Cameron's Compression Systems Group: Ajax Aftermarket Services

Overview

AJAX® is the oldest continuous engine product line manufactured in the United States and has been providing high quality engines and compressors to the Oil and Gas Industry since 1877. The time-proven, horizontal two-cycle design of the AJAX® integral gas engine-compressor combines the engine and compressor on the same crankshaft, which eliminates the power losses associated with gears, belts and couplings. With these design characteristics, its slow operating speed (440 rpm) and AJAX®'s large compressor cylinder valve area, no other compressor moves more gas per bhp than an AJAX®. AJAX® units offer unsurpassed reliability and consistently deliver 98%+ availability while requiring minimal maintenance and parts replacement. AJAX® integral gas engine-compressors are available from 150 to 800bhp and are used in a wide variety of applications from gas gathering, production, transmission, storage, re-injection and gas processing such as propane, helium and coal bed methane.

At Cameron, our primary concern is to help our AJAX® customers achieve maximum equipment availability at the lowest operating expense. Our CAMSERV™ aftermarket services group, along with our extensive AJAX® distributor network, is dedicated to keeping your existing equipment operating at its peak performance with OEM parts and services.

THE LATEST SOLUTIONS FOR AJAX® INTEGRAL ENGINES:

New AJAX® Catalytic Converter

To comply with new EPA regulations, AJAX® applied the first successful application of an oxidizing catalyst for CO/VOC/H2CO reduction which has exceeded the mandated reduction by 34% with only minimal efficiency loss after 24,000 hours of operation. Working with a gas transmission company in Colorado, the AJAX® team converted two 2804 engines using a horizontal oxidizing catalyst. After running continuously for 36 months, the site has shown impressive results without significant degradation of the catalyst. This product is available on all new AJAX® units and utilizes one common element per power cylinder. It can be adapted to any AJAX® model produced since 1958.

New AJAX® Integrated Governer Throttle Body (IGTB)

The AJAX® team has introduced a new Integrated Governor Throttle Body (IGTB) as a field retrofit for the original mechanical throttle valve-style governors. This product can be used on AJAX® units that utilize auto-variable speed operation for load control; it is now standard equipment on all new 2801, 2802, 2803 and 2804 units. The IGTB is a combined throttle valve and electronic governor, and its purpose is to maintain a fixed speed set-point throughout the engine's load range. The governor measures engine speed with a magnetic pickup and compares it to the set-point speed provided by the transducer. When engine speed changes, the IGTB adjusts fuel gas header pressure to maintain the desired speed. Construction consists of aluminum valve body and corrosion resistant plated steel butterfly and sealed bearings. The IGTB is ideal for fuel gas with H2S content, and the flexible fuel connections isolate the IGTB from vibration.

New AJAX® Flexible Fuel Header

AJAX® customers requested a fuel header system that reduced downtime, was easier to maintain, and that provided easier access to the other engine components. The AJAX® team delivered by introducing a new flexible fuel header as standard equipment on all new AJAX® integral engines. The new fuel header system eliminates external forces on the gas injection valves which eliminates costly downtime. In addition, the header improves access to components mounted on the cylinder head, such as ignition and injection equipment, allowing for quicker and easier maintenance.

New AJAX® Power Cylinder Development Project

The AJAX® team is working towards their first new power-end in 18 years. The new DPC-3400 will increase the horsepower by 21% through an increase in the diameter from 15" (381mm) to 16.5" (419mm) while B.M.E.P. remains the same. The horsepower range will extends from 155 to 1,000. In order to increase bore size without significantly impacting the AJAX® frame, engineering took an innovative approach to how air enters the combustion chamber. The current 15" cylinder compresses the intake air around the skirt of the piston and into the combustion chamber. The 16.5" cylinder will compress the intake air through an external jumper mounted on the top of the power cylinder. This development allows for the use of standard internal components as well as easing field retrofits in the future. The new product will see field testing in 2009.