AJAX ®
INTEGRAL
ENGINE-
COMPRESSORS
440...It‘s even better
COOPER
ENERGY SE RVICES
Innovative Energy Solutions
HOW THE BEST…
GOT EVEN
BETTER!
AJAX
®
UPRATE TO
440 RPM
AJAX® INTEGRAL
ENGINE-COMPRESSORS
• 98%+ Availability with Minimal Maintenance
has resulted in Ajax integral engine-compressor’s
reputation as the premier product for gas gathering
and production worldwide.
• Integral Design Provides Higher Efficiencies
by combining engine and compressor on the same
crankshaft, to eliminate losses associated with gears,
belts and couplings. Fewer moving parts mean higher
efficiencies and less maintenance.
• Moves More Gas per horsepower than any competi-
tive product, thanks to slower operating speed and large
compressor cylinder valve areas.
• Increased Horsepower Lowers Initial Cost • Low Emissions: 2.0 grams per BHP means that
per HP. You get more production for your you can rely on Ajax integrals to contribute favorably
investment. to site emission standards without the need for
expensive catalytic converters or complicated
• Lower Operating Costs per BHP. Already controls.
known for reducing routine maintenance (as much
as 33% lower than lighter-duty products); the • Lower Transportation Costs: Portability
operating costs per BHP are now even better. At without sacrificing Ajax durability – our new single-
440, you can maximize production at a lower cost skid package design also provides easier access for
than ever before… all with the security of Ajax maintenance. See page 5 for new package benefits.
long-term reliability.
• Field support that you can rely on: Ajax
integrals are backed by the worldwide engineering
and manufacturing strength of Cooper Energy
Services and an extensive domestic and international
distribution network. The scope of our commitment
to the energy industry is evident by our well known
tradenames: Coberra®, Cooper-Bessemer®,
Enterprise™, En-Tronic®, Penn™ and Superior ®.
NEW ®
AJAX 440
THE PACKAGE
IS BETTER,
TOO!
Along with our uprating to 440 RPM, we have
redesigned the Ajax Integral Engine-Compressor
package for the DPC-2201 through DPC-2802. Based
on a single-skid concept, the new packaging increases
portability and lowers transportation costs…
Lower shipping weight: optional integral concrete
filled skid eliminates the separate portable base for a
lower package weight. Environmental drip lip
standard.
Design reduces transportation costs with the
(optional) muffler on the skid; integral base allows
one shipment.
Process Cooler is a horizontal forced draft inlet
and outlet; allows use of current cooler designs and
shortened delivery cycle.
Simplicity saves money: cooler driven from the
engine, is simpler than electric and less costly than
hydraulic.
Longer wearing: stainless steel tubing with plated
steel fittings for process drain lines provides fewer
leak points with little chance for corrosion.
Reduces cost: carbon steel jacket water tubing for
compressor cylinders, with threaded connections
for engine cooling; not only reduces costs but also
reduces potential leaks.
Improved balance and vibration for a smoother
running unit: improved balancing allows reduction
in the amount of concrete in the skid – which reduces
shipping costs and delivers a smoother running unit.
Easier maintenance: improved package allows
easier access to unit and cooler for maintenance.
Reed valve access doors, standard on DPC-2202
and 2802.
Skid Edge Suction and
Discharge Connections
External Ringfeder
Drive Sheave
Single stage or two stage with
cylinders and bottles to suit
application
External Ringfeder Flywheel:
• 48” O.D.
• Common flywheel singles
• Common flywheel twins
• Can be applied to current
equipment
• Flywheel wedge not required
Air Filter/Silencer:
• With reed valve access
Control Panel - STD
• Skid mounted on end (optional)
OPTIONAL
skid mounted silencer
(Patent pending)
Less than 12’ shipping width
OPTIONAL
Integral skid/porta-base:
• Concrete fill core for mass
• Set on graded earth pad
• Tail board or sling lift
• Environmental drain lip with
decking and concrete surfaces
Flywheel Transport Chocks
(flywheel removal is not required)
Stainless Steel Tubing with
Plated Steel Fittings for Process
Drain Lines
FEATURES
• Common Crankshaft: Eliminates
power losses and wear associated 1 Hydraulic Fuel Injection:
Optimum fuel efficiency.
7 Efficient Lubrication: Force-fed,
lubrication system for power and
with belts and couplings. compression cylinders. Pump to
• Heavy-Duty Governor: 2 Babbitt sleeve and/or double-
row tapered roller bearings for point and divider block.
Constant-speed operation.
(Optional pneumatic operator for
maximum horsepower load and
application requirements.
8 Integral Construction:
Babbitted crosshead design,
speed and capacity control.) both power end and compressor.
• Air Filter: Oversize dry-type 3 Power Cylinders: Two-cycle,
design for long service in dusty
low-BMEP, chrome-plated, with
fewer parts for less mainten-
9 Crankshaft and connecting
rods are closed-die forged in
environment. ance. Port-scavenged, requires precision dies.
• Segmented Packing: Full range neither inlet nor exhaust valves.
of materials and designs to seal-in 10 Frame: Ribbed, cast iron
the most demanding services. 4 Crosshead Guides: Absorb
thrust stresses and prevent
construction for durability.
• Single Skid Construction: contamination of crankcase 11 Distance Piece: API - Type II
extra-length design for ease of
Improves portability of twin lube oil. packing maintenance.
cylinder units.
• Surge Bottles: ASME pre-sized to
5 Splash Lubrication System:
For main and connecting rod
minimize peak-to-peak pulsations. bearings – no oil pump, filter or
• Matched Separators: Complete cooler required. Sealed from
with mist extractor element, combustion process.
automatic dump, liquid level
shutdown, manual drain and
6 Reliable Ignition System:
Solid-state, permanently timed
relief valve. and breaker-less.
• Interconnecting Process Gas
Piping: Nominal velocity of 2500
ft/min (762 m/min).
• Interconnecting Jacket Water
Piping: Completely mounted and
piped.
• Instrument Control Panel:
Ignition-power electrical system
complete with dust-proof
enclosure. Class I, Group D
Division II non-incendive standard.
• Discharge Cooler: Unitized,
belt-driven cooler. Complete
with jacket water and ASME gas
sections; surge tank and water
shut-off valves, mounted on
main skid.
1 2 3 4 5
12 High Rod Load and Cylinder
Working Pressure: Full-load
14 Low Valve Velocity: Longer life,
high performance efficiency. High
15 Clearance/Loading: Manual,
hand-wheel-type, variable volume
operation through a variety of differential poppet valves clearance pocket with indicator
compression ratios up to 6:1 standard. allows cylinder unloading with
per stage. depressuring.
13 Compressor Cylinders: Large
gas passages and valve flow
areas for high efficiency. Bores
range from 3-28 inches (7.62 to
71.1 cm) diameter. Pressures to
6000 psig.
6 7 8 9 10 11 12 13 14 15
DESIGNED TO EXCEL,
BUILT TO LAST.
piping, separators, • More Production Per
AJAX® INTEGRALS vs. HIGH SPEED SEPARABLES
600 600 surge bottles and Horsepower: Compressor
AJAX gas cooler are all cylinders feature large gas
500 SEPARABLE 500 skid-mounted for passages and valve flow areas for
DOWNTIME IN DAYS OF
easy transporting. high efficiency. Low valve velocity
LOST PRODUCTION
TOTAL COST IN $000
400 400 Skids are heavy- provides compression efficiency
duty structural with minimum loss. When
300
TOTAL COST
300 steel for vibration combined with precise cylinder
IN $000 free performance clearances and a long compressor
200 200
and structural stroke, an Ajax unit can move
100 DOWNTIME 100
integrity when more gas per horsepower than
IN DAYS transported. All any competitive unit. A broad
0 0
vessels are range of operating pressures (to
1 2 3 4 5 6 7 8 9 10 designed to ASME 5000psig) is available, higher
YEAR
code. Installation pressures available for special
requires only applications.
• Pioneers in Design: The heavy- simple hookup of suction,
duty Ajax® integral engine-compressor • Patented Fuel Injection:
discharge lines. Patented, cam-actuated hydraulic
design, pioneered by Cooper,
results in the highest reliability • Customized Packages: Ajax fuel injection provides optimum
available today. Troublesome belts, packages can be customized to fuel efficiency.
gears and couplings are eliminated. meet the requirements of a • Highly Reliable Ignition System:
Conservative horsepower ratings particular application. These Permanently timed and
means there is power to spare for include: propane, ethylene, helium breakerless, the highly respected
unexpected overloads. Ajax units compression as well as offshore, Altronic ignition system has set
perform at 98%+ availability with hazardous area classifications the standard for reliability since it
little maintenance. and extreme environments. was introduced on Ajax engines
• Two-Cycle Design: A two-cycle, • Major Components Closed Die in 1965.
versus four-cycle, design has Forged: Critical parts such as
significantly fewer components crankshafts and connecting rods,
such as valves, pushrods, cams, are forged steel for maximum
rocker arms, etc. and therefore strength.
less to maintain and repair.
FOUR CYCLE PRINCIPLE TWO CYCLE PRINCIPLE
• Slow Speed Advantage: The
Ajax integral, slow speed, cross- COMPRESSION STROKE
head design generates lower
operating temperatures with less
friction (wear) on moving parts.
Moreover, it prevents crankcase
COMPRESSION STROKE
contamination thereby requiring
only annual oil changes.
• Reduced Maintenance Cost: POWER STROKE
Two-cycle, slow speed, cross-
head design integrals have a
demonstrated track record of POWER STROKE
reduced maintenance costs. In
most cases, predicted mainten-
ance cost is one-quarter to
one-half of lighter duty, higher
speed machinery. Standard
components allow interchange-
EXHAUST STROKE SCAVENGING
ability of parts throughout the
product line for smaller
inventories.
• Completely Packaged and
Portable: Standard configurations
are completely packaged, ready INTAKE STROKE
to perform. Engine-compressor,
SPECIFICATIONS - MODEL ALL 2201 2801 2202 2802 2802 2803 2803 2804 2804
UNITS STD/LE STD/LE STD/LE STD LE STD LE STD LE
Rated BHP at 100°F Ambient & 1500 FASL 148 192 296 422 384 634 600 845 800
Cooler Horsepower 6 8 12 17 15 25 24 34 32
Compression Horsepower
at 100°F Ambient & 1500 FASL 142 184 284 407 369 609 576 811 768
Rated RPM 440
Speed Range - Minimum 265
Maximum 440
BMEP PSI - Rated 62.8 63 62.8 70.1 63 70.1 63 70.1 63
BMEP PSI - Minimum 37.7 37.8 37.7 42.1 37.8 42.1 37.8 42.1 37.8
Number of Power Cylinders 1 1 2 2 2 3 3 4 4
Engine - Bore Inches 13.25 15 13.25 15 15 15 15 15 15
Stroke Inches 16
Displacement
Per Power Cylinder, Cubic Inches 2,206 2,827 2,206 2,827 2,827 2,827 2,827 2,827 2,827
Total, Cubic Inches 2,206 2,827 4,412 5,654 5,654 8,481 8,481 11,308 11,308
Compressor
Throws 1 1 2 2 2 2 2 3 3
Stroke - Inches 11
Rod Diameter - Inches 2.5
Piston Speed FPM 807
Rod Load - Pounds 30,000 30,000 30,000 30,000 30,000 40,000 40,000 40,000 40,000
DIMENSIONS - MODEL 2201 2801 2202 2802 2803* 2803* 2804* 2804*
STD/LE STD/LE STD/LE STD/LE STD LE STD LE
A - Length - In. (cm) 384 (975.36) 384 (975.36) 384 (975.36) 384 (975.36) 294 (747) 294 (747) 294 (747) 294 (747)
B - Width - In. (cm) 109 (276.86) 109 (276.86) 143.5 (364.49) 143.5 (364.49) 259 (658) 259 (658) 295 (749) 295 (749)
C - Height - In. (cm) 138 (350.52) 138 (350.52) 138 (350.52) 138 (350.52) 126 (320) 126 (320) 156 (396) 156 (396)
Available for DPC-2201, 2202,
2801, and 2802 standard.
*Two piece package standard.
AJAX LOW EMISSION TECHNOLOGY:
Based on “built-in” combustion modification, Ajax Low Emission
Technology avoids the addition of troublesome “bolt-on” solutions.
The Ajax ignitor and pre-combustion chamber provides a more
complete combustion, resulting in lower NOx formation and
cleaner exhaust. Benefits include:
Low Maintenance: avoids the expense of maintaining short-lived
catalytic converters or controls systems.
Reduced Fuel Consumption: a more complete combustion also
reduces fuel costs. Uses the broadest range of fuel gas quality,
including most well-head gas without expensive treatment
processes.
Low NOx Rating maintained over a wide torque range… in fact,
as the torque is reduced the emission levels are also reduced.
Low Compression Ratio resulting in low detonation sensitivity;
low combustion temperatures contribute to longer-life
components.
Standard on all new Ajax 440 models, the benefits of Ajax Low
Emission Technology are also available for existing units through
the LE Conversion Kit… proving that the investment you make with
Ajax today will be extended by our continuing commitment to the
future.
COOPER ENERGY SERVICES’
AFTERMARKET
At Cooper, our first concern is to help our customers achieve
maximum equipment availability at the lowest operating expense.
Our aftermarket services group, along with our extensive distributor
network, is dedicated to keeping your equipment at peak
performance by providing the very best in aftermarket services.
This means fast access to genuine O.E.M. replacement parts. It means
a qualified network of people to diagnose, maintain, service and/or
reapply your units as necessary, or training you to do it yourself.
With Cooper you get what no one else can offer: single
source responsibility and performance, not promises!
Visit our web site at: www.coopercameron.com
Note: Standard equipment and specifications are
subject to change without notice.
Ajax®, Cooper-Bessemer®, Enterprise™, Penn™ COOPER
and Superior® are registered trademarks of ENERGY SE RVICES
Cooper Cameron Corporation. All others
contained herein are the property of their Innovative Energy Solutions
respective owners.
2101 S.E. 18th Street • Oklahoma City, OK 73129
2-201E 2M 6/00 Telephone: (405) 670-4121 • Fax: (405) 672-6126
Copyright © 2000 Cooper Cameron Corporation
Printed in U.S.A.
