GE Ajax DPC 2804 LE Manual

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: [phone]
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
By
0
Initial Release
11/09/2012
Prabhu
1
GE Cover Page Update
7/9/2014
Prabhu
2
GE – Contact Information & Lubrication System (Baffle) Update
09/03/2015
Prabhu
3
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
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