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To browse Academia.edu and the wider internet faster and more securely, please take a few seconds to upgrade your browser. Help Center less You can download the paper by clicking the button above. Books Audiobooks Magazines Podcasts Sheet Music Documents (selected) Snapshots Enjoy thousands of titles when you subscribe Read free for 30 days Cameron Ajax Package Service Manual Uploaded by Anton Kondratyev 75 (12) 75 found this document useful (12 votes) 8K views 829 pages Document Information click to expand document information Description: Cameron Ajax Reciprocating compressors package service manual. Report this Document Download now Save Save Cameron Ajax Package Service Manual For Later Cameron Ajax Package Service Manual Uploaded by Anton Kondratyev 75 (12) 75 found this document useful (12 votes) 8K views 829 pages Cameron Ajax Reciprocating compressors package service manual. For DCP 2802 LE compressor unit More Save Save Cameron Ajax Package Service Manual For Later 75 75 found this document useful, Mark this document as useful 25 25 found this document not useful, Mark this document as not useful Embed Share Print Download now Jump to Page You are on page 1 of 829 Search inside document. Cancel anytime. Share this document Share or Embed Document Sharing Options Share on Facebook, opens a new window Share on Twitter, opens a new window Share on LinkedIn, opens a new window Share with Email, opens mail client Copy Text Related Interests Piston Cylinder (Engine) Internal Combustion Engine Vehicle Parts Vehicle Technology Footer menu Back to top About About Scribd Press Our blog Join our team. Quick navigation Home Books Audiobooks Documents, active. Ajax DPC 2804 Operation and Maintenance Manual.Because of this commitment, changes may occur in your compressor frame that may not appear in this instruction manual. Photographs or illustrations in this manual show details or options may not appear on your compressor frame.
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Guards, covers or other protective mechanisms may have been removed for explanatory purposes. It is very important that personnel associated with operation maintenance of the AJAX series compressor read this manual and support documentation. Keep this manual with related literature and compressor information. Store it so it is easily found by maintenance or service personnel. It is also important that users carefully study the safety information provided in Section 2. Always use good safety practices at all times to prevent injury to personnel or damage to equipment.American Petroleum Institute web address; will default you to You can call 1-800-854-7179 ext. 7969 for copies of ISO 13631. Customers include purchasers of goods and services, co-workers, other departments and suppliers. Providing goods, services and communications with ever-increasing quality and value for our customers is a continuous business process in our company. 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. When factory testing is conducted for measuring and 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, 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 initial 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 rates then in effect at the time of the test. Purchaser shall give Seller fifteen (15) days written notice prior to the date Purchaser intends to commence such test. If the field 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. 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, to 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.
Prerequisites Personnel using this manual should be familiar with compressor systems, standard mechanical service tools, and compressor terminology. Service personnel should have adequate experience in good maintenance and troubleshooting techniques. These safety procedures should not be considered as the only precautions to be taken. Good judgment and careful safety practices should always be used. A CAUTION may appear as follows: NOTE SYMBOL A NOTE Symbol, indicates an essential operating procedure or condition which must be highlighted. A NOTICE may appear as follows: Some general precautions are listed in the following pages. Make sure that all personnel read these precautions and adhere to them. Keep long hair tied back. 5. Locate the nearest fire extinguisher to area where maintenance is to be performed. Ensure a clear path to fire extinguisher in case it should be needed for an emergency situation. 6. Do not open cooling or lubrication systems when engine or compressor is hot, as steam or hot liquids can be released, which can cause severe burns. Be aware that some surfaces can remain hot for several hours after the unit has been shutdown. 7. When draining the coolant and lubricants, prevent contamination of the environment by the equipment fluids. Clean up spills and leaks quickly to prevent accidents caused by slipping and falling. 9. Use only non-flammable, non-toxic cleaning solvents.Always stand on stable surfaces when working on this equipment. 12. Before starting any equipment, make sure all nearby personnel are aware of the start up and are clear of the equipment. 13. Do not use bare hands when checking for leaks of fluids under pressure, as fluids or particles can penetrate skin. Use cardboard or a similar material to check for leaks. Engine Maintenance Precautions Prior to performing maintenance, shut down unit and prevent the possibility of restart. Close the starting gas block valve and remove the tubing line to the starting pilot valve.
THIS IS VERY IMPORTANT IF THE UNIT HAS REMOTE START CAPABILITY - a remote operations center may try to start a unit without knowing that work is being performed on it. This can leave an explosive mixture in the engine and exhaust system. Shut down the engine, by SHUTTING OFF THE FUEL SUPPLY. Do not remove engine cover doors immediately after shutdown.Allow the engine to cool until cover doors can be removed with bare hands. Check all safety shutdown devices (over speed, low oil pressure, high jacket water temperature, vibration, etc.) according to the procedure and schedule in the maintenance section of this manual. After completion of maintenance work, reconnect starter pilot valve line and open block valve. REMOVE MANUAL BARRING DEVICE, if used during maintenance. Before attempting to start a gas engine, it must be cranked with the fuel and ignition off to purge the exhaust system of combustible gases. The engine should be cranked for a minimum of 15 seconds before the ignition is turned on and then the fuel valve opened. Be prepared to shut down the engine if an over speed or other control malfunction occurs on start-up. Before replacing any studs, measure stud height from machined surface and position replacement stud to the same height. Compressor Maintenance 1. Shut down the Integral Engine Compressor first, then prevent it from being started before the work is done. (see ENGINE MAINTENANCE PRECAUTION). Suctions and discharge block valves (see sight plan for location) must be closed to prevent gas from flowing into the compressor during maintenance. (Gas pressure could rotate the compressor and cause injury if not shut off and ventilated properly - see compressor section of this manual). 2. Before attempting any maintenance or repair on the compressor, vent all gas pressure from the cylinders, piping, and other pressurized components or chambers. Know the piping system associated with this compressor.
Vent unloader control pressure line by loosening control line tubing fitting. 3. IF POISONOUS OR SUFFOCATING GASES ARE BEING COMPRESSED, FOLLOW ALL PLANT SAFETY PROCEDURES PRIOR TO AND DURING MAINTENANCE ON ANY GAS EQUIPMENT OR PIPING TO AVOID INJURY OR DEATH DUE TO INHALATION OF SUCH SUBSTANCES. 4. Regularly check around compressor and piping gaskets and joints for leaks which could result in a fire or an explosion. 5. Test all pressure gauges on a periodic basis (see maintenance schedule) to ensure accurate pressure readings. Likewise, check all relief valves for design opening pressure (see manufacturer’s data for each relief valve in packaging section of manual). 6. Check all safety shutdown devices (No Flow for oil lube to divider blocks for packing and rings, high and low gas pressures, vibration, etc.,) per the schedule in the maintenance section of this manual. 7. Remove electrical lockout function if motor driven when maintenance is completed and REMOVE MANUAL BARRING DEVICE, if used during maintenance, before starting unit. 8. Before replacing any studs, measure stud height from machined surface and position replacement stud to the same height. Any performance characteristics indicated herein which are not 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. Should Purchaser desire to conduct a field performance test to verify any performance guarantee, such test must be conducted by Purchaser, at this expense, within thirty (30) days from the date of initial 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 rates then in effect at the time of the test. Purchase shall give Seller fifteen (15) days written notice prior to the date Purchaser intends to commence such test. 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 Purchaser’s sole and exclusive remedy hereunder shall be that set forth in paragraph (a) above. 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, to repair or replace any part of said Equipment that is proven to Seller’s satisfaction not to have been in compliance wit 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 return or replacement of any Equipment or parts that are found not to be in compliance. The integral one piece forged steel crankshaft has both engine crank throws and compressor crank throws. The three and four cylinder units use precision sleeve type bronze backed bearings. The forged steel connecting rods in all units have precision bronze backed bearings at the crank journal and bronze bushings at the crosshead end.
Heavy duty babbited cast iron crossheads and 4140 steel piston rods complete the drive train. Piston The engine pistons are made of cast iron, while the compressor pistons may be either cast iron or aluminum, depending on the balancing requirements and the application. Hard iron finishing is available for special applications. Jet Cell LE, or low emissions applications, use jet cells, or pre-combustion chambers, which are installed in the power cylinder heads. 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 requiring a richer mixture for stable combustion. In addition, the jet cells are applied to units to improve combustion stability and improve fuel consumption when operating at variable speeds and reduced torque. (see Section 9.) Compressor Cylinder The compressor cylinders may be either cast iron or forged steel, depending on the pressure requirements of the application. Lubrication System Lubrication of the crankcase, including crankshaft and layshaft assemblies, is accomplished with a combination of splash and flood lubrication systems, while the power cylinders, compressor cylinders, and pressure packing are lubricated through a pressurized force feed system. A manual or automatic prelube system provides lubrication to the main bearings and crossheads prior to start-up. Piston Rods Power and compressor piston rods pass through stuffing boxes containing oil wiper packing, so the crankcase is isolated from the by-products of the power and compressor cylinders. Fuel System A hydraulic fuel injection system injects the fuel gas into the power cylinders. High voltage, capacitor discharge solid state ignition is standard equipment on all models. The power end cooling system utilizes a standard fin tube cooler, with the coolant being circulated by a centrifugal water pump.
When standing at the power cylinder end, the cooler side of the unit is to the left while the flywheel side is to the right. The power and compressor cylinders are numbered, starting at the flywheel side of the unit. When viewed from the flywheel side, the crankshaft rotation is clockwise. Figure 4-1 shows the Ajax Integral Gas Engine Compressor Unit. Figure 4-1: 2804 Engine Compressor Basic Application Ajax engine compressor units are designed for continuous heavy duty operation and perform best when loaded near rated capacity at the operating speed. Performance curves furnished for each unit show compressor capacity versus suction and discharge pressures at maximum rated unit speed. The rated horsepower of the engine-compressor unit can be used as the continuous duty design capacity less than or equal to 1500 feet above sea level and 100 degrees Fahrenheit ambient temperature without de-ration. When the engine compressor installation is located at an elevation greater than 1500 feet above sea level, or 1500 FASL, or in ambient temperature exceeding 100 F, de-ration of the rated horsepower must be taken into consideration in applying the engine horsepower unit to the anticipated condition of loading. The calculated reduction in horsepower is 3 percent 1,000 feet above 1,500 feet elevation and 1 for each 10. F temperature rise above 100? F. Two-Cycle Principle of Operation The two stroke cycle has one working stroke of the piston for each revolution of the crankshaft. Compression, firing, expansion, exhaust, and scavenging take place in that order, and because these events are completed in two strokes of the piston, this is called the two-cycle design. The piston moves toward the cylinder head, it first closes the intake ports, then the exhaust ports, trapping a fresh charge of air. The piston compresses this mixture, which is ignited by the spark before but near top dead center (TDC).
Expansion of the gases continues until the piston uncovers the exhaust ports, permitting escape of the burned gases. As the piston moves further toward the crank, the intake ports open and the entering air displaces the remaining burned gases. After reaching the crank end of the stroke, the piston starts toward the cylinder head on another cycle. The crosshead construction of this engine-compressor permits complete isolation of the crankcase from the engine cylinder chamber. By this design, the crank end of the piston and cylinder forms a scavenging chamber and provides an efficient scavenging pump. On the compression stroke, a partial vacuum is created in the scavenging chamber at the crank end of the cylinder. The differential in pressure opens the check valves and a fresh air charge enters until the piston reaches the firing end of the stroke. The power stroke of the piston snaps the check valves closed and compresses this air in the scavenging chamber above atmospheric pressure. When the intake ports are opened in the cylinder, the slightly compressed air transfers to the combustion chamber. Figures 4-2 and 4-3 illustrate the two-cycle principle which provides one power stroke for each revolution of the crankshaft, or one power stroke for each two strokes (compression and power) of the piston. Figure 4-4 shows the scavenging process which takes place while exhaust and intake ports are uncovered at the conclusion of the power stroke.Then slide the gauge along the entire length of the crosshead-to-guide fit.These data are based on free field conditions. When reflective walls, such as steel, are present, then the levels will be slightly increased. When attenuation walls are placed between the units and the microphone, then the noise levels are substantially reduced, so, SPLs are affected by the surroundings of the unit. In the following tables, the SPLs are expressed as weighted averages in dBA with the units operating at the design rated RPM.
Table 5-11 lists the SPLs at ten feet from the power cylinders and at ten feet from the exhaust silencer. Weighted dBA (10 Feet from Engine) 90 Avg. Weighted dBA (10 Feet from Exh. Silencer) 91 40 Special Tools Table 5-12 Sound Pressure Levels Vs. If the unit is installed inside a building or adjacent to other machinery, sufficient space must be allowed around the unit to facilitate maintenance and service work (refer to the unit's foundation drawing). Avoid arrangements that allow hot air from the muffler or cooler to flow to the air inlet of the cooler or air cleaner. It is recommended that the engine-compressor skid and accessories be placed on grouting on the foundation to ensure full, even bearing support under the equipment. Grouting is poured after the equipment has been properly set and aligned on the foundation. For a grouted installation, the foundation top surface should have a rough surface (not trowelled) to ensure an optimal grout-to-cement bond. Remote air cleaners may be located outside the building to avoid heat generated by the unit; however, direction of prevailing winds should be considered in their location. Installation of units inside buildings should be designed to allow for the passage of hot air from the coolers to the outside through adequate natural ventilation or through ducting to the outside of the building. Unitized vertical discharge coolers may frequently be installed outside the building to ease the disposal of heated air. The exhaust system must be properly designed for the operating conditions of the engine-compressor, both for proper scavenging of the power cylinders, and for correct dissipation of exhaust heat. The instrument panel should be placed in a location convenient for the operator. Foundation In designing the foundation, the static and dynamic loads must both be considered. The unbalanced forces and couples of each engine compressor unit are available, on request, from the service branch or factory.
The foundation design must include anchor bolts to secure the engine-compressor unit. Anchor bolts must be located to achieve precise alignment with the skid’s anchor bolt holes (refer to the unit foundation drawing). Use sufficiently long anchor bolts to ensure deep placement and adequate length above the foundation (account for full thread engagement of nuts and space required for grouting). Preferred practice is to set anchor bolts while pouring concrete for the foundation. A common practice is to use canister-style anchor bolts to afford position adjustment capability. The open pipe end should be blocked to keep foundation concrete out. This approach is illustrated in Figure 6-1. Figure 6-1: Canister Bolt Detail If the foundation has already been poured, then anchor bolts may be set by first drilling holes in the foundation and then placing and grouting the anchor bolts in. Sulphuring, a means to dissolve concrete, may also be used to create anchor bolt holes. In soils having a low load support capacity, a wider and longer foundation or one which angles out at the bottom should be used to distribute the load over a larger area on the bottom face of the foundation. If the soil bearing capacity is questionable, it is highly recommended that a soil analysis be made prior to designing or pouring the foundation. If unsuitable soil is encountered, the foundation design must be changed to accommodate the soil. Preparation of the Foundation and Skid for Grouting Allow foundation concrete to cure for at least 28 days before installing an engine-compressor package. Any concrete-related problems that may exist, such as low tensile or compressive strength, may be detected at this time. If the concrete is ready for engine compressor installation and grouting, then proceed with foundation surface preparation.
In order to achieve optimal grout-to-concrete bonding, prepare surfaces for grouting by chipping away all laitance, oilsoaked concrete, and damaged concrete until 50 aggregate is exposed (the foundation contractor may have already prepared the foundation in this manner). A chipping hammer or 15-pound chipping gun (with chisel point) may be used for chipping. These may be set by drilling into the foundation and inserting the wickets or dowels. Determine whether or not grout expansion joints are required. Foam strips or other suitable (compressible, temporary) material may be used. Strips may be secured to the foundation with glue; apply wax to exposed surfaces to allow easy removal after the grout has cured. If a crane is to be used to place the engine-compressor unit, then expansion joints may be installed in advance. Set leveling planes in level position on the foundation under the leveling screw locations. Clean all residual paint, oil, grease and dirt from all surfaces which will come into contact with grout. For final surface preparation follow specific grout manufacturer's recommendations for cleaning based on grout type used. The end result will be a properly prepared foundation ready for setting the engine-compressor package. Ajax recommends that the skid bottom in contact with grout be free from all paint, grease, primer, or other material that could inhibit grout bonding. Setting the Engine Compressor The engine-compressor mounted skid is normally set directly on the foundation block. Lifting cables must be provided with spreaders so that the lifting cables will remain parallel to the vertical center-line of the unit. If overhead lifting capacity is not available, then jacks and rollers (cribbing) may be used to move the unit into place over the foundation anchor bolts. Lower the engine-compressor unit to its final elevation. This clearance is recommended to allow sufficient room for placing grout to all necessary locations beneath the skid.
Use leveling screws to make final skid elevation adjustments such that all mounting pads are at the prescribed elevation. Use these measurements to finetune the engine-compressor elevation using the leveling screws. For long term engine performance it is essential that web deflections are held within specification (see Ajax-Superior Engineering Standard ES-4025: Crankshaft Web Deflections for Three- and Four- Cylinder Ajax Engines). Both compressor unit and cooler drive sheaves (pulleys) should properly align if both inertia-base units were properly set and coupled together. Drive alignment may be checked by drawing a line taut between adjacent faces of the two sheaves, lined up to intersect the two hubs. When the drive is properly aligned, the string will just touch the face of each sheave at the points where it crosses the sheave rims. Figure 6-2 illustrates this procedure. Figure 6-2: Sheave Alignment Procedure With proper sheave alignment achieved, install belts on cooler drive and re-check alignment. Accurate alignment is essential to ensure acceptable drive component service life and to eliminate detrimental loads and vibrations. After properly positioning the engine-compressor unit, then finish up by taping off or paste-waxing all leveling screw threads so screws can be removed after the grout has cured. Each type has advantages and disadvantages. Be aware that total package weight is dependent on the number and size of compressor cylinders, and the number of compression stages and associated pressure vessels. If needed, grout manufacturer representatives can help in the grout selection process. Major load-bearing lateral skid members should also be grouted. Grout the skid base using procedures suitable to the application or unit involved. The final grout level should be approximately up to the skid flange thickness. Care must be taken to provide adequate forms to retain grout. Remove any excess grout before it has been completely set.
Final Grouting Instructions After grout has set and cured sufficiently to carry the weight of the unit, relieve the load on all leveling screws. Properly tighten foundation bolts after grout has sufficiently cured, and then recheck alignment. Remove temporary expansion joint materials and fill expansion joints with joint compound. Setting an Inertia-Base AJAX Compressor Unit Inertia-base skids consist of two coupled, concrete-filled portions to serve as a compressor assembly’s foundation, one portion for the compressor unit and one portion for its cooler. Long-term compressor performance and viability is enhanced if: l l l The site is analyzed for its load bearing capacity. This is especially true if the soil load bearing capacity is questionable. If unsuitable soil is encountered, then a solid foundation base must be constructed. The earth bed is properly constructed to achieve proper coupling between unit and cooler skids. Specifically, both skids must remain flat with respect to each other so that proper cooler drive belt coupling is maintained. When settled in, friction between bed and skid is maximum and its tendency to move is minimized. Pit Preparation: A shallow pit must be dug into the earth to accommodate both inertia-base skid portions. Actual pit size (footprint) will vary depending on which inertia-base skid is used. Figure 6-4 provides an overhead illustration showing typical pit dimensions. Pit boundaries should lay approximately 6-inches from each inertia-base skid outer beam. See Figure 6-5 for an illustration. The pit must also be level and well drained. Completely fill the pit with a 6” layer of sand onto which the inertia-base assemblies will be set. Sand with particle size (diameter) We are a non-profit group that run this website to share documents. We need your help to maintenance this website.
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