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Integral Engine-CompressorsContinuous Improvement Without Compromise: Absolutely Ajax

C O O P E RE N E R G Y S E R V I C E S

Forward thinking with 98+% availabilityin one compressor? Absolutely.Unsurpassed reliability at the lowest costWhen reliability and efficiency can't be compromised,Ajax integral engine-compressors stand alone. With atime-proven design and improved features, the Ajaxbrand is as close to worry-free as any compressor productin the world.

Absolute dependability Ajax units typically require onlyone oil change per year, which can mean savings of thou-sands of dollars in maintenance expenses over higher-speed separables. When you run Ajax, you can expectparts and labor costs to be pennies per hour of operation.

Absolute efficiency The proven Ajax integral designcombines the engine and compressor on the same crank-shaft, which eliminates the power losses associated withgears, belts and couplings. And with its low operatingspeed and large compressor cylinder valve area, no othercompressor moves more gas per bhp than Ajax.

Absolute availability The average Ajax unit consistentlydelivers 98%+ availability while requiring no major partsreplacements during five or more years of service. So it'sno wonder Ajax has become the premier compressorbrand for gas gathering and production worldwide.

AJAX APPLICATIONS

Ajax integral engine-compressors are available from

155 to 880 hp and are ideally suited for:

«Gas gathering

• Gas transmission

• Storage

• Ethylene handling

• Gas re-injection

• Gas processing

• Propane processing

• Helium processing

• Coal Bed Methane

processing

Continuous improvements make Ajax an evensmarter choice.Ajax continues to apply new technology to our products,enhancing the performance and reliability our customershave come to expect. Recent Ajax improvements include:

Patented Tilt MufflerThe optional Ajax tilt muffler on single-skid packageallows for one shipment to reduce transportation cost.

Parts InterchangeabilityAjax models share common crossheads, compressorguides, pins and bushings, Cooper poppets and springs,along with same class compressor cylinders.

Integral Concrete SkidOur optional integral concrete-filled skid eliminates theseparate portable base for a lower package weight.

440 Uprate

A 440 rpm uprate delivers more power for your invest-ment with lower operating cost per bhp.

Common Power CylinderCommon power cylinders among bore sizes simplify thelogistics of repair and maintenance.

Long-Life Spark Plugs

Long-life spark plugs lower maintenance costs andincrease uptime by extending operating hours betweenroutine replacement.

EFFECT 1000 Patented Fuel SystemThis cost-effective, fuel-blending system helps lower fuelcosts by automatically adding only the amount of higherBTU fuel needed to maintain efficientengine operation.

Ajax/Rebecca® Fuel ValveThe simple threaded installationcuts labor time for field fuelvalve repair by 60% or more,reducing downtime and lostproduction.

AEGIS 2000 Control System (AjaxElectronically Governed, GasInjected, Inductive Ignition System)AEGIS automatically controls governing, ignition andfuel injection functions, improving performance withbetter retention of cylinder balance, easier balancing ofcylinder, improved fuel economy and lower emissions.Available on new units or as a retrofit for existing units,it replaces lay shaft, crankshaft/lay shaft gearing, controlbox, power plungers and cams, ignition magneto andmechanical governor.

Ajax Millennium III ControllerThe Ajax Millennium III Controller incorporates digitaltechnology with remote monitoring capabilities andexpanded connectivity.

Poppet Valves Standard on Cast CylindersThe standard poppet valves provide lower flow lossesand higher horsepower loss efficiency rating than con-ventional plate valves. Independent poppet operationincreases the overall reliability and life of the valve.

10% Rod Load IncreaseModels 2202 and 2802 have been increased from 30,000 to33,000 Ibs. net rod load for higher production capability.

Smart packaging saves time andshipping costsThe redesigned Ajax Integral Engine-Compressor pack-

age is based on a single-skid concept which increases

portability and lowers transportation costs.

Lower Shipping WeightThe inherently balanced design reduces vibration and

allows the use of a lighter skid. Optional integral concrete-

filled skid eliminates the need for heavier, separate

portable base.

Reduces Transportation CostsA combination of optional tilt muffler and integral, light-

weight base allows one shipment.

Optional Cooler DrivesBelt driven is standard with electric and hydraulic drives

optional.

High Integrity Cooling System MaterialsLonger-wearing stainless steel tubing with plated steel

fittings provides fewer leak points with little chance for

corrosion. Carbon steel jacket water tubing for compres-

The Ajax single-skid package enhances portability, shortens delivery cycle andlowers transportation costs.

sor cylinder and threaded connections for engine coolinghelp reduce potential for leakage.

Easier MaintenanceThe improved package allows easier access to unit and

cooler for maintenance. Reed valve access doors are

standard on models DPC-2202 and 2802.

T H E A J A X A D V A N T A G E

Two-Cycle SimplicityLess is better when it comes to replace-

ment and maintenance of engine parts.

With an Ajax two-cycle engine, you

don't need:

• Cam, camshafts and bearing

• Intake and exhaust valves

• Push rods

• Tappets

• Seats

• Valve stems and valve stem bushings

• Timing gears

• Valve springs

• Rocker arms

• Valve covers and gaskets

FOUR CYCLE PRINCIPLE

COMPRESSION STROKE

POWER STROKE

INTAKE STROKE

TWO CYCLE PRINCIPLE

COMPRESSION STROKE

Integral versus SeparableThe proven integral design avoids the inefficiencies ofseparable engine and compressor configurations.

INTEGRAL vs SEPARABLE

AJAX INTEGRAL

Common crankshaft -no coupling

Alignment not required

Lowest mechanical losses

Matched design

Smooth-running balance-opposed design

HIGH-SPEED SEPARABLE

Coupling required

Critical alignmentwith close tolerances

Higher mechanicallosses

Potential engine/compressor mismatch

Higher vibration

Ajax Low Emission (LE) technologyBased on built-in combustion modification, Ajax LE tech-nology avoids troublesome bolt-on solutions. Ajax LEtechnology actually improves performance by providinglow combustion temperatures, which help extend the lifeof components. The Ajax igniter and pre-combustionchamber provides a more complete combustion, result-ing in lower NOx formation, cleaner exhaust andreduced fuel consumption.

Benefits include:

• Lower maintenance

• Reduced Fuel Consumption

• Low NOx Rating

• Low Compression Ratio

Standard on all Ajax LE models, the benefits of AjaxLE technology are also available for existing unitsthrough the LE Conversion Kit.

RetrofitsMany of the advances applied to new Ajax integral-com-pressors are also available in upgrade form for existingAjax equipment. Applying new technology to an existingAjax integral unit can extend your investment, increaseoperating efficiency, lower fuel cost and meet loweremissions requirements. Upgrades include:

• LE Low Emissions Conversion Kit

• Economizer Gas Injection

• APV-1000 High Efficiency Compressor Valve

• Long-Life Spark Plugs

• EFFECT 1000 Patented Fuel System

• Ajax/Rebecca Fuel Valve

• AEGIS Control System-Electronic Governors

• Ajax Millennium III Controller

Re-manufacturing

In many cases, re-manufacturing existing equipmentoffers a better economic alternative to buying new. YourAjax integral engine-compressor can be cost-efficientlyre-manufactured to increase operating efficiency, loweremissions and meet changing application needs, whileextending your equipment's life. All re-manufacturingwork is performed by Ajax factory-trained personnel,and includes OEM warranties and OEM-qualityparts / components.

Genuine OEM-quality parts and serviceThe extensive Ajax distributor network, backed byCooper Energy Services factory-trained personnel andService Centers, are dedicatedto helping your equipmentmaintain peak performance forlong-term service. Customershave relied on Ajax for morethan a century for diagnostic,maintenance and serviceexpertise, as well as quickaccess to quality OEM parts.

Absolute advantage.For a complete look at all the advantages Ajax can offer,visit our web site at www.cooperenergy.com. Or call405-670-4121.

Standard featuresEvery Ajax integral engine-compressor unit incorporates a long listof standard features that enhance performance and long life.

О Hydraulic Fuel InjectionFor optimum fuel efficiency.

О Babbitt Sleeve and/or Double-RowTapered Roller BearingsFor maximum horsepower load and application requirements.

О Power CylindersTwo-cycle, low-BMEP, chrome-plated with fewer parts for lessmaintenance. Port-scavenged, requires neither inlet norexhaust valves.

О Crosshead GuidesAbsorb thrust stresses and prevent contamination ofcrankcase lube oil.

0 Splash Lubrication SystemNo oil pump, filter or cooler required for main and connect-ing rod bearings. Sealed from combustion process.

О Reliable Ignition SystemSolid-state, permanently timed and breaker-less.

О Efficient LubricationForce-fed lubrication system for power and compressioncylinders. Pump to point or divider block.

О Integral ConstructionBabbitted crosshead design, both power endand compressor.

О Crankshaft and Connecting RodsClosed-die forged in precision dies.

ф FrameRibbed, cast iron construction for durability.

ф Distance PieceAPI-Type II extra-length design for ease of packing maintenance.

ф High Rod Load and Cylinder Working PressureFull-load operation through a variety of compression ratios upto 6:1 per stage.

© Highly Efficient Compressor CylindersLarge 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.

ф Low Valve VelocityLonger life, high performance and efficiency. High differentialpoppet valves standard.

ф Clearance/LoadingManual, hand-wheel-type, variable volume clearance pocketwith indicator allows cylinder unloading with de-pressurizing.

ODEL

iting at 100° F ambient1500FASL

ВНР

KW

ted RPM

ieed rangeMinimum

Maximum

'ration for each 1000 'over 1500' elevation

jmber of Power Cylinders

>mpressor

Throws

Stroke

Rod Diameter

Rod Load

Inches

Centimeters

Inches

Centimeters

Pounds

Kilograms

DPC-2201

STD

147.8

110.2

440

265

440

3

1

1

11

27.94

2.5

6.35

30,000

13,608

LE

147.8

110.2

440

265

440

3

1

1

11

27.94

2.5

6.35

30,000

13,608

DPC-2801

STD

192

143.2

440

265

440

3

1

1

11

27.94

2.5

6.35

30,000

13,608

LE

192

143.2

440

265

440

3

1

1

11

27.94

2.5

6.35

30,000

13,608

DPC-2202

STD

295.68

220.5

440

265

440

3

2

2

11

27.94

2.5

6.35

33,000

14,969

LE

295.68

220.5

440

265

440

3

2

2

11

27.94

2.5

6.35

33,000

14,969

DPC-2802

STD

422.4

315.0

440

265

440

3

2

2

11

27.94

2.5

6.35

33,000

14,969

LE

384

298.3

440

265

440

3

2

2

11

27.94

2.5

6.35

33,000

14,969

DPC-2803

STD

633.6

472.5

440

265

440

3

3

2

11

27.94

2.5

6.35

40,000

18,144

LE

600

447.4

440

265

440

3

3

2

11

27.94

2.5

6.35

40,000

18,144

DPC-2804

STD

845

630.1

440

265

440

3

4

3

11

27.94

2.5

6.35

40,000

18,144

LE

800

596.6

440

265

440

3

4

3

11

27.94

2.5

6.35

40,000

18,144

C O O P E RE N E R G Y S E R V I C E S

2101 S.E. 18th Street

Oklahoma City OK 73129

Phone 405 670 4121

Fax 405 672 8103www.cooperenergy.com

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Note: Standard equipment and specification are subject to change without notice.

Ajax and Rebecca are registered trademarks of Cooper Cameron Corporation.

All others contained herein are the property of their respective owners.

Ajax and Cooper Energy Services are trademarks of the Cooper Cameron Corporation, Cooper Energy Services Division.2-201G 2M 10/01