Ajax Integral Engine-Compressors Field-proven and reliable, the Ajax integral engine-compressor is the durable, low-maintenance solution to maximizing field value while minimizing emissions. bhge.com
Simplicity, durability and enduring value Ajax* integral engine-compressors are designed for simplicity. A low-maintenance, reliable piece of equipment is comprised only of components that are strictly necessary. Fewer parts means a smaller margin for error. Ajax integral engine-compressors maintain a 98% or better performance consistency. As an integral engine-compressor, Ajax avoids many of the challenges inherent in its separable counterparts. Separable compressors must be matched to the driver, which requires alignment in packaging, with associated labor and time. With its integral design, Ajax eliminates these demands on the customer s time and budget less parts, less investment. In contrast to high-speed, separable compressors, Ajax operates at low-speed. This means less wear and tear on the equipment, reduced maintenance requirements and an increase in uptime. Ultimately, operating at low-speed improves customers economic operating environment. For added peace of mind, Ajax is BACT emissions compliant for both attainment and nonattainment areas. Solid reputation. After 50 years of reliable and robust service, Ajax integral engine-compressors continue to be globally renowned for their user-friendly simplicity and long-term effciency. The Ajax product line varies from 147 to 845 hp (110-630 kw), with a cylinder line-up capable of handling a wide range of pressures, from vacuum to 5,500 psi (379 bar). These specifications cover up to six ratios capability and the lowest commercially available BHP per million flows for a wide range of applications, including sour fuel gas. The Ajax integral engine-compressor has a unique two-stroke engine design, which virtually eliminates complications caused by sour fuel gas, with the ability to handle H2S content up to 3.0 mol%. History of experience. First introduced in the 1950s, many Ajax integral engine-compressor units are still in service today. BHGE draws upon more than 120 years of history collaborating with clients as a trusted partner. Our global team leverages access to the best minds and most innovative equipment, in order to improve field productivity and support clients in modern emissions compliance. Guaranteed quality. Ajax integral technology provides lower overall operating and maintenance costs. Best in class technical support is provided from a comprehensive network of service shops and locations. Integral compressor-engine frames and cylinders continue to be manufactured at Oklahoma City as they have since 1958. Ajax is also available as a pre-engineered and prepackaged unit or can be packaged by one of our rigorously certified global packaging partners. Ajax integrals are backed by the worldwide engineering and manufacturing strength of BHGE and an extensive domestic and international distribution network. Customer focus. By listening to feedback from our customers, BHGE has continued to improve Ajax to meet their needs. Customers face worsening gas conditions, wells that deplete over time and newer environmental regulations that must all be addressed in a challenging economic environment. Operational flexibility, environmental performance and cost reduction are critical to success. By incorporating these key factors, Ajax integral engine-compressors simplify operations and maximize value. Dugan Case Study Location: Farmington, New Mexico, USA 18-month idle period, the unit has been in continuous service for 55 years (since 1959), and currently operates at the Davis wellsite in the western San Juan basin, gathering gas from four wells. Results: The DPC-120 engine runs at 475 rpm with an average piston speed of 950 ft/min., meaning that since 1959 at 98% run time its pistons have now traveled approximately 5.1 million miles: the equivalent distance of 10.5 trips to the moon and back, and it still has the majority of its original components. Dugan Production has more than 105 gas gathering compressors, most of which are wellhead units connected to one or more gas wells. The majority of Dugan s larger units are Ajax integral enginecompressors. The company acquired an Ajax DPC-120 with an operating well from Skelly Oil in 1968 and has moved it to two different sites in the San Juan Basin since that time. Apart from an Dugan Production has had the DPC-120 running almost constantly for 15 years at the Davis wellsite with very minimal intervention required. There were 131,400 hours in those 15 years, and the DPC-120 ran for approximately 125,000, with no major repairs or overhauls required. At the end of 2014, Dugan Production purchased four DPC-2802s due to Ajax integral technology providing lower overall operating costs and maintenance expenses. 2 3
Availability and Maintainability Less oil changes, less oil changed Ajax engines inject precise oil amounts with each stroke, which is consumed, meaning no contaminated oil from the power cylinders has to be changed. The power cylinders are also isolated from the crankcase by the crosshead guide design. On a high speed engine, the power cylinders are only separated from the crankcase by the piston rings. Ongoing contamination of that oil by combustion gases necessitates frequent oil changes. Engine oil consumption during operation should be similar, but because of their high speed four stroke engines, separable packages will require more oil changes with each oil change requiring more oil than an Ajax integral package. This could be up to 8-10 annual oil changes versus just one annual oil change for Ajax. The 440 rpm Ajax two stroke engine therefore has a clear advantage over high speed four stroke engines when it comes to oil changes. More flow from less power equals less fuel Ajax compressor cylinders feature large gas passages and valve flow areas for high efficiency. Low valve velocity provides compression efficiency with minimum loss. When combined with precise cylinder clearances and a long compressor stroke, an Ajax unit can move more gas per horsepower than any competitive unit. Savings vs high speed separable package Annual 5 Years DPC-2802LE $9k $44k DPC-2803LE $8k $44k DPC-2804LE $12k $60k Compared to non BHGE high speed separable compressor and engine package. High speed oil $17.11/gal; two stroke oil $13.84/gal; conventional oil $13.47/gal The economic impact of oil maintenance differences can be substantial with the cost of deploying service personnel multiple times to change the oil, and the downtime that incurs. High speed engines will generally require higher grade oil than Ajax. Considering both the amount and cost of required oil, there are substantial annualized savings with Ajax. Ajax DPC-2804LE Sour gas capability The unique 2-stroke design of the Ajax integral engine-compressor eliminates the problems typically caused by H2S presence in fuel gas. Because the power cylinder is isolated from the crankcase, blowby cannot enter the crankcase resulting in acid attack of the bearings. Unlike conventional 4-stroke engines, the Ajax does not have intake or exhaust valves so valve and seat wear are totally eliminated. Primary applications Gas gathering Gas transmission Storage Gas re-injection Gas processing Propane processing Helium processing Coal bed methane processing Fuel gas boosting 4 5
Continual evolution, solid reputation Ajax has continually evolved to meet customer needs and provide reliable service. Improvements over the years have supplemented the strength and simplicity of the original design: the inherent nature of the Ajax engine and compressor has remained fundamentally unchanged since the 1950s. Facilities and packaging Oklahoma City, Oklahoma 2 32,200 sq ft (21,572 sq m) available for manufacturing, warehouse, and testing P rimary manufacturing and testing facility for Ajax integral gas engine-compressors B HGE's primary packaging facility for Ajax products STD When the Ajax was first introduced in its Standard (STD) model, it proved to be the most efficient integral engine-compressor on the market. Facility information: M anufacturing: 108,000 sq ft (10,034 sq m) W arehouse: 116,000 sq ft (10,777 sq m) O ffice: 8,200 sq ft (762 sq m) LE Subsequently, Low Emission (LE) models were developed, maintaining the same high performance design, but achieving lower emissions without requiring costly add-ons or the use of catalytic converters. The LE models reduced fuel consumption, broadened the range of fuel gas quality and maintained NOx emissions over a wide torque range. LE models are rated for 2g NOx, but with engine tuning, the LE achieves 0.5g NOx emissions. C ranes: (6) 1 ton, (5) 5 ton, (2) 10 ton, (3) 15 ton, (3) 20 ton, (2) 30 ton, (2) 50 ton Core Capabilities A jax slow-speed packages F ull manufacturing, assembly and testing capabilities for all Ajax products W elding, electrical, pipe threading, plumbing and assembly expertise A jax assembly facility ULE The Ultra-Low Emissions (ULE) model achieves the same 0.5g NOx emissions as the LE without requiring engine tuning. It is also available as a retrofit to the LE, providing a solution for non-attainment zones and maintaining maximum BHP. 6 O n-site engineering services F ull engine testing capabilities 7
Strong relationships drive strong results and better businesses. For more information, visit www.bhge.com, call +1-844-RECIP-GE (International: +1 713-354-1299) or contact your local sales representative. bhge.com 2017 Baker Hughes, a GE company All rights reserved. Baker Hughes reserves the right to make changes in specifications and features shown herein, or discontinue the product described at any time without notice or obligation. Contact your BHGE representative for the most current information. The Baker Hughes logo is a trade mark of Baker Hughes, a GE company. The GE Monogram is a trademark of the General Electric Company. GEA32583 (11/2017)