Superior® Aftermarket Services

Overview
The Superior® brand name has a long-standing reputation for high quality engine and compression products, dating back to 1889. Today, CAMSERV, Cameron Compression Systems' aftermarket parts and services team, is here to keep your Superior® engines and compressors running in tip-top shape. CAMSERV offers a complete line of OEM parts and services that are available to Superior® customers around the clock and around the world.

Superior® Engines
Superior® engines have been designed to use a variety of fuels such as gas, diesel or dual fuels. Superior® engines are used as prime movers to drive reciprocating and rotary screw gas compressors, pumps, drilling rigs, and electric generators for independent power generation applications. Superior® engines range in size from 500 to 3,200 bhp

Superior® Compressors
New Superior® separable reciprocating gas compressors are available in a wide range of sizes from 290 to 9,000 hp. In addition, Superior® compressors are engineered for operating speeds from 600 to 1,800 rpm.

The following OEM services are available from CAMSERV to our Superior® customers worldwide.

Maintenance and Service Solutions
- Genuine OEM Parts
- Machine Shop Repair Services
- Overhaul and Retrofit Services
- Exchange, Reconditioned and Used Parts
- Preventive Maintenance Programs
- Maintenance and Operating Contracts

Engineering Solutions
- Emissions Reduction
- Horsepower Upgrades
- Re-application of Equipment
- Engine and Compressor Control Systems and Upgrades
- Performance Analysis and Optimization
- Failure Analysis

Remanufactured Superior® Engines, Compressor Frames and Cylinders

For more information about our services, please visit our website at:
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Ajax Introduces the New C-202 Electric, Two-Throw Compressor

ELECTRIC MOTOR-DRIVEN AJAX COMPRESSOR

Cameron’s New AJAX C-202 is Available in Two Ratings, 250 and 600 hp (186 and 447 kW), Depending on the Crankshaft and Bearing Selection

Cameron’s Compression Systems has released the new AJAX C-202, separable, two-throw compressor.  According to the company, it was designed to accommodate applications where a slow-speed (300 to 440 rpm), two-throw compressor offers the most efficient solution and there is a need for an electric motor-driven system for environmental considerations.

The C-202 is available in two ratings, 250 and 600 hp (186 and 447 kW) depending on the crankshaft and bearing selection. Like other AJAX compressors, this unit has 11 in. (279 mm) stroke compressor cylinders, a 2.5 in. (36 mm) piston rod diameter and a 30,000 lb. (133.45 kN) rod load rating.  It is available in both packaged and unpackaged configurations, and this “new” technology shares the benefit of more than 50 years of AJAX packaging experience with single-source responsibility, the company said. It has all aircooled cylinders, eliminating the need for water pumps, antifreeze and water coolers. According to Cameron, splash lubrication in the crankcase eliminates the need for oil pumps, filters and oil coolers, complementing this environmentally friendly compression system.

This is an extension of the wellknown AJAX product line with only four new parts created in its manufacture — the crankcase, crankshaft, flywheel and the drive hub. The C-202 maintains all of the same unit consumables, rods and rod bearings as the AJAX integrals with gas-driven engines.

“For existing AJAX users, this is a tremendous advantage,” said Bruce Chrisman, manager of engineering for the AJAX operations of Cameron’s Compression Systems group. “What this means for customers owning AJAX engine-driven compressors is that they will not need to stock additional parts as they add the C-202 motor-driven compressors to their operations.”  According to Chrisman, the ability to design the C-202 with standard AJAX parts expedited the design process, bringing this product to market sooner than would have otherwise been the case.

Flexibility was a prime consideration in packaging for the C-202. “We wanted to make sure the package was flexible enough to allow the cooler to be located in either the horizontal or vertical position, since the vertical position is needed in challenging operating conditions such as snow and ice,” said Rusty Kight, manager of package engineering. “Taking into account cold-weather considerations, heaters have also been designed for the C-202.  Another new packaging feature on the C-202 is the use of a rotating scrubber with a top outlet flange to allow interchangeability among packages, as well as providing a lower package profile.”

Standard on the C-202 is a 32% turndown rate for a range of 300 to 440 rpm. An optional feature on the C-202 is a 55% turndown rate, increasing the range to 200 to 440 rpm for more flexibility with the addition of only a few additional components.

According to Cameron, the C-202 is ideal for gas gathering, EOR injection, fuel gas boosting and some process markets including propane and ethylene compression.

The project was initiated in March 2008, after numerous discussions with a major energy company that is a significant user of AJAX Integral Engine/Compressors as an alternative to electric-driven rotary screws. The customer was seeking to apply these units in a coalbed methane application and operate in a vacuum to 5 psig (0.34 bar) suction, something it does with its current AJAX integrals. The design criteria included interchangeability with the current products, high efficiency of the 11 in. (279 mm) stroke, low valve velocities and slow speed.

After the initial design was completed in late 2008, the first unit was built and packaged for another major energy company that had viewed the design process. This application is a traditional gas gathering unit in the Dallas-Fort Worth, Texas, U.S.A., area.

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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.

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Innovation and Customer Need Drive the Launch of 5 New Centrifugal Compressor Products

The center-of-excellence for Cameron’s centrifugal compression products is located in Buffalo, New York where technology is king and innovation is standard practice. The centrifugal team systematically surveyed their customers to determine what new products were needed in the market and have recently released five new products as solutions to meet these needs. Those products include the Turbo-Air® 2040, Turbo-Gas™ 2040, Turbo-Air Blower, MSG-18™ and the Maestro Universal™ control system.

Turbo-Air 2040

Turbo-Air 2040 (TA-2040) centrifugal compressor shares the basic technology of the proven TA-2020 and was designed with the PET bottle blowing market in mind. This process requires high pressure air to form a bottle. If the compressed air is not oil-free, then an air purification process is necessary, adding cost to the process. The TA-2040 produces oil-free air with a discharge pressure rated at 585 psig (40 barg), a flow rate up to 1,800 cfm (51 m3/min) and up to 800 hp. It comes standard with the new Maestro Universal control system providing more precise control allowing the compressor to run more efficiently. There are many other high pressure applications that require oil-free air for which the TA-2040 was designed such as fossil fueled power plants and nitrogen gas boosting.

Maestro Universal Control Panel

As the first in the market with a standard built-in web server allowing remote monitoring using your local intranet, the Maestro Universal control system is the perfect example of innovation and technology. The Universal is also the first to use the Windows CE operating system, a USB port to upload and download information, and a built-in commissioning wizard. The panel is easy to use with a 10” color graphic display. Software options expand the capabilities to include system alarm or trip event e-mail messages, remote start/stop operations, load/unload and operator level set point changes and multiple compressor management. The Universal is designed for global use with multiple certifications and languages supported. The Maestro Universal now comes standard on Cameron centrifugal products and is available for retrofits.

Turbo-Gas 2040

Compressor customers wanted a solution for the constant compressor shut down in landfill gas applications, and Cameron delivered them the Turbo- Gas 2040 (TG-2040). The TG-2040 is oil-free and keeps running when oil flooded compressors clog and shut down. The TG-2040 has a flow rate up to 3,000 scfm, discharge pressure up to 585 psig and up to 800 hp. The TG-2040 uses patented squeeze film bearings and the patent-pending buffer-educted seals. The TG-2040’s design is rooted in the proven technology of the TA-2020 and comes with the Maestro Universal control system standard. The reliability of a Cameron oil-free centrifugal compressor, combined with the lack of wearing parts, make the TG-2040 a perfect fit for landfill gas applications.

Turbo-Air Blower
Cameron has taken the first stage of the Turbo-Air compressor and made it into the Turbo-Air Blower (TAB). The TAB utilizes the same proven technologies that make other Turbo-Air products great. With no wearing parts, there is minimal maintenance, reducing life-cycle cost. Customers wanting blowers indicated that they want reliability, efficiency at design point, constant pressure control, guaranteed performance, specification compliance and easy installation. The TAB was designed to meet these requirements. The TAB provides oil-free air needed in numerous applications and provides the ability to customize and handle engineered options. TAB products include the TAB-2000, TAB-2000M2, TAB-3000, TAB-3000M3, TAB-6000, TAB-6000M2, TAB-9000 and TAB-9000M2, the flow rate ranging from 500 – 12,000 icfm.

MSG-18
Customers using our MSG-16™ and MSG-25™ needed a compressor between these two to fill in the performance range. With a flow rate of 45,000 – 75,000 cfm and discharge pressure of 80 – 218 psig, the MSG-18 provides the capacity needed with excellent efficiency. With aircraft quality gearing and proven long life bearing technology, the MSG-18 meets the reliability expectations Cameron customers have come to expect. The innovative design and packaging includes a module design and gearbox mounted main oil pump and the Maestro Universal control system standard.

Cameron listened to the voice of our customer and has provided five new centrifugal compression products in response. Each product was designed using the latest technology and Cameron innovation. These products are also designed to provide the highest level of quality to ensure reliability and efficiency. Cameron is known around the world for providing products that are built to last with minimal maintenance to reduce the life-cycle cost of our equipment.

For more information, please visit our website at:
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