TBN be less than approximately 30% of the original TBN number. 4.14 The frame lubricant must meet or exceed the requirements of MIL-L-2104B, ‘Supplement No. 1. 4.15 A complete oil analysis program on the frame lubricant is required to determine proper oil change intervals as well as to monitor the condition of the lubricant and the ‘unit. 4.16 Compressor cylinder lubricants must adhere to the requirements of Ajax-Superior Engineering Standard ES1002 for Superior models and ESS-L-811 and ESS-L-168 for Ajax models. Viscosities are to be on the high side of the pressure conditions normally required and a 3 to 8% compounding with acidless tallow (similar to steam cylinder oils) is also required. = SSE SE SE = = SS | == ee Oh z.| [vac inde A Mendy =| 8 se Te Wanen "Twit banar Wowie [AR Mant SeatBete ie te tee eee ee eee cee ccc AJAX-SUPERIOR Cooper Energy Services ENGINEERING STANDARDS 42 417 418 419 41.10 41 41.12 41.3 ‘The compressor cylinder lubricant rate is to be double the normal rate for equivalent ‘non-sour gas applications. Brass, bronze, copper, and other copper alloys shall not be used on hardware for gas. ‘wetted parts. On external components, and other components that are not normally gas wetted, yellow metals are to be avoided where practical or as specified by agreement with the customer. This requirement shall be followed for units and Packages. Section 6.0 and 7.0 defines yellow metal removal requirements for Ajax Packaging. ‘The compressor distance pieces are to be properly vented in accordance with local safety standards to provide maximum safety to personnel. Soft iron or aluminum gaskets are to be used between the valve and valve seat. ‘The "O-ring" material used for standard Superior equipment is Viton (Spec. 473) and this is also acceptable for H,S service. For Ajax compressor cylinders, the standard "O-ring" material is Neoprene. For Ajax Packaging requirements in this level, see Section 6.0 and 7.0 of this standard. For RAM compressors, an auxiliary distance piece or an acceptable purged packing, design is required to keep cylinder oil from contaminating the frame oll. For Ajax and Superior models, the standard crosshead guide/distance piece is acceptable, Level 1-11P Trim (2-5% H,S) 421 422 423 Concentrations of H,S from greater than 2% up to and including 5% by volume. Alll of the special requirements already discussed apply plus the additional requirements listed in Section 4.2. ‘A suitable corrosion inhibitor should be added to the cylinder lubricating oil as defined by the user's oil manufacturer. Distance Piece: For Ram compressors, an auxiliary distance piece is required. For Ajax and Superior models, the standard crosshead guide/distance piece is acceptable. For Superior compressors, oil slingers are to be used where adequate space is ES13 Pome‘AJAX-SUPERIOR Cooper Energy Services ENGINEERING STANDARDS: 426 427 428 429 4.2.10 4241 4.2.12 available on each compressor rod in the distance piece compartment to assure that none of the HS contaminated cylinder or packing lubricant works its way back into the crankcase and contaminates the frame lubricating system. An auxiliary distance piece may be required for this application. For RAM units, oil slingers are not required, but can be added as an optic permits. For Ajax compressors, oil slingers ate not required. Cylinders mounted on Joy frames are excluded from this requirement. Packing and Piston Ring: Packing and piston ring material shall either be non- metallic or contain no copper bearing metals, Compressor Valve: Compressor valves will be standard construction and hardness. Carbon Steel Parts: All carbon steel, alloy steel, or 12CR steel parts which are gas wetted (come in contact with the process gas stream) are to have a maximum hardness of 22 HRC. This is to inchide all internal fasteners and V.V. pocket screws, but excludes compressor valve assembly fasteners. Piston Rod: The piston rods are to be either AISI 4140 alloy steel with a hardness of 15-22 HRC (Heat Treat Spec H2S) or Custom 450 stainless steel with a hardness of 30- 34 HRC (Heat Treat Spec Z) or 17-4 PH (Spec 246-A) stainless steel with a hardness of 28-33 HRC (Heat Treat Spec ZA). The reduced hardness 4140 material will have lower mechanical properties and for some Superior compressors will require deration of the rod load capacity of the machine as detailed in Ajax-Superior Engineering Standard ES11. Using the Custom 450 or 17-4 PH material will not require deration. For Ajax cylinders deration is not necessary unless specified by Engineering, Piston Rod Coating: Piston rods must be coated in the packing area. For Superior rods tungsten carbide coating is used. For Ajax rods Colmonoy coating or tungsten carbide coatings are used. Forged Steel Cylinders: Forged steel cylinder bodies made of AIST 1045, 4140, or low alloy steel are to have a maximum hardness of 235 HB. Engineering will evaluate these applications on an individual basis as some cylinder pressure ratings may have to be reduced because of the mechanical properties restrictions. Piping and Vessels: All process piping, pulsation drums, scrubbers and coolers will comply with NACE MRO175 and shall have a minimum 1/16" corrosion allowance. This requirement is the packager's responsibility. Section 6.0 and 7.0 defines Ajax Packaging requirements in this level. Instrumentation: All instrumentation that comes in contact with the process stream, ‘het Eagan’ | Oa a ES 13 A SeabateAJAX-SUPERIOR Cooper Energy Services ENGINEERING STANDARDS 43 (liquid level controls, shutdowns, bourbon tubes, process valving, relief valves, etc.) shall be suitable for corrosion gas service (i.e. plated fittings are acceptable). This requirement is the packager's responsibility. Section 6.0 and 7.0 defines Ajax Packaging requirements in this level. Level 2-11P Trim (5% H,S) 43.1 43.2 433 434 Concentrations of H1,S greater than 5% by volume. [All of the special requirements already discussed in Level 1-11P apply plus the additional requirements listed in Section 4.3. ‘Compressor Valves: Valve seats, guards, and valve bolts made of carbon steel or AIST 4140 alloy steel shall have a maximum hardness of 22HRC (Heat Treat Spec H25). ‘This may reduce the pressure differential capability of specific valve designs and thus the pressure differential capability of the cylinders. Engineering will evaluate these on an individual basis and select appropriate alternative valve designs to meet the application requirements. For Superior compressor valves free-machining carbon or alloy steel material shall not be used for this level H,S. For Ajax compressor valves, free machining material shall be used unless H,S levels warrant special Engineering selections. ‘This reduced hardness requirement also includes steel valve cages (retainers) when they are used. ‘Compressor valve components may also be made of AISI 416 stainless steel with a maximum hardness of 2HRC. ‘Compressor Valve Plates: Valve plates wherever possible are to be plastic to better prevent seat wear against the softer valve seats. For discharge temperatures to 280°F,, glass filled nylon plates (Spec 484A) can be used; for higher discharge temperatures, PEEK (Spec 490) material can be used as the non-metallic plate. ‘When metallic plates are required Inconel X-750 (Spec 241) will be used Compressor Valve Springs: The standard 17-7PH valve spring material will be used. Distance Piece: For Ajax and Superior model compressors, two compartment configura-tion is required with pressure packing located between the distance piece and the compressor frame. This means an auxiliary distance piece must be added to the standard crosshead guide/distance piece. The outer compartment must be purged with inert gas to a pressure of 3-5" H,O (see Section 4.3.10). The inner compartment can either be separately vented or purged with inert gas to a pressure 0f 35° H,0. ES 13, Geert ‘Cie Ergheer Poesia latAJAX-SUPERIOR Cooper Energy Services ENGINEERING STANDARDS. e The packing case is to be tubed to an extemal point on the distance piece for these models. For Ram compressors, purging is required for the auxiliary distance piece. 43.7 Compressor Fasteners: All compressor cylinder and distance piece critical bolting, ‘capscrews, studs, and nuts which come in contact with the process gas stream shall ‘conform to ASTM A193-B7M (bolts and studs) and ASTM A194-2HM (nuts). 438 Piping and Vessels: Unless otherwise specified by the purchaser, all process piping, pulsation drums, scrubbers, and cooler headers will be 100% radiographed and post heat-treated and shall have a minimum 1/8" corrosion allowance. Threaded connections over 3/4” are not allowed. 100% ASME inspection criteria is to be used. This requirement is the packager's responsibility. Section 6.0 and 7.0 defines Ajax Packaging requirements in this level. Also, for Ajax Packaging threaded connections up to and including one inch will be specified; all ‘connections above this shall be flanged. 4.39 Instrumentation: Alll instrumentation that comes in contact with the process stream. (iquid level controls, shutdowns, bourdon tubes, process valving, relief valves, etc.) shall meet the full requirements of NACE MRO125 except stainless steel tubing fittings are required. This requirement is the packager’s responsibility. @ Section 6.0 and 7.0 defines Ajax Packaging requirements in this level 4.3.10 Purge Systems: The distance piece shall be purged with inert gas. The packager is responsible for purging per these requirements. If other venting or purging systems are desired, the details are to be negotiated between the purchaser and the packager (Le. vacuum systems, or sweet natural gas purge). The final detailed system should provide for the safety of persons around the equipment and should prevent contamination of the frame oil with sour gas. Packing cases will not be purged unless required by the customers. 43.11 Cooler Tubes: The gas cooler tubes shall be furnished in 304 or 316 stainless steel This requirement is the packager's responsibility. ‘Section 6.0 and 7.0 defines Ajax Packaging requirements in this level 5.0 ENHANCED H,S TRIM REQUIREMENTS 5.1 These sections cover H,S trim requirements based on guidelines established by NACE MRO175. These sections specify more rigid H,S trim levels than required for standard API UIP trim. 5.2 Whena customer requires H.S trim in excess of API-11P for requirements meeting NACE the Ajax and Superior equipment will be trimmed using the guidelines known as Class IV and described in the remaining sections. eo = tu Sad. | __ Won haceAJAX-SUPERIOR Cooper Energy Services ENGINEERING STANDARDS 5.3 This enhanced level of trim can be used for any concentration of H,S as required by the customer. Trimming to this level may be required for even very low concentrations of H,S. (600 ppm) if regulations controlling the equipment require strict adherence to NACE MRO175, 54 ClassIVH,S Trim, S41 52 543 54d 545 546 547 548 549 A suitable corrosion inhibitor should be added to the cylinder lubricating oil as defined by the user's oil manufacturer. Al the special requirements specified and recommended in Section 4.1 of this standard should be followed. ‘The cylinders are to be equipped with a suction flushing system (injection of cylinder lubricating oil into the suction nozzle of each cylinder). ‘Two compartment distance pieces are required. The outer compartment must be purged with inert gas to a pressure of 35" H,O (See Section 5.4.16). The inner ‘compartment can either be separately vented as described previously or purged with inert gas to a pressure of 3-5” H,O. For Superior model compressors, oil slingers are to be used where adequate space is available on each compressor rod in the distance piece compartment to insure that none of the HS contaminated cylinder or packing lubricant works its way back into the crankcase and contaminates the frame lubricating system. For Ajax model compressors, oil slingers are not required. ‘Compressor valve springs are to be Inconel. Packing garter springs are to be Inconel. Piston Rod: The piston rods are to be either AISI 4140 alloy steel with a hardness of 15-22 HRC (Heat Treat Spec H2S) or Custom 450 stainless steel with a hardness of 30- 34 HRC (Heat Treat Spec Z), or 17-4PH (Spec 246-A) stainless steel with a hardness ‘of 28-33 HRC (Heat Treat Spec ZA). The reduced hardness 4140 material will have lower mechanical properties and for some Superior compressors will require deration Of the rod load capacity of the machine as detailed in Ajax-Superior Engineering Standard ES11. Using the Custom 450 or 17-4PH material will not require deration. For Ajax cylinders deration is also not necessary unless specified by Engineering. ‘Tungsten carbide coating is required in the packing travel area of the Superior piston rods. For Ajax rods Colmonoy coating or tungsten carbide coatings are used. Compressor Valves: The valve seats, guards, and valve bolts are to be made of carbon steel or AISI 4140 alloy steel with a hardness of 22 HRC maximum (Heat Treat Spec H2S). This may reduce the pressure differential capability of the cylinders.AJAX-SUPERIOR Cooper Energy Services ENGINEERING STANDARDS e Engineering will evaluate these on an individual basis and select appropriate ‘alternative valve designs to meet the application requirements. For Suy and for Ajax guards and seats in this classification, free machit Ferorror scp atedl shall pat be used eee Compressor valve components may also be made of AISI 416 stainless steel with a maximum hardness of 22 HRC. ‘This reduced hardness requirement also includes steel valve cages (retainers) when they are used. 54.10 Forged Steel Cylinders: Forged steel cylinder bodies are to be made of AISI 1045, 4140, or low alloy steel with a maximum hardness of 235 HB. Engineering will evaluate these applications on an individual basis as some cylinder pressure ratings may have to be reduced. 5.4.11 Carbon Stee! Parts: All steel gas wetted parts are to have a maximum hardness of 22 HRC. This is to include all internal fasteners and V.V. pocket screws, and also includes compressor valve assembly fasteners. 5.4.12 Compressor Valve Plates: Valve plates, wherever possible, are to be plastic to better prevent seat wear against the softer valve seats. For Superior compressors with discharge temperatures to 280°F. glass filled nylon plates (Spec. 484A) can be used; for higher discharge temperatures, PEEK (Spec. 490) material shall be used as the e won etal For all RAM and Ajax cylinders, Peek material shall be used at all temperatures. When metal plates are required, Inconel X-750 (Spec. 241) shall be used. 5.4.13 Compressor Fasteners: All compressor cylinder and distance piece critical bolting, capscrews, studs, or nuts which come in contact with the process gas stream shall conform to ASTM A193-B7M (bolts and studs) and ASTM A194-2HM (nuts). 5414 Piping and Vessels: Unless otherwise specified by the purchaser al process piping, pulsation drums, scrubbers and cooler headers will be 100% radiographed and post heat-treated and shall have a um 1/8" corrosion allowance. Threaded connections over 3/4” are not allowed. 100% ASME inspection criteria is to be used. This requirement is the packager's responsibility. Section 7.4 defines the Ajax Packaging requirements in this level. Also, for Ajax Packaging, threaded connections up to and including one inch will be specified; all connections above this shall be flanged. 5.4.15 Instrumentation: All instrumentation that comes in contact with the process stream (quid level controls, shutdowns, bourbon tubes, process valving, relief valves, ete.) all meet the full requirements of NACE MRO175 except stainless steel tubing fittings are required. This requirement is the packager's responsibility. ES 13 BendaAJAX-SUPERIOR Cooper Energy Services ENGINEERING STANDARDS 54.16 54.17 Section 7.4 defines the Ajax Packaging requirements in this level. Purge Systems: The distance piece shall be purged with inert gas. The packager is responsible for purging per these requirements. If other venting or purging systems are desired, the details are to be negotiated between the purchaser and the packager (ie., vacuum systems, or sweet natural gas purge). The final detailed system should provide for the safety of persons around the equipment and should prevent ‘contamination of the frame oil with sour gas. Packing cases will not be purged unless required by the customers. Cooler Tubes: Gas cooler tubes shall be furnished in 304 or 316 stainless steel. This requirement is the packager's responsibility. 60 AJAX PACKAGING REQUIREMENTS FOR H,S SERVICE (API 11P GUIDELINES) 6a 62 ‘This section covers H,S trim requirements for the Packaging portion of the Ajax model frame and compressor units. These requirements are based on the guidelines of API 11. For trace H,S (trace is defined as 0.005 mole % H,S or 50 ppm) up to and including 2% by volume: 624 622 623 624 625 626 627 All gaskets in the process gas wetted piping shall be stainless flexitallic (spiral wound AISI 316 stainless steel). The distance piece(s) shall be vented to the skid edge. Use HS trim scrubber controls including stainless stee! float and body for scrubber level switch, level controller, and automatic dump valve; stainless steel for expanded ‘metal in scrubbers; 3041 mesh; and stainless steel ball valve for scrubber manual drain, Remove yellow metals from the instrument gas Meco regulator. Use H,S trim manual blowdown valve including stainless steel valve body and bal Provide tinnized wiring in the panel (this is standard release for panel wiring). Provide Altronic PHL or Murphy environmentally sealed pressure gages with stainless steel movement and bourdon tube. 63 For H,S concentrations from greater than 2% up to and including 5% by volume: 63. Include all of the special requirement already discussed in Section 6.2. 632 Corrosion allowance for the process gas piping, pulsation bottles, scrubbers, and a, Ca Ege ES13 | {eo 7 | A Pam oat wa ‘ApterAJAX-SUPERIOR Cooper Energy Services ENGINEERING STANDARDS. 633 cooler gas headers shall be 1/8”. Provide H,$ trim for instrument panel. 634 Provide H,S trimmed process gas relief valves. 635 Provide two (2) compartment lubricators with additional day tank and level switch. 64 For HS concentrations greater than 5% by volume: 64. Include all special requirements already discussed in Section 6.2 and 6.3. 642 Piping and vessels: Unless otherwise specified by the purchaser, the following is required: 64.2.1 100% radiography of process gas pressure vessel butt and seam welds. 642.2 100% radiography of butt welds in gas piping. 6423 All vessels and gas piping shall be stress relieved. 64.24 Allcooler gas section headers shall be stress relieved. 642.5 Magnetic particle test all flanged connections in pressure vessels per ANSI 8313. 64.2.6 Magnetic particle test threaded connections (couplings, etc.) in pressure vessels and process gas piping per ANSI B31.3. 64.3 Use 316 stainless steel in place of plated steel fittings for panel instrument and lubrication tubing, 644 Use 304 or 316 stainless steel for gas cooler tubes and use shoulder plug design. 645 Use 316 stainless stee! in place of carbon steel for panel pulsation dampeners. 64.6 Compressor packing vent to be tubed to the edge of the skid. 647 Provide NACE trimmed instrumentation and process valves for parts coming in contact with the process stream. 65 Fuel Gas Packaging 65.1 Itis not the intent of this standard to specify allowable levels of HS in the fuel gas. However, if HS is present in the fuel gas ot starting gas above a trace amount (50 ppm), then special piping and packaging will be necessary to properly handle the gas. Caray ‘ha Eres] Das Comers | ecane, o b ES 13 wn sua |] ‘arene | 28" [SentraCooper Energy Services ENGINEERING STANDARDS 652 ‘These special requirements for Ajax Packaging, are listed in this section Provide H,S trimmed fuel gas relief valve. 7.0 _ ENHANCED AJAXPACKAGING REQUIREMENTS FORH;S SERVICE (SPECIAL CUSTOMER REQUIREMENTS) 7.1 This section covers H,S trim requirements for the Packaging portion of the Ajax model frames and compressors when special customer requirements or stricter adherence to NACE MRO175 is necessary. 7.2 HS concentration of trace or above (Trace is defined as 0.005 mole % H,S or 50 ppm): 7.21 Piping and Vessels: Unless otherwise specified by the purchaser, the following, is required whenever there is a trace or above concentration of H,S. This requirement ‘exceeds the requirement of API 11-P. 7.2.1.1 100% radiography of process gas pressure vessel butt and seam welds. 7.2.1.2 100% radiography of butt welds in gas piping. 7.2.1.3 100% radiography of cooler gas header welds. 72.14 All vessels and gas piping shall be stress relieved. 72.15 Allcooler gas section headers shall be stress relieved. 7.2.2 Allgaskets in the process gas wetted piping shall be stainless flexitallic (spiral wound AISI 316 stainless). 7.23 Scrubbers used for H,S service should have 304L mesh which is normally standard. 7.24 — Use stainless steel ball valve for scrubber manual drain which is normally standard. 7.25 All process gas wetted instrumentation to be suitable for H,S service with all yellow ‘metal removed. 7.2.6 Remove yellow metals from the level controllers and dump valves. 7.2.7 Remove yellow metals from the instrument gas Meco regulator. 728 Provide Altronic PHL or Murphy environmentally sealed pressure gages with stainless steel movement and bourdon tube. 729 Provide tinnized wiring in the panel (this is standard release for panel wiring). 7.2.10 Use carbon steel in place of bronze valves in the jacket water system. 7.211 Provide two compartment lubricator with additional day tank and level switch. 7.3 H,S concentration >0.5% Dam] Sema ane, ES 13) (ereees| pa =2 peg 7 Fait wee Page 1204 14 ee [Shae . WainonAJAX-SUPERIOR Cooper Energy Services ENGINEERING STANDARDS 7.3. Include all the special trim as specified in Section 7.2. 73.2 Corrosion allowance for the process gas piping, pulsation bottles, scrubbers, and cooler headers, shall be 1/8". 73.3 Magnetic particle test of flanged connections in pressure vessels is to be performed per ANSI 831.3. 7.34 Magnetic particle test of threaded connections (couplings, etc.) in pressure vessels and process gas piping is to be performed per ANSI B31.3. 735 Use 304 stainless steel or SA 179 seamless carbon steel tubes for cooler gas sections. 73.6 Use stainless steel in place of carbon steel for expanded metal in scrubbers. 73.7 _ Use stainless steel float for scrubber level switch. 73.8 — Use stainless steel body for scrubber level switch, level controller, and use stainless steel automatic dump valve. 739 Use stainless steel in place of carbon steel for the blowdown valve body and ball. 7.3.10. Provide NACE trimmed process gas relief valves. 73.11 Use 316 stainless steel in place of carbon steel for panel pulsation dampeners. 73.12 Remove all yellow metals from all components including external and non-gas e@ wetted components (i.; drains, valves, cooling systems, etc.) 74 H,S concentration > 5%: 74.1. Include all the special trim as specified in Section 7.2 and 7.3. 7A2 Pressure vessel design criteria will include full couplings. 743 Pressure vessel design criteria will include reinforcement pads on all flanged connections. 7AA Use 316 stainless steel in place of plated steel fittings for panel instrument and lubrication tubing 74.5 Corrosion test connections (couplings) are to be fabricated in the cold side discharge Piping. 7.4.6 Use 304 or 316 stainless steel for gas cooler tubes and use shoulder plug design. 75 Fuel Gas Packaging: 75.1 _Itisnot the intent of this standard to specify allowable levels of H,S in the fuel gas. However, if H,S is present in the fuel gas or starting gas above a trace amount (50 ppm), then special piping and packaging will be necessary to properly handle the gas. ‘These special requirements for Ajax Packaging are listed in this section. 75.2 Use carbon steel in place of ductile iron for Fisher fuel gas regulator. Nuts WN Stade “a. Wate! ES13 BeateAJAX-SUPERIOR Cooper Energy Services ENGINEERING STANDARDS 753 Provide NACE trimmed fuel gas relief valve. @ a ES13 Sompreesen Peete | 8250" Wh cacnEss-Fe01 “Tis: nation OF Sheave And Fp SERVICES Engineering Sales & Service Bulletin Ajax-Superior Engines/ Oklahoma City, OK 73129 Compressors. ESS-F-961 Installation of Sheave and Flywheel This bulletin applies to all Ajax models 2201, 2202, 2801, 2803, & 2804. The flywheels and sheaves of these AJAX models are installed with a RINGFEDER locking device, which is inserted over the hub of the flywheel (or sheave) and locks them to the crankshaft. The special procedures which must be followed for installation and removal are as follows: Installation 1. Clean the flywheel (or sheave) hub, bore and mating diameter on the crankshaft. Surfaces must be dry and free of any burrs, rust or lubricants. 2. Remove RINGFEDER (collar, inner ring and locking screws) from shipping container. Check if supplied locking screw threads, screw head bearing area, and the taper of the inner ring are lubricated. If not, lubricate them with a molybdenum disulfide grease, such as MolykoteGn Paste or similar. 3. Slide Half Shrink Disk (collar and inner ring) over hub projection and push it to required position. ‘The hub outside diameter may be greased. When retrofitting ringfeder on a keyed shaft, ensure inner ring split is 180° from shaft keyway. 4, Put the locking screws with hardened washers through the web clearance holes and screw them into the corresponding collar holes, finger tight. See Figure 1: ‘© Figure1 Collar Crankshaft 5. Slide hub over shaft to desired position. 6, Take any 3 or 4 locking screws equally spaced and snug them up to establish a parallel or perpendicular position of the Shrink Disk collar relative to the hub web or shaft, respectively. This will seat the collar on the taper of the Inner ring and avoid cocking of the collar. Page 1 of3 Released: 17 October 1906‘ie: naatation Of Shaeve And Eijwos! 7. Using a torque wrench, tighten all locking screws gradually (no more than 1/2 turn on each screw at one time) and all the way around, in either a clockwise or a counterclockwise sequence (not in diametrically opposite sequence). Several passes are required until all screws are torqued to the specified tightening torque. See Table 1: @ Table 1 BM-11878-D-1 2201, 2002, 2801, 2602, 2803, & 2804 BM1878-0-2 2201, 2002, 2801, 2802 BM 1878-E-+1 2808 BM11878-E-2 2804 8. Check and make sure that no screw will tun anymore by applying specified tightening torque (see Table 1). Only then is the installation completed. 9. After final tightening of screws, check flywheel run-out. See Figure 2 for maximum tolerances. If run-out exceeds maximum, loosen all socket head screws and tap flywheel into position using a soft hammer on wood block. Retighten screws following same sequence as before, and check that run- out is within tolerance. a TAR. © Figure? 020" T..R.—>|| Removal 1. Gradually release locking screws all the way around. Initially each screw should be released about a quarter of a turn only. Thus tilting and jamming of the collar will be avoided. DO NOT remove locking screws completely at this time, otherwise collar may spring off. 2. Any rust formed adjacent to hub must be removed first. Once the screws are loose, pull hub from e shaft. Page 20f3 Released: 17 October 1996Ess-F061 ‘ie: Inatalton OF Sheeve And Fj! Re-Installation 1. Upon removal of component, disassemble Shrink Disk. Clean and Inspect all parts. Reinstall following the Installation procedure, beginning with Step 2 of the appropriate section. Page 3.ot3 Released: 17 October 1996ess.s63 ‘Tide: Keylese Fy! instalation And Timing COOPER ae ENERGY SERVICES Engineering Sales & Service Bulletin Ajax-Superior Engines/ Oklahoma City, OK 73129 Compressors ESS-F-963 Keyless Flywheel Installation and Ignition Timing This procedure applies to all Ajax models 2200 and 2800 series Ajax engines. It covers the installation of the keyless ringfeder locking device fitted on flywheels on 2200 and 2800 series engines. The procedure explains the method used to find top dead center (TDC) and proper ignition timing of the engine. Installation 1. Stand the flywheel up on its edge, allowing access to both sides of the flywheel. /\Caut on’ Firmly secure the flywheel to prevent it from falling over. 2. Remove the rust inhibitor paper from the inside of the machined split ring on the ringfeder. Remove ringfeder (collar, inner ring, and locking screws) from shipping container. Verify that the supplied locking screw threads, screw head bearing area, and the taper of the inner ring are lubricated. Ifnot, lubricate with molybdenum disulfide grease, such as Molykote GN paste or equivalent. 3. Place the green ringfeder and split ring assembly on the machined diameter of the flywheel. 4, The bolts to be used on the ringfeder are metric. A 16 mm (FWF2500-1600) hardened flat washer is required for every bolt. Start each bolt into the ringfeder, but DO NOT TIGHTEN. Collar Inner Ring Crankshaft 5. Usea fine file or emery cloth to remove any burrs from the flywheel and crankshaft, cleaning both for assembly. 6. Coat the flywheel and crankshaft sparingly with engine oil. The flywheel to crankshaft fit is between .001”-.003". Do not over-lubricate. Step 6 should only be performed during initial engine assembly. Do not lubricate on field units. 7. Carefully place the flywheel on the end of the crankshaft. Do not bump the crank as this will create a burr that can impede installation. Push the flywheel evenly onto the crankshaft until the face of the Paget of 4 Released: 6/8/99esseo6o Tie: Keyless Flywheel instalation And Timing flywheel and the end of the crankshaft are even. Do not wiggle the flywheel inlout or try to turn the flywheel onto the crankshaft! It will create heat o and possibly gall the surface of the crankshaft. 8. After the flywheel is installed, snug several of the bolts in a criss-cross pattern to lock the flywheel to the crankshaft. 9. Remove the crosshead side access door from power cylinder one. 10, Set the timing pointer on the ignition bracket, allowing 1/8” clearance from the flywheel. Adjust the pointer until it is located in the middle of vertical slot on the bracket. Finding TDC and Timing Degree Marks 11. Place a4” bar or equivalent between the end of the crosshead and the pack flange. Bar the engine over clockwise until the bar stops against the packing. Hold the flywheel in this position, keeping the crosshead against the bar. 12. Mark the flywheel on the outer diameter (O.D.) with an ink marker at the pointer location. This is, “Temporary Mark #1”. 13, Remove the tension on the bar in the crosshead and remove. 14, Rotate the engine clockwise until is has passed TDC far enough to re-insert the bar. 15, Reinsert the bar and rotate the engine counter-clockwise until the bar stops the crosshead against the packing. Hold the flywheel in this position. 16. Mark the flywheel on the O.D. with an ink marker at the pointer location. This is “Temporary Mark 2”, 17. Release the tension from the bar and remove. Rotate the engine to allow access to both of the tempo- 6 rary marks. 18. Measure the distance between the marks. Divide the distance by two and, using an ink marker, cre- ate a third mark equidistant between the two marks. This will be “Temporary Mark #1”. Mark T represents the Top Dead Center (TDC) of the crankshaft. ‘You can verify the position of the TDC mark by measuring the distance between marks #1 and T, then marks #2 and T. These distances should be equal. It is now necessary to add the ignition timing mark. Verify that the ignition is properly set. All 2200 and 2800 engines use a 48” diameter flywheel. This means that: 3° = 114" Flywheel O.D. distance 9° = 3X" Flywheel O.D. distance 11° = 4.5/8" Flywheel OD. distance 20. Using one of the above distances, create a temporary mark on the flywheel to represent either 3°, 9° ‘or 11° (depending on model) before TDC or clockwise from the T mark on the flywheel. 21. Rotate the engine so that the timing mark is aligned with the flywheel pointer. This sets the crank- shaft in the general range of normal ignition timing. Use the nut and stud expanders to lock and hold the crankshaft in position. These should be installed between the sheave and end cover. See Figure 2. This picture shows the method of locking, the crankshaft used during engine assembly. Alternate methods of locking are acceptable for field ® tallation. 23. Check that the timing mark is still aligned with the flywheel pointer. As a double check, verify that Page 2 of 4 Released: 6/809ess-.o60 Tie: Keyes Flywheel Installation And Ting the scribed line located on the end of the crankshaft is positioned below horizontal. See Figure 3. 24. Loosen the ringfeder bolts to free up the flywheel on the crankshaft. e YW Figure 2 Figure 3 End of Crankshaft Horizontal Page 3 ot Released: 6/88ess-.ons ‘Tie: Keyless Fywhasnatalaton And Timing SERVICES Engineering Sales & Service Bulletin 9 Ajax-Superior Engines/ Oklahoma City, OK 73129 Compressors . ESS-F-963 Setting Timing Of the Flywheel 25, Ensure that the ignition pickup coils are in the proper holes: © 3° -Top Holes ‘ 9° - Two Holes From The Bottom @ 11°-Bottom Holes 26, Rotate the flywheel on the crankshaft, without moving the crankshaft itself, until the recessed mag- net is centered over the number 1 pickup coil. This is the “A” pickup coil or the one closest to the power end. 27. While keeping the magnet aligned, re-tighten the ringfeder to the flywheel. Now place a permanent timing mark on the flywheel and mark it either 3°, 9°, 11° accordingly. 28. Permanently mark the TDC location and then erase all of the temporary marks made on the fly- wheel. 29. Remove all crankshaft locking devices and find TDC as in the above procedures to verify that the ‘TDC position and the ignition timing mark have been correctly located relative to the magnet posi- tion. 30. When certain that the permanent marks are correct, tighten and torque all flywheel bolts. @ 31, Match mark the flywheel coincident with the scribe line on the end of the crankshaft using a chisel. Stamp a “1” next to this mark. Stamp the engine serial numbers on the crankshaft and hub of the flywheel. }. Chisel mark a line on the OD of the flywheel at TDC. Metal stamp a “0” next to this mark. Chisel mark a line at either the 3°, 9°, or 11° (depending on model) on the OD of the flywheel. Metal stamp the correct timing value next to this mark. eSs 35. It may be necessary after engine start-up to readjust the timing pointer. The pickup coil should be centered over the cylinder #1 recessed magnet when the pointer is pointing at the timing mark. 2804 (DPC-800) Engines Only These engines do not use flywheel magnets and pickup coils. When finished with Step 20 above go directly to Step 29.The magneto should be adjusted via the slotted holes on the mounting flange until the cylinder #1 is aligned with the flywheel timing marks. Page 4of 4 Released: 6/99ESS-L981 ‘AJAX LOW EMISSIONS ENGINES ER GY SERVICES ENGINEERING SALES & SERVICE BULLETIN AJAX-SUPERIOR ENGINES; OKLAHOMA CITY, OK 73129 COMPRESSORS ESS-L-981 Date: July 13,1998 Supercedes ESS-L-921 AJAX LOW EMISSIONS ENGINES AJAX JET CELL OPERATION AND MAINTENANCE ABSTRACT The jet cell concept is required for low emission or emission reduction engines. The high- energy torch issuing from the pre-chamber allows the main chamber to be operated with a leaner mixture and consistently ignited, as compared to a conventional spark plug ignition of a lean mixture. Also, the jet cell is applied to units to improve combustion stability and improve fuel consumption when operating at variable speeds and reduced torque. This paper describes the jet cell operation and general maintenance procedures relating to AJAX Low Emissions Two-Cycle Engines. ‘AETCELL OPERATION ‘The jet cell, or pre-combustion chamber, is a unit which is installed in the cylinder head. ‘The nozzle end is designed with a specific volume and has a communicating angled exit orifice. A spark plug for ignition and a fuel admission check valve complete the necessary operational components. Pilot fuel headers supply fuel to each admission check valve. The supply to the header is taken prior to the governor regulated fuel valve, filtered, and the pressure regulated with an additional regulator. The ignitor fuel pressure is thus regulated manually according to site conditions. For one cycle of operation, as the piston comes up on compression, the pressure within the cylinder is lower than the pilot gas pressure and fuel is admitted into the cell. When 1 Revised 07/98ESs-L-981 AJAX LOW EMISSIONS ENGINES the pressure within the cylinder becomes greater than the fuel pressure, then the pilot @ check valves close. The main fuel valve admits fuel into the cylinder per the designed timing. Ignition occurs within the jet cell and the rich fuel mixture ignites. The pressure rise caused by this energy release forces the burning mixture to exit through the nozzle orifice across the top of the piston in the main combustion chamber, igniting the main combustible charge. IGNITION TIMING In standard spark ignited engines, the spark plugs ignite the charge and a progres flame front occurs within the combustion chamber. Due to the time required for this flame propagation, the ignition timing is approximately 9°-12° before top dead center @IDO). With the jet cell, a torch of fire emitting from the exit orifice penetrates into the fueV/air mixture within the main combustion chamber. The mixture is ignited uniformly by this higher energy source, which promotes faster burning. For this reason, the ignition timing is set at 3° BTDC. For an engine operating at 440 rpm, this sequence of fuel admission, ignition, etc., occurs 7.3 times per second, 440 times per minute, 26,400 times per hour, 663,600 times per day (24 hrs), and 30 days of operation would equal 19,008,000 times. e MAINTENANCE ‘The jet cell, when installed into the cylinder head, has a round Armco iron gasket which acts as a fire seal; a graphoil seal employed as a bottom water seal, and an ‘O” ring as the top water seal. The unit is held in place with a two-bolt flange and torqued to 70 ft-Ibs. If acell is removed from the head, it is important that the access hole for the cell is clean and free of any scale build-up. New gaskets and seals should be installed and the unit properly torqued. A locating dowel is used to assure proper orientation of the exit orifice of the cell in relation to the main combustion chamber. SPARK PLUGS Cooling of the spark plug is accomplished primarily through the spark plug gasket seating surface and the threads. These areas within the cell have thin metal sections and are surrounded with engine coolant. In service, the center and ground electrodes will deteriorate, which increases the spark plug gap. Erratic firing will occur once the gap increases 0.005"-0.010" from the original setting and the plugs should be replaced. e 2 Revised 07/98ESS-L-981 AJAX LOW EMISSIONS ENGINES ‘On older LE equipment (pre 9/92), where a YK-8209-C jet cell was used, a Champion RW77N (BM-1022-2) spark plug with an initial gap of 0.015” to 0.018” was used. The main chamber spark plug utilized the Champion W-18 (BM-1022). Current production models (post 9/92) where a YK-8209-C-1 is utilized, use a Champion W-18 (BM-1022) spark plug is used with an initial gap of 0.020”. This allows use of the same spark plug for both the main chamber and igniter. The current production jet cell (YK-8209-C-1) identified with a ‘3/4’ stamped on the top face. IMPORTANT: Do not install the W-18 spark plug in the YK-8209-C jet cell. Damage ‘may occur to igniter and/or spark plug threads as the result of thread depth and thread reach respectively. ‘The secondary ignition wiring and associated components should always be in good condition. FUEL ADMISSI CHECK VALVES The primary check valve (P/N YK-8338-A) is most important in the operation of the jet cell. As noted previously, the number of cyclic operations relates to the unit's speed, with fuel being admitted when the cylinder pressure is less than the pilot fuel pressure and being shut off the cylinder pressure increases. The check valve also withstands the high pressure within the cell at time of ignition. Present production check valves use a ceramic ball with tool steel enclosure and seat. Ajax continues to improve the life and operation of the valves with ongoing research and development programs. From the primary check valve, the fuel gas enters the cell through drilled communication holes. Due to fuel entrapment, incomplete combustion can occur in these passages, which tends to produce a soot-carbon residue. In some cases, this build-up is not detrimental to the check valve’s operation, but in other cases it can be severe. If this build-up becomes heavy, erratic operation of the check valves will occur and they should be removed, cleaned and tested. Whenever the spark plugs are replaced, it would be appropriate to remove and clean the check valves. Some end users have a spare set of check valves which are installed at this time, and the removed set is cleaned for reinstallation at a later date. ‘An orifice (P/N K-8050) is installed on the inlet side of the primary check valve to allow pilot fuel pressures to be comparable to main fuel pressure. The orifice resembles a 1/8” toe nipple. Ensure this is an orifice by visual inspection, noting a small 0.038” internal hole. Clean when servicing the primary check valve. Connected directly upstream of the orifice is a secondary check valve (P/N BM-21064). This is utilized only as a backup to the primary check valve. 3 Revised 07/98ESS-L981 AJAX LOW EMISSIONS ENGINES A jet cell-equipped engine does require some additional maintenance over a standard ‘combustion engine. This additional maintenance is offset by gains in combustion stability, lower emissions and improved fuel economy. 4 Revised 0798 ®ESS-L983, LE RETROFIT CONVERSIONS 7 SUPPLEMENT ASSEMBLY PROCEDURE Vg COOPER ENERGY SERVICES ENGINEERING SALES & SERVICE BULLETIN AJAX-SUPERIOR ENGINES) OKLAHOMA CITY, OK 73129 COMPRESSORS ESS-L-983 Date: July 14, 1998 Supercedes ESS-L-923 AJAX LOW EMISSIONS RETROFIT CONVERSIONS 13-1/4” & 15” BORES SUPPLEMENT ASSEMBLY PROCEDURE The new AJAX Low Emissions (LE) Engine utilizes a squish design combustion chamber that includes a jet cell (ignitor cell). The assembly procedure is basically the same as on a standard engine, with the following additions and changes in gas valve timing, ignition timing and power piston position. 1. PISTON & HEAD INSTALLATION: ‘A) The piston used on the LE engine does not incorporate notches or tapped holes in the crown for installation as compared to the standard combustion engine. It is recommended that a rod wrench (or strap wrench) be used to install or remove the power piston. B) Screw piston into crosshead until approximately three (3) threads are left showing. Do not tighten rod nut at this time. C) Install cylinder head (with gasket) and torque to 600 ft-lbs. D) Using solder, set piston-to-head striking clearance at 0.110” (+: 0.010"). This is ‘measured at the 6:00 position by inserting solder through the gas injection hole down towards bottom of head. Roll piston forward (rotate crankshaft in CW direction) past TDC, thus crushing solder. Using a micrometer or dial calipers, ‘measure thickness of crushed solder. Adjust piston position accordingly, to obtain proper striking clearance. Refer to Figure 1. 1 Revised 07/98ESS-L-983 LE RETROFIT CONVERSIONS SUPPLEMENT ASSEMBLY PROCEDURE Figure 1, Measuring Proper Piston-To-Head Distance @ HEAD power crunocn \ e PISTON 0.400" 40.010") ‘COLD STRIKING CLEARANCE - PISTON @ D.C. FIG. 1 - Piston To Head Striking Clearance Revised 7798 E) Once clearance is set, torque rod nut and check clearance again. Piston has a tendency to turn out slightly when tightening nut. rp . GAS CAM TIMING: Refer to ESS-T-91] as a basis for fuel injection timing. The following changes must be made when converting an engine to LE application. A) The flywheel and gear shield must be removed in order to remove layshaft and reset cam timing. B) Cam timing is retarded from the standard 13° ABDC beginning of injection to 37° ABDC. DO NOT GO BEYOND 37°ABDC! If gears do not line up with cams at 37° ABDC, go back towards BDC (ie. 35° ABDC). Beginning of injection is 37° e@ 2 Revised 0718ESS-L-983 LE RETROFIT CONVERSIONS SUPPLEMENT ASSEMBLY PROCEDURE, ABDC on all LE engines but the method of setting the timing is different on DPC-800s & DPC-2804s. ©) On DPC-800s & DPC-2804s, the control box utilizes one (1) cam for two (2) cylinders. #1 & #3 power cylinders run off the cam closest to the power cylinders. #2 & #4 cylinders run off the other cam. Refer to Figure 2. Figure 2. Control Box And Cams x ‘2, % SPACER —= cYL.2-4 CAM CYL.I-3 CAM Ya" O18 HOLES IN caMS 10 0 SEO mM CavsHArT Tmt. CONTROL BOX AND CAMS #1 power cylinder gas cam timing is referenced off #3 bank on the control box. ‘The crankshaft should be rotated in a clockwise direction to 26° ABDC #1 power cylinder. DO NOT GO BEYOND 26°ABDC! If gears do not line up with cams at 26° ABDC, go back towards BDC (i.e. 24° ABDC). The crankshaft is positioned at 26° ABDC for setting cam timing on DPC-800s & DPC-2804s only. This is due to the way the cam is installed on the layshaft. The result will be injection beginning at 37° ABDC. Refer to FIG 3. The cam can now be set using the method illustrated in ESS-T-911. D) Once the preceding is complete, the layshaft gear should be installed and re- indexed. 3. IGNITION TIMING: Ignition timing is changed on all LE engines to 3° BTDC. New mag pickup brackets are furnished for all conversions through the DPC-600 & DPC-2803 to accommodate the timing change. 3 Revised 07/98ESS-L-983 LE RETROFIT CONVERSIONS ‘SUPPLEMENT ASSEMBLY PROCEDURE e ‘On DPC-800 and DPC-2804 engines where the ALTRONIC III is used, the alternator must be removed and re-indexed to 3° BTDC (refer to the standard DPC-800/DPC- 2804 Operation & Maintenance Manual for procedure). Figure 3. Alignment Of Crankshaft ~ 1 BN HORIZONTAL \ ete GAS VALVE TIMING USING ee 1 CYLINDER AS REFERENCE ™s eee ROTATION CRANKSHAFT FACING FLYWHEEL sor va" Dia ROD 1 eans, “N ROTATION M_ELY’ TOWARDS CONTROL BOX 4. IGNITOR ASSEMBLY INSTALLATION: Refer to FIG 4 A) Ignitor assembly is indexed with a roll pin that lines up with a slot machined in the LE power head. This ensures proper direction of ignitor exit orifice. It is very important that they are lined up properly! Misalignment will result in severe piston crown damage. It should be noted that when ignitor is torqued into head, the roll pin will not completely set into slot. This is only an alignment reference. B) Install gasket (P/N SF-34-65) onto end of ignitor by pressing on or using small amount of grease to hold gasket in place when installing ignitor into the head. Insure O-ring is installed on ignitor at this time also. C) Install water seal (P/N 2-013-129-002) into head. 4 Revised 07/98ESS-L-983 LE RETROFIT CONVERSIONS : SUPPLEMENT ASSEMBLY PROCEDURE e igure 4. Ignitor Assembly DRILLED HEAD CAP scREW LOCKWIRE PER js0-132"1 LAN ROLL PIN iz 3/6" 2-v2" $06 HO CAP SCREW, IGNITER ASSEMBLY D) Install ignitor into head being very careful not to damage water seal. This may take some hand fitting of seal. Torque down in progressive 5 ft-Ib increments to 70 ft-lbs. 5. SPARK PLUGS: On older LE equipment (pre 9/92), where a YK-8209-C jet cell was used, a ‘Champion RW77N (BM-1022-2) spark plug with an initial gap of 0.015” to 0.018” was used. The main chamber spark plug utilized the Champion W-18 (BM-1022). Current production models (post 9/92), where a YK-8209-C-1 is utilized, use a Champion W-18 (BM-1022) spark plug with an initial gap of 0.020”. This allows use of the same spark plug for both the main chamber and igniter. The current production jet cell (YK-8209-C-1) is identified with a *3/4” stamped on the top face. IMPORTANT: Do not install the W-18 spark plug in the YK-8209-C jet cell. Damage may occur to ignitor and/or spark plug threads as the result of thread depth ‘and thread reach, respectively. 5 Revised 0798ESS-L-983 LE RETROFIT CONVERSIONS SUPPLEMENT ASSEMBLY PROCEDURE 6. GAS INJECTION VALVES: The gas injection valve used in the LE power end is of the same basic design as the ‘one used in the standard combustion assembly but the valve housing and plunger housing are not interchangeable. The gas injection valve assembly on the LE engine has a longer valve body housing and a shorter plunger housing to accommodate the profile of the power head 7. MISCELLANEOUS: In addition to the preceding requirements, engines that are converted to the LE design must have: A) Dry-type, low restriction intake system B) Ring gear start system on 15” bore engines C) 3/8” hydraulic supply lines on gas injection system D) Exhaust line adjustment to compensate for length of insertion pipe in muffler If you have any questions or problems pertaining to an LE retrofit conversion, contact your local AJAX-SUPERIOR representative. 6 Revised 07/98Technical Information Bulletin # 020326 March 26, 2002 Subject: Preventive Maintenance for DPC-2200 & DPC-2800 Series Check the following WEEKLY, and correct or repair as necessary Date: -__ = O lube oil reservoir for adequate level lubricator oil level (drain accumulated water) Co make sure each lube point is receiving oil at its terminus CD erankcase oil level Orecord RPM_ O record intake air manometer reading __ C record main fuel gas pressure __ O record LE fuel gas pressure O hydraulic fluid level in gas injection tank (record any amount added) CO coolant level (record any amount added) O record EJW and CJW temperature ___ O record exhaust temperatures, adjust if QT is greater than 40° record compressor discharge temperatures ___ hot compressor valves, repair as needed Grecord operating process gas pressures Crecord VVP settings for operating conditions, adjust ifnecessary ‘CO walk around the compressor and note abnormal vibration or sounds, and gas or liquid leakage Check the following MONTHLY (or 800 hours), and correct or repair as necessary Date: - 7 0 perform weekly maintenance O check safety control panel and fuel valve for proper operation and shutdown Cl panel mounted safety limit switches and set point values unit mounted safety limit switches 1 compressor rod packing blow-by drain oil from compressor distance pieces and record quantity lubricate the throttle linkage (O manually actuate scrubber and fuel filter dump valves,MONTHLY (or 800 hours) cont'd, The compressor unit needs to be shut down and blocked in for the following: @ 1 clean or replace air filters ‘lubricate the water pump with one shot of grease/point lubricate the cooler bearings with one shot of grease/point CO lubricate the idler bearing with one shot of grease/point inspect the belts for proper tension, replace if worn clean debris from the cooler 1 drain the power cylinder scavenger ports and record quantity 1 clean or replace spark plugs and spark plug wires (gap the plugs at OEM specs) C clean the LE check valves and orifice nipples © inspect the LE fuel filter 1 tightness of external fasteners O frame to skid TI compressor crosshead guide (to the frame and the skid) 1 compressor cylinder supports, adjust if necessary © compressor cylinder to crosshead guide Check the following ANNUALLY (or 8000 hours), and correct or repair as necessary Date:__-__- 1 perform weekly and monthly maintenance e change crankcase oil, clean the crankcase, inspect for metal, water, etc |G Bump check rod bearings replace if necessary ‘C clean the crankcase breathers, or renew replaceable elements 1 drain and clean the lubricator box remove and inspect the fuel injection valves C crosshead-to-guide, and pin-to-bushing clearances, and record C intemal fasteners for proper torque O piston rods for wear and scuffing change rod packing if leakage is noted remove and inspect compressor valves, inspect compressor cylinder condition through the valve ports Ci remove, clean, and inspect mixer valves; assure a smooth, scratch-free seating area and replace all the valve plates (reed strips) and springs 1 inspect power cylinders through fuel injection port and LE ignitor port Check the following every 16,000 Operating Hours, and correct or repair as necessary Date: . *, O perform weekly, monthly, and annual maintenance re-ring power and compressor cylinders replace wiper and pressure packing 1 inspect pistons, rods and cylinders e 1 inspect crosshead pins and bushings 1 inspect connecting rod and main bearingsTechnical Information Bulletin # 020718 12 August 24, 2004 Subject: Ajax Component Wear Limits all 15” Bore x 16” Stroke includes DPC-180, -360, -600, all 13%" Bore x 16” Stroke (Includes DPC-115, -140, 3100, & 2800 Series models) 30, -280, & 2200 Series models) The following component dimensional specifications and wear limits should be used as a guide for preventative maintenance programs for Ajax equipment. Problems can be detected early before failures occur. These specifications are based on data gathered from a broad range of Ajax installations covering many decades of operating experience. Specific unit performance and maintenance requirements may vary based on application conditions and preventative maintenance practices. Engine End Data Tem ‘As New Limits | Max. Acceplable 15” Cylinder Bore 14997. 15.001 | UPI 15.013, 15” Piston Skirt Diameter 14968-14970 _ [Down to 14.961 15" Piston-to-Cylinder Clearance | .027-.033 Upto .045 15 Piston Ring 1 & 2 Side Clearance _| 010 -.0125 Upto 015 15° Piston Ring 3 & 4 Side Clearance _| 008 -.0105 Upto 013, 15” Piston Ring End Gap 15-135 Upto 145 13%" Cylinder Bore 13.247 — 13.251 Caen 13/4" Piston Skirt Diameter 13.220- 13.222 _| Down to 13.213 ; 025-031 Upto 045 13/4" Piston Ring 1 &2Side Clr. | 010-0125 Upto 015 13/4" Piston Ring 3 & 4 Side Cir. | 008 - 0105 Upto 013, “100-126 Upto 145 2497-2500 __| Down to 2.495 Crosshead Guide 12,000 12.002 _| Up to 12.004 Crosshead OD. 11.987- 11.989 | Down to 11.985 (Crosshead-To-Guide Clearance 009 - 013, Upto 016 *Note: determine the minimum clearance by passing the thickest feeler gauge possible over the top of the crosshead to project out the opposite side. Then slide the wuge along the entire length of the crosshead-to-guide fit12> Engine End Data (continued) Tem ‘As New Limit Max. Acceptable ‘Conn Rod Pin Bushing LD 5.5044 5.5069 _ | Upto 5.509 ‘Conn Rod Side Clearance 010 - 026 Upto .029 : Down to $4985 Crosshead Pin O.D. 5.4995 ~ 5.5000 | Down in 5.08 Crosshead-to-Pin Clearance -0044-.0074 | Up to .0085 7 Upto 7507 Conn Rod Bearing Bore sts 1505e |e - Down to 7.4975 Crank Pin O.D. 7499-7500 | Down 10 74975 Crank Pin-to-Bearing LD. Clearance _ | .0044 - .006 Up to .0075 Main Brg. Joumal O.D. 8374-8375 | Down to 8.3725 , 7 Up to 83831 Main Bearing 1D. 83796-83816 | YPtOe Ser Main Joumal-to-Bearing ID. -0046-.0076 | Upto .0091 Main Bearing Thrust, Deca, PCO DPCM, DPC 204 poe ed Une Layshaft Bearing Bore 1502-1503 | Upto 1.504 Layshaft O.D. 1498-1500 | Down to 1.497 Tayshaft 0.D.-t0-Bearing Bore aoe ratoor Clearance Center Main Bearing LD. on Twins | 7.754-7.756 | Upto 7.757 Crankshaft Journal on Twins 7.749 -7.150___ | Down to 7.748 Center Main-o-Joural Clearans on | oq _9g7 aaa wins Compressor End Data Ttem ‘AsNewLimits | Max. Acceptable Cylinder Bore = = Piston Rings & Riders = = Piston-to-Cylinder Clearance ** contact the Technical Support department at Ajax Piston Rod, 2%" 2.497 — 2.500 2.495 Piston Rod, 24" 2.249 — 2.250 2.2455 Crosshead Guide 11.999 12.001 [ Up to 12.008 Crosshead 01 11.984 - 11.986 __ | Down to 11.982 (Crosshead-To-Guide Cir.* O11 - 015 Up to 018 *Note: determine the minimum clearance by passing the thickest feeler gauge possible over the top of the crosshead to | gauge along the entire length of the crosshead-to-guide fit. project out the opposite side. Then slide the ‘Connecting Rod Pin Bushing LD. 4.5035 - 4.5062] Up to 4.507 Crosshead Pin O.D. 4.4995 - 4.500 | Down to 5.4985 Pin Bushing-to-Pin Clearance 0044 - 006 Up to .0066 Connecting Rod Bearing LD. 7.503 - 7.505 Up to 7.506 ‘Crank Pin O.D. 7.499 7.500 Down to 7.498, Crank Pin-to-Rod Bearing Clearance _ | .0042 - .0066 Up to .008Technical Information Bulletin # 030910 September 10, 2003 Subjects: 1) Warm up and loading of cold engines 2) Coolant safety shutdown set point Individual equipment operators have the largest influence on the long term service life of the equipment for which they are responsible. Engine damage can be avoided by practicing the following two rules of operation: 1. Donot apply load to the engine until the COOLANT TEMPERATURE coming out of the engine is 150° F. 2, Assure that the cylinders are receiving the correct amount and quality of lubricant. ‘The length of time it takes to warm up the engine’s coolant to140°-150° F is dependant upon several factors. [fit has been out of service for a short time for routine preventive maintenance, a relatively short warm up period is needed. If the engine has been out of service for more than five hours and the surrounding temperature has been < 50° F, then follow the procedures prescribed in Ajax Engineering Standard ES 1006 on pages 2 and 3. The chart shown below describes the amount of load (% of total) that can be applied when engine coolant outlet temperatures between 40° F and 150° F. Use caution and patience when ‘trying to accelerate the warm up period. % Site Rated Load © 1010160 Engine Coolant Outlet Temperature (F) For engine lubrication refer to the Operation Manual’s section on Power Cylinder Lubrication for details. Generally, normal oil consumption is 1 pin/30 BHP per day. For example: DPC-2802LE at 4500" elevation, 100° F, operating at 440 rpm has a site rated available BHP of 349.4. 349.4 BHP + 30 BHP/day = 11.6 pints/day per engine ‘An empirically determined amount can be used for consistently reduced load operation.If counting a force feed lubricator pump’s “drops per minute” be certain that the individual pump is in good condition, and has no wear between the plunger and its bore. If using a digital lubrication meter, compare its reading to the unit's Lube System Operating Schematic for the correct lube rate. Engine Coolant Safety Shutdown Temperature ‘Ajax has traditionally specified 206°F as the engine's coolant high temperature limit. This value is based upon experience with thermosyphon coolant systems. A shutdown value of 185°F is more appropriate for DPC-2200 and DPC-2800 series engines ‘with pressurized and 150°F thermostatically controlled systems. ‘When the fuel has greater than 0.15% HS by volume, the coolant temperature should be raised to 160°F to minimize sulfuric acid formation. The safety shutdown temperature should then be set at 190°F. Fuels containing more than 0.02% HO should be dried to avoid the formation of sulfuric acid. Action: If the fuel has more than 0.15% H,S by volume, change the thermostat’s control element to attain 160°F. Adjust the safety shutdown trip point on the coolant temperature monitor in your unit's control panel to the appropriate value.Technical Information Bulletin # 031104 : November 4, 2003 Subject: Hydraulic Fuel Injection System ‘a) Potential Fire Hazard ») Purging Procedure ) Recommended System Modifications A potential fire hazard exists on Ajax engines with hydraulic fuel injectic 1) An incorrect purging procedure can allow hydraulic fuid to contact a hot exhaust pipe and ignite. Use the following procedure: Hydraulic System Purging Procedure: |. Shut the engine off, . Pressurize the hydraulic reservoir to 15-20 psig, }. Open the flow control valve (at control box) forthe gas injection valve line to be purged. J. Connect a 10-12" length of clear plastic 3/8” hose to the bleed valve, 5. Slowly open the bleed valve while directing purged fluid and bubbles into a clean container for reclamation, 5. After the fluid runs without bubbles, close the bleed valve. Close the flow control valve atthe control box. ‘Check the reservoir’s fluid level. Be certain to depressurize the reservoir before replenishing the fui. Wate raul Mal pla VAE-2150-2, Use Ain @ 32a te the Dd. 2) A damaged purge valve assembly can allow hydraulic fluid to leak and contact a hot ‘exhaust pipe and ignite As seen in Figure 1, the bleed valve is assembled to the cap of the injection valve by use of a pipe nipple and pipe tee. These assembled parts can be bumped and damaged when servicing ‘adjacent components such as cylinder heads. The pipe nipple can also be damaged if the gas. injection valve assembly is mishandled during servicing. Traditional bleed valve location for Purging of the hydraulic injection system,{As seen in Figure 2, relocation of the bleed valve to the topmost part of the gas injection valve minimizes damage potential, and permits more efficient purging of the hydraulic system. e Bend tubing to 45° for for improved purging ‘optimum fluid flow and of the hydraulic vibration resistance injection system. Clear plastic 3/8” hose temporarily connected for purging the system, Convert to the current design by replacing the injection valve’s cap with the current design. A parts kit for the conversion is available, or individual pieces can be specified. See the appropriate table below for a kit P/N or the individual P/Ns. See Figure 2 for a typical installation of the current design. “Top Purge Conversion Kit” (one per Gas Injection Valve) pin: SPEC 7456-S pin: SPEC 7456-SS (steel valve & fittings) (ss valve & fittin Tem | Description PIN Qe] [Tem [Description PIN Oy T_| Valve Cap A2S6S-FA 1 T_| Valve Cap) A25S-FA 1 2 [Bleed Valve BM-10936 1 2_| Bleed Vaive BM-16580-2 1 3 [38 Tube x “NPT BM-11573-S-64 |_1 3_[ Tube x NPT BM-11573-S8-64 | 1 Reducer, Ys NPT(F) na $4 Reducer, % NPTCF) “2 4 | aneron BM21147-5-42 | 1 ie BM.21147-9842 | 1 S_[UTube Nut & Ferries | BM-21163S4 | 1 3_[% Tube Nut & Ferules | BMT163-98-4_| 1 (6 [8 Tube Nut & Ferrules | BM-21163-S-6 | 1 6 | 3 Tube Nut & Ferrules | BM-21163-88-6 | 1 7_[ “Tubing, 3168S 1BM-21071-2-035 | 4° 7_[ “Tubing, 3168S 'BM-21071-2-035_| 4 [8 Tubing, 3168S____| BM-21071-3-035 | 4” [38 Tubing, 31685 BM-21071-3-035 | 4| Technical Information | Bulletin # 040910 ‘September 10, 2004 ‘Subject: Lubrication Rates for DPC-2200 and DPC-2800 series engine-compressors Use of divider valve designs provides a simple, reliable and predictable approach to engine cylinder and compressor cylinder lubrication. Simplicity is enhanced by use of a lubrication monitor that senses divider valve operation, and displays pints/day of lube oil consumption based on RPM and a divider valve assembly’s displacement volume. ‘The following rates for engine cylinders are based on the use of dry gas, and lube oil per Ajax engineering standard ES-1006. HP listings are at standard conditions of 100°F and <1500" elevation. Toad Tbe Rate Toad Tube Rate Condition Lakes Pints/Day Condition a Pints/Day 01 LE 74HP 440. 29 317 HP 440, 12.7* 76 HP 300 2.6 324 HP 300. 10.8 U1 HP 440 3.7 475 HP. 440, 15.8 101 HP 300 34 432 HP 300. 144 wasHP | aa0 49 ane | ao | ai DPC.2803LE o 148 HP 59* 300 HP 440 12 151 HP 5 some | 300 | 102 222 HP 14 asonp | 440 15 202 HP 67 aoonp | 300 | 136 296HP | 440 99 coonp | 440 20 DPC.2804 soup | sso | 38+ sane | ao | 169 senp | 300 33 aur | 30 | 144 isn | 440 48 esenp | ao [on isin | 300 43 s7np_| 300 [191 iouP | 440 64 sasnp | aio | 282 DPC.2802 & LE DPC.2804LF isonp_| ao | 77+ 4oonp | 40 | 160+ is6uP_| 300 65 ane | 30 [36 2seHP [440 96 coup | 40 | 200 20np [300 87 sasup | 300 | 181 seanp [440 128 soonp | 440 | 267 ‘This rate for inital break in unning. Tris calculated at | pind 25 HP. Engine lubrication rates for normal operations are based on 1 pin/30 HP.‘The following rates for compressor cylinders are based on the use of clean and dry gas, and lube oil per Ajax engineering standard ES-1006. Rates listed are based on MWP and maximum bore size and include the rod packing's requirements. Refer to the O & M manual for other conditions. NOTE: to attain the total lube rate for a compressor unit, add the lube rates forthe individual cylinders. Cylinder MW. Bore Total Lube Rate-PintsDay Mosel 1) aches 340 RPM @ 300 RPM, YKeBA | 1500 735 2a 1 veep | 1800 | 500875 22 17 yxoe | 1350 | 650.800 2a 1 venica | 90 | 900-1050 27 19 Kur | 600 | 1.003300 29 21 veug | 400 1400 30 2 0 1500 a2 22 via | 400 | 16001700 35 24 vei | 275 1800 36 25 yank | 250 20.00 29 27 YKNIMA | 200 | 2200-2800 43 30 venR | 100 28.00 50 3 soo | 3.00350 23 19 vKnS | 5000 | 400-425 2s 20 so00 | $00.55 36 a vent | ss | 300350 a ar ssoo | 400-450 aa 2a Individual cylinder and rod packing assembly lubrication rates are based on the following formula: (0.000314 x Cylinder Bore x Stroke x RPM) + (0.000333 x Discharge Pressure) + 0.75 Example: YKING, 14” bor, 11” stoke, @ 440 RPM, 400 psig (0.000314 x 14x 1 x 440) =2.13, (0.000333 x 400) 0.13 075 =075 3.00 pints/day ‘The lube monitor's rate display is calculated by using the divider valve assembly's cycle signal, and @ BLOCK TOTAL of the assembly. The assembly's BLOCK TOTAL is determined by adding the “sizing number” for each element within the assembly. Refer to the following table forthe sizing number fora particular SMX clement: DropSa Element | Sizing Number ‘SMX-08 3 'SMX-12 8. 'SMX-16 10 'SMX-25 15 'SMX.35, 20 'SMX-40- 25 ‘SMX-50- 30 Assure thatthe correct values are used for the engine's divider valve assembly, and the compressor cylinder's divider valve assembly. (Metering element designation (the SMX number) is stamped on each element's nameplate.)Technical Information Bulletin # 050610 June 10, 2005 ‘Subject: Engine Operation with Fuel Containing H,S (Hydrogen Sulfide) ‘Ajax engines can operate with some amount of HS in the fuel. The standard engine configuration can tolerate 100 grains HS per 100 scf natural gas without operational or ‘mechanical alteration, (This amount is 0.16% when expressed as volume.) However, successful engine operation with up to 3% (volume) of HpS can be achieved when extra protective measures are made. Background: HS in fuel gas will combine with water to form sulfuric acid. The source of the water is either saturated fuel, or a byproduct of combustion. Depending upon the amount of HS in the fuel, corrosion will occur. The corrosion affects parts with brass, bronze, copper (bearings, bushings, wiring, etc.) as well as many ferrous alloy materials. The effect is erosion of some materials, and slress corrosion cracking of others. Ajax engines can tolerate higher fuel HS levels than competitive four stroke cycle engines because: a) there are no intake or exhaust valves. Seats, guides, and valve faces are very susceptible to HaS attack. ) the engine’s crankcase is isolated from the power cylinders because of the crosshead type design. The piston rod’s packing separates the crankcase and the power cylinder. Acid laden combustion products which blow by the piston rings do not contaminate the crankcase oil. Required Criteria vs, Fuel H2S (% volume) Fuel’s H2S_ | Operational (BVotune) | "Level Engine Requirements <0.16% 1 ‘Standard engine configuration 0.16% - 0.50% 2 ‘Thoroughly dried fuel Level 2+ 0.50% - 1.0% A a. change JW thermostat 0165°F b. increase power cylinder lube rate 10% assure rod packing is sealing Level 2+3-+ a. use hard iron plated power cylinders 1.0% - 3.0% 4 instead of chrome plated cylinders . use 316SS tubing and tubing fittings, and “NACE trimmed” fuel gas controls (pressure regulators, relays, pressure pauges, etc.) ‘Not recommended. Consult Ajax Engineering > 30% 5 __| when the HaS % volume exceeds 39% Refer to Engineering Standard ES 13 for use of Ajax compressor cylinders and packaging requirements when HyS is present in the compressed gas.