Compression Systems

Ajax Technical Information Bulletin #061013

Subject: Instructions for the installation, operation, and maintenance of a catalytic

converter on an AJAX engine-compressor silencer.

This bulletin provides instructions on how to use a catalytic converter in a manner that
will ensure operator safety, efficient use, and long catalyst life. Also presented are
guidelines to consider prior to start-up of your unit, instructions on installing the converter
elements, the proper oil to use with the catalyst, troubleshooting, catalyst regeneration
and storage, and spare parts information.

This bulletin also provides instructions on taking temperature and pressure

measurements on the catalytic converter, including measurements that are required by
the United States Environmental Protection Agency (U.S. EPA).

Contents

Factors That Affect Catalyst Operation .................................................... 2

Before Initial Start-Up................................................................................ 3

Installing the Catalyst Elements ................................................................ 3

Catalyst Measurements.............................................................................. 8

Warning Signs ............................................................................................ 13

Inspecting and Troubleshooting a Catalyst.............................................. 13

Catalyst Regeneration ............................................................................... 13

Storing the Catalyst ................................................................................... 13

Catalyst Spare Parts.................................................................................... 14

Optional Spare Parts .................................................................................. 14

Ajax Contact Information.......................................................................... 14

Contents 1
Ajax Technical Information Bulletin #062005 AJAX®

Factors that Affect Catalyst Operation

Catalysts can control exhaust pollution for years, and require minimal maintenance, as
long as the operator watches for:

• catalyst inlet temperatures that fall below or exceed certain limits

• chemicals in the exhaust that can harm the catalyst
• coolant or water that leaks into the catalyst
• engine oil that is not recommended for use with the catalyst
• improper catalyst sizing

Catalyst Inlet Temperature: Catalysts are meant to operate between 450° and 800°F.
Exhaust temperatures lower than 450° are not hot enough to produce an efficient
catalytic reaction, so the catalyst will not control emissions at these low temperatures.
Temperatures higher than 800° will crystallize the precious metals in the catalyst
elements, eliminating the catalyst’s emission-reducing properties.

Chemicals in the Exhaust: Certain chemicals in exhaust gases will also render the
precious metals useless as catalysts; these chemicals include lead, zinc, tin, copper,
sulfur, mercury, antimony, chromium, phosphorus, chlorinated hydrocarbons and silicon.
Contact the manufacturer for a list of all chemicals that are harmful to the catalyst. Proper
sizing of the catalyst, as well as proper maintenance of the engine, will reduce the
potential for catalyst fouling due to these chemicals. Regeneration of the catalyst
elements will remove chemical build-up on the catalyst elements as well (refer to the
“Regeneration” section on page 11).

Coolant or Water Leaking into the Catalyst: A catalyst that has been flooded with
rainwater or antifreeze is permanently damaged, and the catalyst should be replaced.
Make certain that no coolant or water is allowed to leak into the catalyst.

Proper Engine Oil: Using the proper engine and cylinder oil is critical to the successful
operation of the Ajax exhaust catalyst. GE Oil And Gas AJAX® worked with ExxonMobil
to develop an oil that would ensure proper catalyst operation and maintain the designed
emissions control. Both lab and field engine tests have validated the performance of
the new catalyst friendly oil in maintaining optimum catalyst life, as well as cylinder
liner, bearing, and crosshead guide protection.

Mobil Pegasus Special CF must be used to ensure proper performance of the

catalyst.

For assistance in sourcing Pegasus Special CF via your local ExxonMobil Distributor,
please contact ExxonMobil at 1-800-662-4525, or visit www.mobil.com.

Factors that Affect Catalyst Operation 2

 Compression Systems

Improper Catalyst Sizing: Catalysts are sized based on engine specifications. If the
engine is not operating according to those specifications, the catalyst is not sized
properly, which will result in a shortened catalyst life span.

Before Initial Start-up

A new or rebuilt engine started for the first time may not run properly, or according to
specifications, which may damage the catalyst. To prevent damage to the catalyst, follow
these steps:

1. Before starting the engine, remove the catalyst elements and gaskets.

EXHAUST GASES ARE

POISONOUS! BEFORE
START-UP, ENSURE THAT
ALL EXHAUST GASES ARE
PROPERLY VENTED TO THE
ATMOSPHERE AND THAT
ALL COVERS ARE SEALED
AND IN PLACE

2. Start the engine.

NOTICE: For engine break-in and debugging purposes, the EPA allows the engine
to run without the catalyst elements for a maximum of 200 hours.

3. Measure and log exhaust gas temperatures, as well as exhaust gas constituents, to
ensure that the engine is running according to the manufacturer’s specifications.
4. Once you are certain that the engine is running properly, install (or reinstall) the
catalyst elements.
The following section, “Installing the Catalyst Elements,” describes in detail how to
properly install catalyst elements.

Installing the Catalyst Elements

It is important to install the catalyst elements into the catalytic converter correctly so that
the element gaskets properly seal and no unfiltered exhaust is permitted to bypass the
elements. There are 4 main steps in installing the catalyst elements:

Step 1: Adjust the Converter Tray

Step 2: Insert the Catalyst Elements into the Converter Housing
Step 3: Compress the Element Gaskets

Before Initial Start-up 3

Ajax Technical Information Bulletin #062005 AJAX®

Step 4: Install the Adhesive Gasket for the Access Door

Step 1: Adjust the Converter Tray

a) Ensure that the silencer is secure and all safety precautions have been addressed.
b) Open the access door by removing the bolts from the access door and allowing it to
swing open (see Figure 1 below).

Converter Housing

Door Bolts

Door Hinge

Figure 1: Opening the Access Door

NOTICE: In order to install the catalyst elements, the converter tray must be
lowered.

c) Check the position of the tray (refer to Figure 2 below).

• If the surface of the tray is flush with the bottom edge of the window, the tray is
down, or lowered
• If the surface of the tray is higher than the bottom edge of the window, the tray is up,
or raised

Converter Tray

Access Door

Window
(Bottom Edge)

Figure 2: Location of Converter Tray

Installing the Catalyst Elements 4

 Compression Systems

d) Adjust the tray by first loosening the top nuts on the adjustment studs (See Figures 3
and 4 below).

Adjustment Studs

Figure 3: Tray Adjustment Studs

Top Nut

Bottom Nut

e) Raise or lower the tray as

needed to position the tray flush
with the bottom edge of the
window.
• To lower the tray, turn the
bottom nuts counter-clockwise
(facing nuts from the top)
• To raise the tray, turn the
bottom nuts clockwise (facing
nuts from the top)

Figure 4: Top and Bottom Nuts on Adjustment Stud

Installing the Catalyst Elements 5

Ajax Technical Information Bulletin #062005 AJAX®

Element

Gasket 3/8”
OD Section Gasket

Figure 5: Catalyst Element and Gasket O.D. Section

Step 2: Insert the Catalyst Elements Into the Converter Housing

a) Inspect the catalyst element to ensure that the gasket is in good condition, and make
sure that the gasket is secure around the element and that the 3/8” O.D. section is on
top of the element (see Figure 5 above). When compressing and sealing the gasket,
if any part of the gasket O.D. section is not on top of the element, but instead is bent
outward and away from the element, the gasket will not seal properly.
b) Align the element with one of the tray openings inside the housing and slide the
element in until it stops (see Figure 6 below).
c) Insert remaining elements into the remaining tray openings.

NOTICE: Be sure to install the elements with the gasket side of the elements
facing upward.

Figure 6: Inserting Catalyst Element Into Tray Opening

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 Compression Systems

Step 3: Compress the Element Gaskets

a) Raise the tray by turning the bottom nuts on the adjustment studs clockwise (facing
nut from the top) beginning with the studs opposite the access door (refer to Figure 7
below).

NOTICE: At this point, as you are turning the nuts to raise the tray, begin applying
high temperature anti-seize to each stud. Apply the anti-seize to the stud as the
nut goes down the stud, so that whenever you want to lower the tray, the nut will
easily go back up the stud without seizing.

b) Adjust the studs (alternately) until the gaskets on the back side of the elements begin
to lightly compress.

NOTICE: Ensure that the gaskets are seating on the top surface of the element
evenly.

c) Move to the access door side and adjust the remaining two studs until the entire
gasket is lightly and evenly compressed (see Figure 7 below).
d) Turn the bottom nuts of each stud two full revolutions. Alternate front to back, back to
front when tightening.
e) Tighten the top nuts of each stud to lock in place.

First, beginning with the back

two studs, turn the bottom nuts
clockwise (facing nut from the
top) to raise the element tray

Next, adjust the front two studs,

raising the tray until all element
gaskets are lightly and evenly
compressed

Door Bolt Holes

Figure 7: Compressing the Element Gaskets

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Ajax Technical Information Bulletin #062005 AJAX®

Step 4: Install Adhesive Gasket for the Access Door

a) Cut strips of adhesive gasket as needed to place around the converter window.
b) Make holes in the center of the adhesive gasket for the bolt holes surrounding the
converter window (see Figure 7 above).
c) Remove tape from the back of the adhesive gasket strips, and place strips around the
converter window so that when the converter access door is closed, the door will seal
completely and no gases will escape.
d) Close the access door, and tighten the nuts for the door bolts alternately until the door
is completely and firmly sealed.

Tips on Properly Installing the Catalyst Elements

If catalysts are installed improperly, some exhaust products may bypass the catalyst
elements. To avoid this problem, follow these instructions:

• Replace a catalyst gasket with a new gasket if you are unsure of a gasket’s quality or state of
repair
• Clean all mating surfaces so that the gasket can seal properly
• Tighten all nuts, bolts, and washers to prevent leaks
• Do not use silicone-based gasketing compounds

Catalyst Measurements
Once you install the catalyst elements, you can start the engine and make initial
performance measurements. Important catalyst measurements to take are:

• Catalyst Inlet Temperature

• Pressure Drop Across the Catalyst

Perform all measurements at the same engine operating points (RPM, BHP, etc.) that
were specified when the catalyst was first sized. Do not test a cold system - perform
measurements after the unit has reached thermal stability.

Catalyst Inlet Temperature Measurement

The EPA requires that catalyst inlet temperature is monitored and logged.

NOTICE: For compliance with EPA emissions standards, catalyst inlet temperature
cannot fall below 450°F or exceed 800° F.

Catalyst Measurements 8
 Compression Systems

Measure catalyst inlet temperature using the 1” NPT measurement port located on the
side of the housing opposite the access door (see Figure 8 below).
“Access Door” Side of
Catalyst Housing

Catalyst Inlet Temperature

Measurement Port, 1” NPT

Figure 8: Catalyst Inlet Temperature Measurement Port

Using this port ensures that the thermowell will be positioned above one of the baffle
tubes in the muffler. At this location, the thermocouple will take the most accurate
temperature measurement, since this is one of the hottest locations in the silencer.

To further ensure that the thermowell tip is positioned above the baffle tube, use a
thermowell that is at least 12” long, and no more than 18” long.

Catalyst Pressure Drop Measurement

The EPA requires that the pressure drop across the catalyst is measured and logged
monthly.

NOTICE: The pressure drop across the catalyst cannot increase by more than 2
inches of water above the measurement taken during initial startup. The pressure
drop must be measured when the engine load is between 90% and 100%. The EPA
will accept load calculations performed using “eAjax,” the compressor
performance software for AJAX units. The eAjax software is free and can be
downloaded from www.aciservicesinc.com/ajax.

If the pressure drop does increase by more than 2 inches, the catalyst elements need to
be inspected and regenerated. To make the pressure drop measurement, we
recommend using the test equipment displayed in Figure 9 (on the following page), and
listed below Figure 10.

Catalyst Measurements 9
Ajax Technical Information Bulletin #062005 AJAX®

90° Elbow, 1/4” Tube x 1/4” MNPT

Ajax P/N 2507 4202

Kiene V-10 Indicator Valve

Teflon PTFE Tubing,

1/4” -410° to +500°F

Differential Pressure Gauge

Magnehelic Series 2000

Figure 9: Recommended Test Equipment for Measuring Pressure Drop

“Pre-Catalyst” Connection 90° Elbow

1/4” Tube X 1/8” MNPT
Ajax P/N 2507 4201

“Post-Catalyst” Connection

Figure 10: Magnehelic Pressure Gauge Rear View

• Magnehelic Series 2000 Differential Pressure Gauge - measures the differential pressure in
inches of water

Catalyst Measurements 10
 Compression Systems

• Teflon PTFE Tubing, heavy wall, 1/4” O.D., 1/8” I.D. - connects the pressure gauge to the
Kiene indicator valves
• 90°Tubing Elbows, 1/4” Tube x 1/8” MNPT - Connects the Teflon tubes to the pressure gauge
• 90° Degree Tubing Elbows, 1/4” Tube x 1/4” MNPT - Connects the Teflon tubes to the Kiene
indicator valves
• Kiene V-10 Indicator Valves - Connects the pressure gauge to the 3/4” differential pressure
measurement ports on the catalytic converter

Connect the Kiene V-10 indicator valves to the pre- and post-catalyst 3/4” pressure
differential indicator ports on the catalytic converter housing (see Figure 11 below). The
Kiene valves connect to the Magnehelic differential pressure gauge by way of 1/4” Teflon
PTFE Tubing. See Figure 10 above for the proper pre- and post- catalyst connections on
the pressure gauge. Note that the pre- and post catalyst connections on the gauge are
1/8” NPT.

To connect the 1/4” x 1/4” tubing elbows to the Kiene indicators, you will need 2 Kiene
AX-34 valve adapters.

3/4” Pressure
Differential
Measurement Port
- Post-Catalyst

3/4” Pressure
Differential
Measurement Port
- Pre-Catalyst

3/4”Pre-Catalyst
Emissions
Sampling Port

Figure 11: 3/4” Pressure Measurement and Emissions Sampling Ports

Catalyst Measurements 11
Ajax Technical Information Bulletin #062005 AJAX®

Log Sheet
Below is a log sheet for recording the catalyst temperature and pressure measurements
required by the EPA.

Catalyst Measurements 12
 Compression Systems

Warning Signs
Catalyst maintenance may be necessary if you see the following warning signs:

• unusual pressure drop across the catalyst

• emissions test failure
• emissions testing data revealing an upward trend. The following factors can contribute to
increases in emission levels:
- change in engine operating parameters (RPM/BHP, etc.)
- change in the engine fuel
- engine misfires. Misfires add fuel to the exhaust and cause temperature increases in
other engine cylinders
- engine modifications
- catalyst exposure to antifreeze or to harmful compounds such as lead, zinc, tin, copper,
sulfur, mercury, antimony, chromium, phosphorus, chlorinated hydrocarbons, and sil-
icone

Inspecting and Troubleshooting a Catalyst

After you remove a catalyst, inspect it for:

• soot in the housing, gasket, and on the face of the catalyst element; this soot is evidence that
some exhaust has bypassed the catalyst. To remove the soot, the catalyst can be vacuumed
or blown with dry, oil-free compressed air
• burned places on the face of the element, indicating excessively high exhaust temperatures,
or fuel/oil fires. Check and service an engine that has excess oil or fuel in the exhaust

Catalyst Regeneration
Catalyst regeneration, or catalyst washing, involves immersing the catalyst into solutions
of non-phosphate alkaline cleaners and acetic acid in order to restore the catalyst’s
effectiveness. Catalysts can be regenerated 2 to 3 times before they finally have to be
replaced. Regeneration is usually performed by a contractor or the catalyst
manufacturer, because using the wrong chemicals, or incorrect concentrations of proper
chemicals, can permanently damage the catalyst, and because the chemicals used in
regeneration have to be properly disposed of.

Data log a regenerated element as if it were new. After 2 to 3 cleanings, when you see
from emissions measurements that the conversion efficiency is below 58% (the EPA
limit), replace or regenerate the catalyst element.

Storing the Catalyst

Store catalysts in areas protected from rainwater, ice, lubricants, antifreeze, and other
chemicals. If catalyst have been exposed to any of the above, or if the catalysts appear
corroded, the catalysts may have to be regenerated or even replaced.

Warning Signs 13
Ajax Technical Information Bulletin #062005 AJAX®

Catalyst Spare Parts

ITEM DESCRIPTION AJAX PART NUMBER QUANTITY
Catalyst Element 6321 9753 1 per Power Cylinder

Catalyst Element Gasket 3018 0030 1 per Element

Access Door Gasket 3018 0010 25’

Relief Valve Gasket 2553 5009 1

Optional Spare Parts

ITEM DESCRIPTION AJAX PART NUMBER QUANTITY
Thermowell 2558 0155 1 (minimum)

Ajax Contact Information

GE Reciprocating Compression
2101 S.E. 18th Street Oklahoma
City, Ok 73129-8351 (405)
670-4121 (Ajax Marketing)

Optional Spare Parts 14