Section 5: General Data

Section 5: General Data

General Data
Table 5-1 General
1. Manufacturer and Packager Cooper Compression - Ajax Division
2. Model Ajax 2804 & LE
Naturally aspirated, slow speed, 2-stroke cycle, integral gas
3. Type
engine-compressor
4. Engine Standard DEMA
5. Compressor Standard API 11P
6. Expected Site Loading 100% of Maximum Continuous
7. Expected Site RPM 300 - 440(100% of maximum, to minimum)
8. Expected Site Availability 98%
9. Factory Re- Building No
10. Site Overhaul Time 40,000+ Hours
11. Expected Life 25-40 Years

Table 5-2 Power and RPMs

DPC-2804 - 845

1. Rate Power (2804) DPC-2804LE - 800

100° F and less than 1500º FASL

2. Rated Speed/ Overspeed (RPM) 440 / 484 (this value is 10% above rate speed)
3. Speed Range (RPM) 300 - 440
4. Minimum Loading Speed 70%
5. Minimum Loading Torque 70%
DPC - 2804 - 592
6. Minimum Horsepower, Rated BHP
DPC-2804LE - 560
STD - 67.2
7. Rated BMEP (PSI)
LE - 63.7
STD - 47.1
8. BMEP minimum (PSI)
LE - 44.6
9. Speed at 70% of Maximum (RPM) 308

Table 5-3 Basic Specifications - Engine

2-Stroke, horizontal, naturally aspirated, directional port scav-
1. Type
enged, gas injected, natural gas fuelled
STD - 8000 BTU/BHP-HR

2. Fuel Gas Consumption LE - 7670 BTU/BHP-HR

Natural gas, raw or treated

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General Data

3. No. of Power Cylinder DPC -2804 - 4

4. Power Cylinder Bore (inches) 15”
5. Power Cylinder Stroke (inches) 16”
6. Cylinder Displacement, (Cubic Inches) 2,827 per cylinder
7. Piston Speed 1,173 ft/min
8. Fuel Gas System Integrate Governor Throttle Body (IGTB), hydraulic gas injection
9. Speed Control Manual (Standard)
10. Exhaust Temperature Monitor Yes, individual cylinder
11. Exhaust Temperature at Full Load 2804LE - 740ºF
10-12% above normal exhaust temperature (See “Exhaust Sys-
12. Exhaust Temperature Shutdown.
tem” in Section 5)
13. Cylinder Differential Temperature MAX 20º
14. Crankshaft Rotation when facing flywheel Clockwise

Table 5-4 Compressor

DPC -2803 - 2
1. No. of Compression Throws
DPC -2804 - 3
2. Compressor Cylinder Stroke (inches) 11”
3. Compressor Piston Speed (RPM 807 @440
4. Rod Diameter (inches) 2.5” (Standard)
5. Maximum Allowable Rod Load (lbs) 40,000

Table 5-5 Auxiliary Systems

1. Speed Governing IGTB Woodward - Ajax Electronic 24 VDC Governor
2. Ignition System (standard) Altronic III
3. Panel and Control System (standard) Altronic solid-state digital electronic devices
4. Air Cooler Fin fan type, belt driven from crankshaft

Table 5-6 Estimated Weighs & Dimensions

Component L (in) W(in) H(in) Weight (lbs)
Main Skid 315 295 156 110,500
Cooler Skid INCL INCL INCL INCL

Table 5-7 Engine Component Dimensional & Clearance Data

As New Limits
Item Max. Acceptable (inches)
(inches)
15” Cylinder Bore 14.997 - 15.001 Up to 15.013, Max .002 TIR
15” Piston Skirt Diameter 14.968 - 14.970 Down to 14.961
15” Piston to Cylinder Clearance .027 - .033 Up to .045
15” Piston Ring 1 & 2 Side Clearance .010 - .0125 Up to .015
15” Piston Ring 3 & 4 Side Clearance .008 - .0105 Up to .013
15” Piston Ring End Gap (Ring 1) .115-.130
15” Piston Ring End Gap (Ring 2) .115-.125
15” Piston Ring End Gap (Ring 3) .125-.135
15” Piston Ring End Gap (Ring 4) .115-.125
Piston Rod 2.497 - 2.500 Down to 2.495

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 General Data

Crosshead Guide 12.000 - 12.002 Up to 12.004

Crosshead O.D. 11.987 - 11.989 Down to 11.985
Crosshead-to-Guide Clearance .009 - .013 Up to .016
Note:Determine the minimum clearance by passing the thickest feeler gauge possible over the top of the crosshead
to project out the opposite side. Then slide the gauge along the entire length of the crosshead-to-guide fit.
Conn Rod Pin Bushing I.D. 5.5044 - 5.5069 Up to 5.509
Conn Rod Side Clearance .010 - .026 Up to .029
Crosshead Pin O.D. 5.4995 - 5.5000 Down to 5.4985 Max .001 TIR
Crosshead-to-Pin Clearance .0044 - .0074 Up to .0085
Conn Rod Bearing Bore 7.503 - 7.505 Up to 7.507 Max .001 TIR
Crank Pin O.D. 7.499 - 7.500 Down to 7.4975 Max .0015 TIR
Crank Pin-to-Bearing I.D. Clearance .0044 - .006 Up to .0075
Main Bearing Journal O.D. 8.374 - 8.375 Down to 8.3725
Main Bearing I.D. 8.3796 - 8.3816 Up to 8.3831 Max .002 TIR
Main Journal-to- Bearing I.D. .0046 - .0076 Up to .0091
Main Bearing Thrust .010 -.020 Up to .022
Layshaft Bearing Bore 1.502 - 1.503 Up to 1.504
Layshaft O.D. 1.498 - 1.500 Down to 1.497
Layshaft O.D.-to- Bearing Bore Clearance .002 - .005 Up to .007

Table 5-8 Compressor Component Dimensional and Clearance Data

Item As New Limits (inches) Max. Acceptable (inches)
Cylinder Bore ** **
Piston Rings & Riders ** **
Piston-to-Cylinder Clearance ** **
Piston Rod, 21/2 2.497 -2.500 2.495
Piston Rod, 21/4 2.249 - 2.250 2.2455
Crosshead Guide 11.999 - 12.001 Up to 12.008
Crosshead O.D. 11.984 - 11.986 Down to 11.982
Crosshead-To-Guide Clr. .011 - .015 Up to .018
Connecting Rod Pin Bushing I.D. 4.5035 - 4.5062 Up to 4.507
Crosshead Pin O.D. 4.4995 - 4.500 Down to 5.4985
Pin Bushing-to-Pin Clearance .0044 - .006 Up to .0066
Connecting Rod Bearing I.D. 7.503 - 7.505 Up to 7.506
Crank Pin O.D. 7.499 - 7.500 Down to 7.498
Crank Pin-to-Rod Bearing Clearance .0042 - .0066 Up to .008

** contact the Technical Support Department at Ajax

Table 5-9 Torque Table for Critical Ajax Fasteners
Type of Unit (Refer- Torque (lb-ft) (Note #2 or other
Fastener Location Type of Fastener
ence Note #1) indicator)
Frame and Crankshaft
Flywheel shrink disk Bolts All 185
Drive shaft shrink disk Bolts All 185
Main bearing cap Studs 3&4 250

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General Data

Main bearing cap Stud nuts 3&4 360

Tie bars to frame Bolts 3&4 260
Top Center for crosshead guide Bolts 3 100
Power cylinder to frame Bolts All 490
Connecting rod caps Bolts All, P & C 650 - 700
Power cylinder side cover plate Allen Bolts All 38
Cylinder Head
Head to cylinder Studs 15 Bore 220 -250
Head to cylinder Stud nuts 15 Bore 600
Head to cylinder Studs 13-1/4 Bore 600
Head to cylinder Stud nuts 13-1/4 Bore 490
Pre-chamber hold down flange Bolts All LE 70
Pilot fuel check valve clamp Bolts All LE 15
Spark plugs Plugs All 60
Indicator cock Valve All 70
Control Box and Layshaft 1
Control box to frame Stud nuts 1 95
Control box to frame Stud nuts 3, & 4 160
Support bracket on crank end of lay-
Bolts All 45
shaft
Cover on crank side of control box Bolts All 10 -12
Caps for hydraulic power plungers Bolts All 11
Cover on top of control box Bolts All 25
Gears in control box Set Screws All 25
Cams in control box Set Screws All 25
Ajax governor drive gear Nut All 0.003 - 0.006 clearance
Woodward gov. drive gear Nut All 7 - 15 (line up with pin)
Crosshead and Piston Rod
Compressor guide to frame Stud nuts All, C 280 - 300
Rod packing ass’y to x-head guide Bolts All 38
Piston rod to crosshead Nut All, P & C 3200
Crosshead set screws Set screws All 55
Crosshead jam nuts Nuts All 50

Note #1: Key to “Type of Unit Abbreviations"

4 2804
P Power Side
C Compressor

Note #2: Torques are based on the use of Lubriplate

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