GE Ajax DPC 2804 LE Handbuch

GE Oil & Gas

Ajax

Compressor

Ajax DPC 2804 LE / Non-LE Operation & Maintenance Manual

GE Oil & Gas

GE Oil & Gas Compression Systems, LLC is the entity owning this Installation, Operating and

Maintenance Manual.

GE Oil & Gas Compression Systems, LLC can be contacted as follows:

Phone: +1-866-754-3562

Website: www.geoilandgas.com

Cameron is not affiliated with this manual, and any reference to Cameron or Cameron International

herein is unintentional.

GE Oil & Gas

Revision History

Rev

No.

Rev Description Date

Revised

Initial Release

11/09/2012

Prabhu

GE Cover Page Update

7/9/2014

Prabhu

GE – Contact Information & Lubrication System (Baffle) Update

09/03/2015

Prabhu

Content added in Sections, General Data, Fuel System & Power Cylinder

10/19/2015

Prabhu

4Sealing Compound Instructions added in Section : 6 03/22/2016Prabhu

Table of Contents

Table of Contents 3

Section 1: Introduction 13

Message from GE Oil & Gas Compression Systems LLC 13

GE Oil & Gas Compression Systems LLC Policies 13

Standards 13

Our Quality Policy 13

Warranties To Original Purchaser (Non-Transferable) 14

Prerequisites 15

Additional Information 16

GE Oil & Gas Compression Systems LLC Contact Information 16

Section 2: Safety Information 17

Introduction 17

Danger, Caution and Note Symbols 17

DANGER SYMBOL 17

CAUTION SYMBOL 17

NOTE SYMBOL 17

Safety Decals 18

Danger, Caution and Note Decals 18

Figure 2-1 Safety Decals 19

Figure 2-2 Safety Decals 20

General Precautions 21

Engine Maintenance Precautions 21

Compressor Maintenance 22

Section 3: Warranty 25

Warranties to Original Purchaser (Non-Transferable) 25

Section 4: Basic Design and Application 27

Basic Design 27

Engine & Frame 27

Piston 27

Power Cylinder 27

AJAX®3

Table of Contents

Jet Cell 27

Compressor Cylinder 27

Lubrication System 27

Piston Rods 27

Fuel System 27

Figure 4-1: 2804 Engine Compressor 28

Basic Application 28

Two-Cycle Principle of Operation 28

Figure 4-2: Compression 29

Figure 4-3: Power 29

Figure 4-4: Scavenging 30

Section 5: General Data 31

General Data 31

Table 5-1 General 31

Table 5-2 Power and RPMs 31

Table 5-3 Basic Specifications - Engine 31

Table 5-4 Compressor 32

Table 5-5 Auxiliary Systems 32

Table 5-6 Estimated Weighs & Dimensions 32

Table 5-7 Engine Component Dimensional & Clearance Data 32

Table 5-8 Compressor Component Dimensional and Clearance Data 33

Table 5-9 Torque Table for Critical Ajax Fasteners 33

Table 5-10 General Torque Table for Fasteners (for use when a specific torque is not specified) 35

Clearance and Torque 37

Figure 5-1 Crankcase and Main Bearing Journal Group 37

Figure 5-2 Power Cylinder Group 38

Figure 5-3 Power Piston, Crosshead, and Connecting Rod Group 39

Figure 5-4 Compressor Crosshead and Connection Rod Group 40

Ajax Engine Compressor Noise Data 40

Table 5-11 Sound Pressure Levels 2804LE 40

Table 5-12 Sound Pressure Levels Vs. Frequencies - 2804LE 41

AJAX®4

Table of Contents

Special Tools 41

Figure 5-5: Special Tools 41

Section 6: Unit Installation 43

Installation Design for Permanent Ajax Compressor Packages 43

Foundation 43

Figure 6-1: Canister Bolt Detail 44

Preparation of the Foundation and Skid for Grouting 44

Setting the Engine Compressor 45

Sheave Alignment Procedure 46

Figure 6-2: Sheave Alignment Procedure 46

Grout 47

Table 6-1: Grout Compressive Strength Requirement Estimates (for reference only) 47

Final Grouting Instructions 47

Setting an Inertia-Base AJAX Compressor Unit 47

Figure 6-3: Typical Concrete-filled AJAX Inertia-base Skid 48

Figure 6-4: Typical Pit Dimensions for Inertia-base Units 49

Figure 6-5: Recommended Pit Depth and Sand Pad Specification 50

Setting Inertia-Base Compressor Unit and Cooler: 50

Figure 6-6: Recommended Sand Placement following Unit Placement 51

Fabricated Piping Assembly 51

Keyless Flywheel Installation and Ignition Timing 51

Installation 51

Figure 6-7: Flywheel Cross-Section 52

Finding TDC and Timing Degree Marks 53

Setting Timing of the Flywheel 54

Installation of Sheave and Flywheel 54

Installation 54

Table 6-2: Screw Tightening Torques, Sheave and Flywheel 55

Figure 6-8: Flywheel Tolerances 56

Removal 56

Re-Installation 56

AJAX®5

Table of Contents

Field Connections 56

Fuel Gas Piping 56

Figure 6-9: Typical 2804 Starter/Fuel Gas Piping 57

Air Starting System 57

General Information 58

Product Identification 58

Unit Specific Model # and Serial # 58

Table 6-5: Starter Motor Pressure Ratings and Part Numbers 58

Figure 6-10: Starter Motor Diagram 59

Air Starter Motor Precautions 59

Exhaust System 60

Exhaust Pipe and Mufflers 60

Exhaust Temperature Shutdown Settings 60

Sealing Electrical Fittings in Hazardous Locations using CHICO A Sealing Compound 61

Installation 61

Dam: 61

Use the EYS-TOOL-KIT to pack a proper fiber dam (do not use metal tools). Proceed as follows: 61

Compound: 61

Follow these instructions carefully: 61

For Applications Involving Groups C and D 62

For Group B Applications 62

Section 7: Unit Start-Up 63

General Information 63

Overview 63

Power Cylinder Pre-Start-up Servicing 63

Compressor Cylinder Pre-Start-up Servicing 64

Compressor Purging 65

Start-Up Procedure (with bypass) 66

Start-Up Procedure (without bypass) 68

Section 8: Lubrication Systems 71

General 71

AJAX®6

Table of Contents

Crankcase Lubrication System 71

Crankcase Oil Level Control 71

Figure 8-1: Oil Level at the center of the sight glass 71

Oil Control Baffle 72

Figure 8-2: Oil Control Baffle 72

Function and Design 72

Notes and Precautions: 72

Frame Oil Level 72

Baffle Maintenance 73

Figure 8-3: Cylinder 3 Shown, Typical Configuration at Cylinder Locations 1, 2, 4 73

Table 8-1: Baffle Fastener Torque table 73

Crankcase Oil Maintenance 74

Figure 8-4: Frame, Crosshead Guide, & Scavenging Chamber Drains 75

Figure 8-5: Lube Oil from Frame Mounted Supply Reservoir 76

Figure 8-6: Lube Oil from Frame Mounted Supply Reservoir 77

Lubrication System Components 77

SMX Divider Valve 77

Base 78

Table 8-2: Metering Elements 78

Table 8-3: SMX Divider Valve Specifications 78

DNFT - LED Digital No-Flow Timer 79

Table 8-4: DNFT-LED Specifications 79

DNFT-LED Operation 79

Power Cylinder Lubrication 80

Power Cylinder Lubrication Rates(for DPC-2800 Series Compressors) 80

Table 8-5: Lubrication Rates - DPC-2804 & LE 80

Lubricating Oil Recommendations for Ajax Engine-Compressors (Ajax ES-1006) 81

General 81

Quality and Performance 81

General Specification 81

Table 8-6:Physical Properties of Recommended Oil 81

AJAX®7

Table of Contents

Ash Level 81

Viscosity Requirements 81

Figure 8-7: Oil Selection for Ambient Temperature 82

Low Temperature Operation Procedures 82

Table 8-7: Low Overnight Temperature Starting Chart 83

Crossheads 83

Section 9: Fuel System 85

Operating Instructions for plunger type, spill-port gas injection systems 85

General Description 85

Figure 9-1: Fuel System 85

Operation of the system 86

Figure 9-2: Fuel Suction Stroke 86

Hydraulic Fluid 87

Fluid supply Tank 87

Pump Assembly 87

Flow Control Valve 87

Injection Valve Assembly 87

Bleeder Cock 87

Bleeding of Air Before Starting 88

Gas Pressure 88

Adjusting Fuel Injection Valves 88

Figure 9-3 Fuel Injection Valve adjustments 88

Gas Injection Timing Instructions 89

Checking the gas injection timing on the DPC-2804LE engine 89

Figure 9-4: 2804LE Crankshaft with Straight Edge and Level Vial 89

Figure 9-5: View Looking from Flywheel Towards Control Box 90

Figure 9-6: Marked Keyway Locations 90

Ajax Jet Cell Operation and Maintenance 91

Jet Cell Operation 91

Ignition Timing 91

Maintenance 92

AJAX®8

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