Ajax™ Performance

Enhancements & Upgrade

Offerings

April 3, 2018
© 2017 Baker Hughes, a GE company, LLC - All rights reserved.
Performance Enhancement & Upgrades

Introduction timeline
• 1963: Gas Injection Fuel Systems
• 1977: Flywheel Ring Gear Start Systems
• 1988: Compressor Poppet Valves
• 1991: LE (Low Emissions) Engines
• 1991: Dry Type Air Intake Systems
• 1995: 440 RPM
• 1998: Rebecca Gas Injection Valve Cartridge
• 2001: High Compression/Elevation Power Pistons
• 2002: Exhaust Expansion Chamber Systems
• 2003: IGTB Electronic Governor
• 2003: Catalyst Mufflers
• 2005: Flexible Fuel Header
• 2008: Screw in Pre Chambers (SIP)
• 2014: Auto Pre-Lube Systems
• 2014: Poppet Intake Valves

October 25, 2016 2

© 2017 Baker Hughes, a GE company, LLC - All rights reserved.
“Economizer” Gas Injection System
PERFORMANCE

Description Benefits
• Fuel is injected directly into the power cylinder • Reduces fuel consumption by up to 33%.
instead of being drawn into the engine through • From 11-14 scf/bhp-hr
the scavenging chamber utilized on the Ajax two
• To 8.5-9 scf/bhp-hr
cycle engine.
Model Annual Fuel Annual Savings
• In addition to saving on fuel, this design provides Savings
$1.50/Mscf $2.00/Mscf
precise balancing of the load on Ajax multi- (Mscf)
cylinder engines E-42/C-42 1,343 $2,015 $2,686
DP-60/DPC-60 2,368 $3,552 $4,736
DP-80/DPC-80 3,146 $4,719 $6,292
DP-115/DPC-115 4,034 $6,051 $8,068
DP-160/DPC-160 5,624 $8,436 $11,248
DP-230/DPC-230 8,072 $12,108 $16,144
DP-300/DPC-300 10,512 $15,768 $21,024

October 25, 2016 3

© 2017 Baker Hughes, a GE company, LLC - All rights reserved.
Ring Gear Starting
PERFORMANCE MAINTENANCE

Description Benefits
• Many end users are faced with declining • Eliminates the need for air/gas receivers
site gas pressures. Air-in-head start • Eliminates the need for auxiliary air
systems require 200-250 psig pressure. compressors
With ring gear start, pressures as low as • Lower pressure supply required – as low
30 psig.
as 30 psig
• Legacy Ajax engines & engine- • Components readily available
compressors originally built with air-in-
head start systems can now be
retrofitted with ring gear start systems. Ring
Gear
Start

October 25, 2016 4

© 2017 Baker Hughes, a GE company, LLC - All rights reserved.
Compressor Poppet Valves
PERFORMANCE MAINTENANCE

Description Benefits
• Poppet valves deliver the highest • More efficient performance
efficiency of any valve design. Compared • Longer service life
to conventional plate, channel or strip • Reduced losses to 4-12%
valves, poppet valves offer significant
fuel or horsepower savings through • Fuel savings up to 12%
more efficient and reliable operation. • Retrofitting payback in 6-18 months

October 25, 2016 5

© 2017 Baker Hughes, a GE company, LLC - All rights reserved.
Compressor Poppet Valves

Poppet vs. Plate valves performance - example Economics of converting to poppet valves
• DPC-2804LE operating with plate valves,
moving 5.19 MMscfd at current
conditions
• Convert to Poppet valve, now moves
5.37 MMscfd
PS = 60 • Additional gas volumes of 0.18 MMscfd
PD = 570
bhp/MMscfd/stage Plate = 147.55
@ $3.00 per Mscf :
bhp/MMscfd/stage Poppet = 142.66
Q w/Plate = 5.19 MMscfd
• +$540/day; +$16,200/mo;
Q w/Poppet = 5.17 MMscfd +$194,400/yr

October 25, 2016 6

© 2017 Baker Hughes, a GE company, LLC - All rights reserved.
Low Emissions (LE) Conversion Kit
EMISSIONS

Description Benefits
• Ajax LE technology is based on • Lower NOX
combustion modification in order to • Low maintenance
achieve NOX emission control. • Reduced fuel consumption
• The main component of the system is • Enhanced fuel tolerance
the ignitor assembly that creates a high
energy ignition source, igniting a leaner • Field installations of one day per power
mixture of fuel, resulting in lower NOX cylinder
formation and cleaner exhaust. • Available for all the large bore 13.25”
and 15” Ajax engines.

October 25, 2016 7

© 2017 Baker Hughes, a GE company, LLC - All rights reserved.
Dry Type Air Filter Conversion
PERFORMANCE MAINTENANCE

Description Benefits
• Since the mid 1980’s Ajax integral engine- • Air filter housing designed with simple bolt-on flange
compressors have been packaged with “Dry Type” matched to each individual integral model for easy
engine air filters instead of the “Oil Bath” systems. installation.
• Now Ajax owners with the older oil bath type air • Air filter housing designed for maximum aerodynamic
cleaner can benefit from this product improvement. efficiency.
• Dry type air filters are enclosed in sturdy frame for
effective sealing.
• Filters rated at 97% - 99% efficiency.
• Simple design provides easy access for filter removal.
• Dry type air filter improves air flow by providing a
clearer air path thus reducing air restriction.
• Engines run cleaner extending the service live of the
unit.
• Maintenance costs associated with air filtration
system are drastically reduced

October 25, 2016 8

© 2017 Baker Hughes, a GE company, LLC - All rights reserved.
440 rpm Upgrade
PERFORMANCE

Description Economics of 440 rpm’s

• Increases the speed of the large bore • DPC-360 operating at 400 rpm, moving 3
Ajax units from 360 & 400 rpm to 440 MMscfd at current conditions.
rpm, increasing horsepower ratings • Uprated to 440 rpm, now moves 3.3
while maintaining emissions ratings. MMscfd
• Eliminates the wedged flywheel design • Additional gas volumes of 0.3 MMscfd @
to use an external Ringfeder® design, $3.00/Mscf:
which allows for the higher inertial • +$900/day; +$27,000/mo;
forces at the increased operating +$324,000/yr
speeds.

October 25, 2016 9

© 2017 Baker Hughes, a GE company, LLC - All rights reserved.
Rebecca Fuel Cartridge
MAINTENANCE

Description Benefits
• The two-part system consists of a permanent • Low-friction operation and reduced stem leakage
valve body and replaceable cartridge assembly. thanks to spring-loaded, non-metallic, self-
The cartridge contains the complete valve adjusting packing
mechanism and seat. • Eliminated the need for lube maintenance due to
• For inspection, maintenance or replacement, low-friction, pre-lubricated bushings at both ends
simply remove the valve cartridge — the cage of the Rebecca valve stem
and all fuel gas piping remain in place • Simplified maintenance - valve replacement
• New Rebecca valve can be supplied as original without removing cage or piping
equipment or can be easily retrofitted to existing • Reduced replacement time, from hours to
installations. minutes
• No heavy lifting or special tools

October 25, 2016 10

© 2017 Baker Hughes, a GE company, LLC - All rights reserved.
Rebecca Fuel Cartridge

October 25, 2016 11

© 2017 Baker Hughes, a GE company, LLC - All rights reserved.
High Compression Ratio (HCR)
Power Pistons PERFORMANCE EMISSIONS

Description Benefits
• Compression ratios at 5,000-6,500 FASL: • Improves Combustion Stability at Higher
mechanical = 9.25:1 Elevations
• Compression ratios at 6,500 FASL: • Greater Rich Fuel Tolerance
mechanical = 9.45:1 • Sustains Emissions Compliance
• vs. standard compression ratio of 8:1 • Can typically be installed in the field in
less than one day
STD LE HCR

October 25, 2016 12

© 2017 Baker Hughes, a GE company, LLC - All rights reserved.
Exhaust Expansion Chambers
PERFORMANCE EMISSIONS

Description Benefits
• Substantially increases the mass of fresh air • Increased hp with more efficient performance
that is trapped inside the power cylinders • Reduced NOx with improved combustion
• This configuration results in added hp, cooler • Increased MMscfd/bhp
combustion, and/or reduced NOX levels.
• Fuel savings with reduced loads at same MMscfd
• This method of exhaust emissions reduction
• Payback in weeks not months
does not rely on any moving mechanical
devices nor does it require system adjustments • Low Maintenance with virtually no moving parts
and maintenance to achieve the emissions
reduction

October 25, 2016 13

© 2017 Baker Hughes, a GE company, LLC - All rights reserved.
Integrated Governor Throttle Body
(IGTB) PERFORMANCE MAINTENANCE

Description Benefits
• The IGTB is a combined throttle valve and • Fast response to compressor load change
electronic governor. Its purpose is to maintain a • Improved stability of compressor
fixed speed set-point throughout the engine’s
• Easy installation
load range.
• If needed, no electrical power required
• The governor measures engine speed with a
magnetic pickup and compares it to the set- • Ideal for usage with fuel gas containing H2S
point speed provided by the transducer. • Vibration resistant
• When engine speed changes from the desired
level, the IGTB automatically adjusts fuel gas
header pressure as required to maintain the
desired speed.

October 25, 2016 14

© 2017 Baker Hughes, a GE company, LLC - All rights reserved.
Integrated Governor Throttle Body (IGTB)

Three governors’ response to load change

Ajax Flyweight Governor
• Rpm set point at 380 w/100% torque load
• Decrease load to 75% and rpm increases to 420 rpm
• Reestablish 100% torque load, and rpm returns to 380

Woodward TG-13 Governor

• Rpm set point at 420 w/100% torque load
• Decrease load to 75% and rpm increases to 448 rpm
• Reestablish 100% torque load, and rpm returns to 420

IGTB Governor
• Rpm set point at 440 w/100% torque load
• Decrease load to 75% and rpm increases briefly to 454 rpm and returns to the 440 rpm set
point
• Reestablish 100% torque load, and rpm decreases briefly to 438 rpm and returns to 440 rpm
set point

October 25, 2016 15

© 2017 Baker Hughes, a GE company, LLC - All rights reserved.
Noise Control
PERFORMANCE MAINTENANCE

Major noise sources Benefits

• Exhaust • Exhaust silencers – hospital 89 dBA;
Silencer critical 83 dBA; super critical 76 dBA
@10ft
Exhaust lines
• Insulation – 9 dBA reduction
• Air intake
• Air intake filtered silencers - standard
• Process and engine heat exchangers
intake 88 dBA; residential grade 80 dBA;
• Mechanical noise of the engine and critical grade 67 dBA @10ft
compressor
• Process & engine heat exchangers – fan
tip speed 12,000 fpm 83 dBA; 10,600
Ajax fpm 79 dBA; 9,100 fpm 77 dBA @10ft
insulation

October 25, 2016 16

© 2017 Baker Hughes, a GE company, LLC - All rights reserved.
Oxidizing Catalytic Converter
EMISSIONS

Description Benefits
• The Ajax oxidizing catalytic converter is • Lower emission available with good,
designed to meet the new better, best element selection.
environmental guidelines for 2-stroke, • Available on any Ajax fuel injected
lean-burn (2SLB) gas engines., with engine
impressive removal efficiencies of CO,
• Internal baffles and pipes designed to
VOC, & H2CO. silence exhaust and protect the catalyst
• As a result of an exhaustive research element
and development program, the • Catalyst elements in retainer rack
converter is now available for new units
as well as retrofit applications. • One identical element per power
cylinder

October 25, 2016 17

© 2017 Baker Hughes, a GE company, LLC - All rights reserved.
Flexible Fuel Header System
MAINTENANCE

Description Benefits
• Expedite fuel gas valve accessibility • Low cost 100% Retrofit able on Ajax legacy single,
• Eliminates header misalignment by utilizing twin, trip & quad engines
single piece fuel header system. This also • Reduces scheduled / unscheduled downtime for
eliminates cumbersome couplings with multi- servicing gas injection valves ultimately saving
piece fuel header systems. money.
• Eliminates stress & distortion on gas valve body. • Relocates fuel header allowing easy access to
Rigid systems can put undue stress on gas valve power end without removing header
bodies when trying to align & tighten header
connections that can distort valve body
preventing proper valve operation causing
leakage and/or premature wear/failure.

October 25, 2016 18

© 2017 Baker Hughes, a GE company, LLC - All rights reserved.
Screw In Pre-chamber
EMISSIONS

Description Benefits
• New device can be installed on all •Reduced emission and fuel consumption
Ajax products with easily installed •Screw-in design to existing spark plug hole
conversion kit available in one part eliminates requirements for new cylinder heads
number. Kit includes pre-chamber,
•Easy maintenance due to water jacket cooling and
piping, regulators, cooling water
less engine misfires
pump (if required).
•Standard Spark Plug utilized to ignite gas in pre-
chamber
•Corrosion resistance utilizing high quality alloy
steel.
•Easy conversion kit available for single and twin
cylinder engines

October 25, 2016 19

© 2017 Baker Hughes, a GE company, LLC - All rights reserved.
Auto Pre-Lube Systems
MAINTENANCE EMISSIONS

Description Benefits
• Pre-Lube systems are standard • Increases unit dependability & product
equipment on current production Ajax life
units, offered with manual, electric or • Reduces start-up and idle time
pneumatic configurations. • Reduces maintenance costs associated
• Available in retrofit kits for all Ajax units. with cold weather starts
• Various controls logic is also offered to • Allows for start – up sequencing to
accommodate permissive / custom comply with various emissions
start-up sequencing regulations

October 25, 2016 20

© 2017 Baker Hughes, a GE company, LLC - All rights reserved.
Scavenging Intake Poppet Valve
PERFORMANCE MAINTENANCE

Description Benefits
• Air Flow Improvement: Available for • Fuel consumption/costs reduced
DPC-2800 Series Engines • Emissions reduction
• The Scavenging Intake Poppet Valve is a • Lower operating/maintenance costs
bolt on retrofit able by just replacing the
reed strip valve plate.
• Allows more scavenging air to the
combustion chamber that subsequently
increases combustion efficiency.

October 25, 2016 21

© 2017 Baker Hughes, a GE company, LLC - All rights reserved.
Integral Engine-Compressor
Reconfiguration PERFORMANCE EMISSIONS

Description Benefits
• Compression requirements change as a • Lower initial cost vs. new equipment
result of: • Quicker return on investment
Natural gas demands in the market • Increased production
Changes in site conditions
Relocation of equipment • 100% utilization of available horsepower
Changes in compression applications • No need to transport unit
• Our Applications Engineering team can • OEM components / same Ajax reliability
take your new application conditions • One year warranty
and determine what is required to get
the optimum utilization of your existing
equipment.
October 25, 2016 22
© 2017 Baker Hughes, a GE company, LLC - All rights reserved.
Integral Concrete Skid
MAINTENANCE

Description Benefits
• A traditional separate removable • Portability. A single compressor
concrete base is also available for use package can be moved from site to site
with existing units. Existing units can be as needed with relative ease
mounted to the traditional separate • Reduced installation cost. A Concrete
concrete base to allow for portability. foundation is no longer required
• Reduced tear down cost.
• Reduced Inventory of compressor
packages
DPC-2802 with Integral
Concrete Filled Skid

October 25, 2016 23

© 2017 Baker Hughes, a GE company, LLC - All rights reserved.
ULE Conversion Kit
PERFORMANCE EMISSIONS

Description Benefits
• Incorporates distinct parts and configurations, • Reduced NOx emission to a level as low as 0.5
enhancing the overall emissions performance of g/bhp-hr
existing LE units at full horsepower. • Enhanced fuel and combustion efficiency
• Features: • Enhanced air flow by way of the expansion
Enhanced intake system chambers
Upgraded heads, pistons and a pre-chamber
• Ability to maximize horsepower while reducing
design
emissions, all at an ambient temperature rating
High-pressure fuel injection for enhanced air/fuel
of 100°F
mixing
Tuned exhaust system as part of the air flow
operation

October 25, 2016 24

© 2017 Baker Hughes, a GE company, LLC - All rights reserved.
Resources

• engageRecip
www.engagerecip.com
• +1 844-RECIP-GE (US/Canada), +1 713-354-1299
(International)
• Diagnostics List & Recommended Spare Parts
Available on Spreadsheet
• Fact sheets
TBD
October 25, 2016 25
© 2017 Baker Hughes, a GE company, LLC - All rights reserved.