GE H301 Series Operating Manual
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GE H301 Series Operating Manual

GE H301 Series Operating Manual

High speed reciprocating compressors
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GE Oil & Gas
High speed reciprocating compressors
H301 and 302 series operating manual
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  • Page 1 GE Oil & Gas High speed reciprocating compressors H301 and 302 series operating manual...
  • Page 2 Document Revision Chart The following chart lists the revisions made to this document tracked by version. ©2012 General Electric Company All Rights Reserved Revision Revision description Date Author Approver Updated safety information and made 3/9/2012 Luette A. Jim H. document usable online Added piston head end and crank 7/10/12 Luette A.

  • Page 3: Table Of Contents

    Contents Acronyms ............. . Lisf of Figures .
  • Page 4 Chapter 4: Installation ....... . . 39 Access and Safety ........... 39 Vents and Drains.
  • Page 5 Oil Viscosity ........... . . 73 Non-Lube Cylinder Applications .
  • Page 6 Acronyms PRV - Pressure regulating valve VVC P - Variable voulme clearance pocket IV | H301/302 HSR Compressors | Rev. 2.1...
  • Page 7 F ig uR e 13 GE oil filter standard 1-105292 .......

  • Page 8: List Of Forms

    List of Forms FoR m 1 Startup report ........... . . 13 FoR m 2 Pre-startup checklist .

  • Page 9: List Of Tables

    Table 19 GE Oil filter upgrade ........

  • Page 11: Chapter 1: Getting Started

    First time users select “HSR support site registration”, fill in required data and submit. You will receive an automated e-mail from GE Support Central. Follow the instructions in the e-mail to confirm the request. A GE employee will then complete the authorization process.

  • Page 12: Parts

    HSR Compressors. These compressors are mostly used for compressing flammable and/or hazardous gases. If you are installing, operating or servicing a GE Oil & Gas product, it is your responsibility to ensure full compliance with all applicable safety codes and 24/7 365 days a year requirements.
  • Page 13 The message of the note will be written here. These notes call out information vital for the proper operation, maintenance or repair of the equipment. Complies with ANSI Z535, ISO 3864, OSHA 1910.145 (f) (9) Caution This symbol identifies information about hazards or unsafe practices. Disregarding this information could result in MINOR OR MODERATE PERSONAL INJURY.
  • Page 14 Complies with ANSI Z535, ISO 3864, OSHA 1910.145 (f) (9) On any field startup, it is important to use trained mechanics and operators that have experience with GE compressors, utilizing the most current technical information. Failure to follow and implement proper commissioning instructions can result in equipment damage.

  • Page 15: Safety Symbols

    Safety Symbols Caution, warning and danger use a variety of safety symbols to depict the specific risk. These symbols are used throughout this manual. DANGEROUS ELECTRICAL AIR GAS INLET MOVING PARTS TEMPERATURES HAZARD PRESSURE CUT AND CRUSH HIGH PRESSURE FLAMMABLE EXPLOSIVE ASPHYXIATION TOXIC AND POISONOUS...

  • Page 16: Technical Support

    Warranty The warranty is effective when: An authorized representative of GE Oil & Gas – High Speed Warranty Reciprocating (HSR) gas compressors or the authorized packager is present at the initial start-up All frame and cylinder assembly components received proper...
  • Page 17 H301/302 HSR Compressors | Rev. 2.2 | 7...

  • Page 19: Chapter 2: Introduction

    Chapter 2: Introduction GE Oil & Gas designs, manufacturers and supplies HSR Compressors to customers, qualified packagers and distributors. The following basic compressor components are listed by frame/running gear assembly and cylinder assembly. H 301/302 Series Frame/Running Gear Assembly Normally includes:...

  • Page 20: Commissioning Report

    Components of the H 301/302 Series The components of the H series compressor are displayed in “Figure 2 H 301/302”. 7 24 Concentric valve HP liner Suction valve cover Packing lube inlet Cylinder lube divider block main bearing H 301/302 H Series compressor components Fi gu Re 2 Crankcase breather Crankcase...

  • Page 21: High Speed Reciprocating Compressor - Startup Report

    Complete and send the startup report to GE in order to activate the warranty policy. GE Oil & Gas High Speed Reciprocating Compressor – Startup Report COVERAGE UNDER GE’S HSR WARRANTY POLICY IS BASED UPON RECEIPT OF THIS REPORT WITH COMPLETE INFORMATION Date Mail To: GE Oil &...
  • Page 22 Coupling/Flywheel Data MFGR Type Size Cylinder Data Series VVCP Distance Pieces Throw # Cylinder Serial # Cylinder Bore Dia. Stage MAWP Lubed/Non-lubed Examples Yes/No Yes/No (95/03/89) Lubrication Data Frame Oil Minimum Viscosity: SAE 40 (ISO-150) Weight Cylinder Oil Brand Brand Type Type ISO Viscosity...
  • Page 23 Frame Support & Alignment Verification Frame Soft-Foot Check Alignment & Axial Thrust Anchor Bolt Diameter Applied Bolt Torque COLD FACE Drive End Crankshaft Axial Thrust FACE Aux End Crankshaft Axial Thrust Cylinder Piston End Clearances Crosshead to Guide Clearances Throw Throw Middle Notes...

  • Page 24: Pre-Startup Checklist

    Pre-Startup Checklist Use the pre-startup checklist to bring the compressor online. Verify that all steps are complete before initial compressor loading.. F L A M M A B L E FLAMMABLE GAS, NO OPEN FLAME. Complies with ANSI Z535, ISO 3864, OSHA 1910.145 (f) (5) H I G H P R E S S U R E USE APPROPRIATE PROCEDURES TO DEPRESSURIZE.
  • Page 25 Is a copy of the compressor performance prediction run of expected operating conditions on-site and has valve tailoring been checked for this application? Are expected startup and operating conditions within compressor design limits? If in doubt, contact the GE Authorized Packager or GE HSR for confirmation of the compressor’s operational limitations.
  • Page 26 44. Has the Packager’s representative reviewed the unit’s startup and operating instructions with the site operator(s)? 24 HOUR ASSISTANCE: PARTS: +1 866 565 2303 TECHNICAL SERVICE: +1 832 978 9780 Frame Serial No. Fo Rm 2 Pre-startup checklist GE Oil & Gas 16 | Chapter 2: Introduction...

  • Page 27: Post-Startup Checklist

    Note: Alignment is usually verified within 500 hours of initial operation, about 3 weeks after startup. 15. Has this “Startup Report” been completed and a copy mailed to the GE HSR compressor address on the 1 page? GE Oil &...

  • Page 28: Gas Compressor Record

    (x) if yes 10. Variable volume clear pocket (x) if yes * If changing cylinder valves due to operating conditions, list the new valve part numbers. Fo Rm 4 Gas compressor record GE Oil & Gas 18 | Chapter 2: Introduction...

  • Page 29: Crankshaft Rotation

    Crankshaft Rotation The throw closest to the crankshaft drive end is the first throw. Crankshaft rotation FiguRe 3 H301/302 HSR Compressors | Rev. 2.2 | 19...

  • Page 31: Chapter 3: General Data/Specifications

    Chapter 3: General Data/Specifications Frame Specifications H Series Compressor Frames are available in either 2 or 4 throw configuration. The table below depicts the 2 throw H Series configuration. Frame model H301/302 General data Number of throws Crosshead shoe type Babbitted Cylinders series available for mounting 30 series...

  • Page 32: Bearings And Running Gear

    Bearings and Running Gear H302 Frame size Inches (mm) 3.3755 (85.738) Main bearing bore diameter 3.3765 (85.763) Crankshaft 2.9975 (76.1365) Main bearing journal diameter 2.9980 (76.149) 3.2495 (82.537) Rod bearing journal diameter 3.2500 (82.550) 0.006 (0.1524) End thrust clearance 0.008 (0.2032) Maximum allowable end thrust clearance 0.012 (0.3048) Crankshaft web deflection –...
  • Page 33 Crosshead pin roller bearing Inches (mm) Outside diameter 2.0625 (52.387) Inside diameter – Installed 1.500 (38.100) Width 1.250 (31.750) 0.0000 (0.00000) Pin to roller bearing clearance 0.0002 (0.00508) Maximum allowable clearance 0.003 (0.0762) Crosshead body 5.115 (129.92) Diameter 5.117 (129.97) 1.5000 (38.100) Pin bore diameter 1.5002 (38.100)

  • Page 34: Lubrication System

    Lubrication System H Frame series Inches (mm) Units of measure Foot Pounds (N-m) Deliron cycle magnetic indicator torque 15 Ft –lbs. (20 N-m) Divider block mount screw torque 80 Inch-lbs. (1.7 N-m) H302 PRV cap-nut torque 12 to 15 ft. lb. (16 to 20 N-m) Gallons (Liter) Oil Sump capacity 5.75 Gallon (21.77 Liter)

  • Page 35: Piston Head End And Crank End Clearance

    Piston Head End and Crank End Clearance The piston head end and crank end clearance is variable and determined by the assembly of 10 or more parts depending upon the cylinder configuration. Standard practice is to set the crank end piston clearance at 1/3 (but not less than 0.040”) and head end clearance at 2/3 the summation of the head and crank end clearances.
  • Page 36 Double Tandem/ Acting Stepped VVCP Cylinder Cylinder Piston Clearance cylinder cylinder assembly head size Bore diameter diameter assembly assembly estimated estimated inches estimated estimated weight weight inches inches (mm) inches (mm) (mm) weight weight (mm) pounds (kg) pounds (kg) pounds (kg) pounds (kg) 5.000 (127.000) 4.973 (126.310)

  • Page 37: Piston Ring And Packing Ring Clearances

    Piston Ring and Packing Ring Clearances H 301/302 piston ring side clearance Piston ring width, Inches 0.114 0.187 0.213 0.215 0.248 0.248 0.25 0.257 0.116 0.189 0.215 0.217 0.25 0.253 0.252 0.26 Material PEEK Teflon Teflon PEEK Teflon Non-lube Non-lube Teflon Side clearance, inches 0.005...

  • Page 38: Fastener Torquing

    Fastener Torquing Follow the torque wrench manufacturer’s instructions to properly operate a torque wrench. Complies with ANSI Z535, ISO 3864, OSHA 1910.145 (f) (9) To ensure that fastener tightening is accurate and design torque values are properly applied. A calibrated torque wrench must be properly used to achieve the required fastener torque for critical parts assembly.

  • Page 39: Fi Gure 5 Torque Wrench With Adapter At Any Angle Except 90° Right Angle

    calibration accuracy. Torque wrench accuracy must be verified annually or as required. Special wrench adapters are sometimes required to tighten fasteners that are not readily accessible. When torque wrench adapters (socket, boxed end or crow’s foot) are used, the torque setting will not match the applied torque. The only exception to this rule is when the adapter is used at a right angle (90°) to the wrench center line;...

  • Page 40: Hold Down Bolting

    Hold Down Bolting Frame and crosshead guide support hold down bolting ensures the compressor is firmly attached to the skid. Larger compressor frame feet have a “through bolt” hole that can accommodate an all-thread fastener, hardened washer & nut. All torque values are based on petroleum based thread lubricants. See the Standard Material: Rod packing flange and valve cover bolting.
  • Page 41 H301/302 series (2 stage) counterweight chart Double acting piston assemblies NO CTWT NEEDED NO CTWT NO CTWT NEEDED NEEDED 406-6518 406-6518 NO CTWT NEEDED 406-6518 406-6518 NO CTWT NO CTWT NEEDED NEEDED NO CTWT NO CTWT NO CTWT 406-6518 406-6518 NEEDED NEEDED NEEDED...
  • Page 42 H301/302 series (3 stage) counterweight chart Stepped piston assemblies 4 x 2.5 5 x 2.5 5 x 3 5.5 x 3 5.5 x 3.5 5.5 x 4 6.5 x 3 6.5 x 3.5 6.5 x 4 7.5 x 4 8 x 4 8 x 5 NO CTWT NEEDED...
  • Page 43 H301/302 series (3 or 4 stage) CNG counterweight chart Stepped piston assemblies Double acting piston asemblies 5 & 3 5.5 & 3 7.5 & 3.5 7.5 & 4 8 & 4 1.25 & 2.5 408-0861 408-0861 408-0861 408-0861 409-2979 420-9924 424-2930 424-2930 420-5670 409-6362...
  • Page 44 H301/302 series balance crosshead jam nut weight Part number Weight lbs. (kg) 406-5173* 0.75 (0.34) 406-6445 7.57 (3.43) 406-6453 13.70 (6.21) 406-6461 19.84 (9.00) 406-6486 6.92 (3.14) 406-6494 17.80 (3.54) 406-6518 11.67 (5.29) 407-4593 3.05 (1.38) 408-0861 7.45 (3.38) 408-7552 9.24 (4.19) 408-8727 5.59 (2.54)
  • Page 45 H301/302 series (2 stage) sour gas double acting piston assemblies with counterweights (type 3 packing case ACC. to API 11P) Sour gas double acting piston assemblies NO CTWT NEEDED NO CTWT NO CTWT NEEDED NEEDED NO CTWT NEEDED NO CTWT NO CTWT NEEDED NEEDED...
  • Page 46 H301/302 series (3 stage) stepped piston assemblies with counterweights Stepped piston assemblies 4 x 2.5 5 x 2.5 5 x 3 5.5 x 3 5.5 x 3.5 5.5 x 4 6.5 x 3 6.5 x 3.5 6.5 x 4 7.5 x 4 8 x 4 8 x 5 NO CTWT...
  • Page 47 H301/302 series counterweight sour gas service (type 3 packing case ACC. to API 11P) Part number Weight +/- .05 lbs. (kg) 406-5173 0.75(0.340) 409-2962 1.25 (0.566) 420-9819 1.82 (0.825) 420-9802 2.07 (0.938) 409-7690 2.87 (1.301) 407-4593 3.05 (1.383) 420-9924 3.54 (1.605) 427-4350 3.76 (1.705) 409-3932...

  • Page 49: Chapter 4: Installation

    Chapter 4: Installation Perform the installation of HSR compressors, with its associated driver and piping, with precision. This chapter addresses installation requirements. Refer to the packager’s standards for installation requirements. Complies with ANSI Z535, ISO 3864, OSHA 1910.145(f) (9) Access and Safety Any installation of a compressor assembly must include providing adequate space for routine operation and maintenance activities.

  • Page 50: Secure The Skid And Foundation (Sub-Base)

    H I G H P R E S S U R E DEPRESSURIZE THE COMPRESSOR PACKAGE BEFORE PERFORMING MAINTENANCE. Complies with ANSI Z535, ISO 3864, OSHA 1910.145(f) (7) L E T H A L G A S VENT GAS IMPROPER VENTING WILL RESULT IN SEVERE PERSONAL INJURY OR DEATH.

  • Page 51: Skid Leveling And Alignment

    Reciprocating inertial forces are balanced on HSR’s, but unbalanced couples also exist. The magnitude of these unbalanced forces and couples, if not shown on the foundation drawing, may be obtained from the Packager. Complies with ANSI Z535, ISO 3864, OSHA 1910.145 (f) (9) B.

  • Page 52: Alignment

    Refer to compressor Hold-Down Bolting for recommended bolt sizes and minimum torquing requirements. Complies with ANSI Z535, ISO 3864, OSHA 1910.145 (f) (9) alignment Frame Deflection (Soft Foot) Use a magnetic base dial indicator to check for frame deflection (soft foot) when tightening the frame sub-base bolts, .

  • Page 53: Fi Gu Re 8 Sketch Description Of Misalignment

    Angular (A) Face Misalignment Parallel Offset Radial (R) Misalignment Sketch description of misalignment FiguRe 8 Dial indicator positions for checking the radial (R) and angular (A) alignment are suggested in "Figure 9". Dial indicator arrangement FiguRe 9 Thermal Growth The compressor’s cast iron frame thermally grows between ambient (cold) to normal (hot) operating conditions.

  • Page 54: Maximum Allowable Drive Train Misalignment

    Center line height (nominal) Thermal growth Frame model series Inches (mm) Inches (mm) H302 12.3125 (312.7375) 0.007 (0.178) Compressor frame thermal growth Ta ble 13 For example: 12.315 x 0.0000058=0.00007 0.00007 x 100°F=0.007" The tabled compressor frame thermal growth figures are based upon a 100°F (38°C) temperature rise and use a cast iron thermal expansion coefficient of 0.0000058 inch/ inch/ °F.

  • Page 55: Compressor Crankshaft End Thrust Clearance

    Check the alignment with one set of bolts removed. Design the mounting bracket indicators for known minimum sag (droop). In order to correct the R readings, the sag must be known. Rotate the driver (both coupling halves) slowly; taking readings at four points 90º...

  • Page 56: Skid Hold-Down Bolting

    Check the crankshaft end thrust using a dial indicator with resolution increments of 0.001" (.0254 mm). Rotate the compressor crankshaft to position a counterweight near the top of the crankcase. Mount the indicator base on the top cover gasket surface of the crankcase. Position the dial indicator contact point on the counterweight face enabling the dial to register axial crankshaft movement.

  • Page 57: Bolting Requirements

    bolting Requirements The packager is responsible for locating and drilling the bolt holes in the fabricated compressor pedestal. The drilled holes should not be less than .875" (22.225 mm) nor more than 1.0" (25.4 mm) diameter to allow for minor hole location variances in the pedestal and frame.

  • Page 58: Piping

    Verify the hold down bolting torque and soft foot checks quarterly. See the "Quarterly maintenance checklist" Piping Process gas Piping Install all compressor suction and discharge process gas piping as follows: The suction and discharge piping should never be smaller than the compressor suction and discharge pipe flange connections.

  • Page 59: Lubricating Oil Piping And Tubing

    Inlet strainer FiguRe 10 Properly install designed pipe supports and clamps. The scrubber, cylinder and cooler connections may not be designed to adequately support the piping. lubricating oil Piping and Tubing All frame lubricating oil piping and tubing should be made of stainless steel. All electric motor driven compressors require a frame pre lube pump.

  • Page 60: Compressor Valves

    Compressor Valves Compressor valves control the inlet low pressure and higher outlet gas pressure gas from the compressor cylinder. During normal operation, these valves open and close by differential pressure across the valve. Valve springs keep the valve plate closed against the respective inlet and discharge valve seat preventing reverse gas flow through the valves.
  • Page 61 H301/302 HSR Compressors | Rev. 2.2 | 51...

  • Page 63: Chapter 5: Operation

    Chapter 5: Operation The startup, commissioning and operation of HSR compressors requires thorough knowledge of the equipment, the application and proper starting procedures. For the safe operation of this compressor, do not attempt to start the unit without being knowledgeable. Complies with ANSI Z535, ISO 3864, OSHA 1910.145(f) (9) Before starting a new, relocated or reapplied compressor, or after a major overhaul, ensure that the Pre-startup checklist...

  • Page 64: Maximum Allowable Working Pressure (Mawp)

    H I G H P R E S S U R E ENSURE ALL PRESSURE IS REMOVED. Complies with ANSI Z535, ISO 3864, OSHA 1910.145(f) (7) D R O P / F A L L H A Z A R D DO NOT STAND ON THE COMPRESSOR.

  • Page 65: Cylinder Discharge Temperature Shutdown Settings

    Cylinder Discharge Temperature Shutdown Settings Shut Down Setting Recommendations The discharge temperature shut down set point of each cylinder must be set at 10%, but NEVER more than 25°F (14°C) above the highest NORMAL daily discharge temperature of that cylinder. Complies with ANSI Z535, ISO 3864, OSHA 1910.145 (f) (9) Due to changing operating and ambient conditions, it is the operator’s responsibility to daily check, justify, confirm, and...

  • Page 66: Compressor Relocation Or Reapplication

    Logic Controller (PLC) using the following input values and formula to calculate the expected DT. Programming of the actual alarm and shut down points should be password protected to allow changes by only those qualified individuals authorized to make changes. DTal = DT + 12°F.

  • Page 67: Compressor Frame And Cylinder Information

    Compressor Frame and Cylinder Information Record the following compressor frame and cylinder information for future reference prior to starting the compressor (see “Form 4”). The serial number, bore and MAWP is found on the cylinder nameplate. See “Figure 4”. Compressor Model: Serial Number: Compressor Frame Lube Oil, Make/Type/Viscosity: Cylinder Lube Oil, Make/Type/Viscosity:...

  • Page 68: Crankcase Oil Level

    When non-foaming oil flows from the tube fitting, re-tighten each tubing fitting in flow sequence. Compressor Reapplication or Relocation Checklist Use the following checklist and consult GE or the packager if any of these changes occur: • Gas properties change •...
  • Page 69 22. Prepare the compressor driver according to manufacturer’s instructions. Comply with the Packager’s instructions for all equipment. 23. Replace all safety guards and covers. Signed Date Notes F o R m 6 Reapplication or relocation checklist GE Oil & Gas H301/302 HSR Compressors | Rev. 2.2 | 59...

  • Page 70: Initial No-Load Rotational Test Run

    initial No-load Rotational Test Run Perform a low speed, no-load rotational test run, in the shop and in the field, to mechanically check the driver and compressor at a minimum operating speed. Refer to the No-Load Operational Checklist for the specific items to check during the test run.
  • Page 71 Perform the following checks prior to a no-load rotational test run: D A N G E R O U S T E M P E R A T U R E WAIT 15 MINUTES AFTER SHUTDOWN BEFORE REMOVING THE TOP COVER. Complies with ANSI Z535, ISO 3864, OSHA 1910.145 (f) (6) Description Initials...

  • Page 72: Initial Load Run

    initial load Run After completing the “Pre-startup checklist” and No-load rotational test run, the compressor may be started, warmed up and put online. Use the Initial load run checklist to observe the compressor operation and make adjustments of safety shutdown devices. Adjustments to the safety devices must to be within the compressor design limitations.

  • Page 73: F Ig Ur E 11 Piping Schematic

    Piping schematic FiguRe 11 Follow site and or organizational policies when purging the process gas system. Complies with ANSI Z535, ISO 3864, OSHA 1910.145 (f) (9) T O X I C A N D P O I S O N O U S S U B S T A N C E S USE APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT.

  • Page 74: Start The Compressor

    Start the Compressor Follow these steps to start the compressor: Open the process gas discharge, by-pass, and vent/blow down valves. Open the suction valve allowing process gas to flow through the compressor package, forcing out the ambient air from the process gas system. Close the vent/blow down valve to pressurize the process gas system.

  • Page 75: Stop The Compressor

    Stop the Compressor General compressor shutdown guidelines are listed below: Reduce the engine speed. To prevent overload shutdown, in some applications, may require reduction of the inlet pressure. Complies with ANSI Z535, ISO 3864, OSHA 1910.145 (f) (9) Unload the compressor: Open the bypass valve and run the compressor in an unloaded/minimized load condition for a few minutes to cool down the package.

  • Page 77: Chapter 6: Lubrication

    Chapter 6: Lubrication R O T A T I N G C O M P O N E N T DO NOT TOUCH MOVING PARTS WHEN IN USE. Complies with ANSI Z535, ISO 3864, OSHA 1910.145 (f) (6) There are two separate lubrication systems on H series compressors: A gear type positive displacement pump provides pressurized oil from the crankcase sump to the frame and running gear.
  • Page 78 Complies with ANSI Z535, ISO 3864, OSHA 1910.145 (f) (9) oil Filtration Oil filtration is vital for the successful operation of a compressor. In 2010 GE upgraded the H302 series frames with improved oil filtration technology. The new filter offers improved particle removal micron rating, greater filtration surface area, reduced pressure drop across the filter, and improved debris-holding capacity.

  • Page 79: Pressure Regulating Valves (Prv)

    126.5 (grams) Filter OD x Length 4.6875" x 3.6875" x 7.125" 4.250" x 7.3437" 5.04" x 6.66" (inches) 11.2812" GE oil filter standard 1-105292 Figu R e 1 3 GE part number 405-046 427-6355 1-103539 1-105292 Filter element Replaced by...

  • Page 80: Table 20 Prv Size, Part Number And Spring Rating And Information

    DO NOT TOUCH. Complies with ANSI Z535, ISO 3864, OSHA 1910.145 (f) (6) GE sets the initial PRV during its factory test run. The PRV utilizes a manually adjusted, spring-loaded piston to control oil pressure throughout the compressor’s operating speed range. Since higher oil pressures occur during cold startups, adjust the oil supply pressure during normal (hot) operation.
  • Page 81 These PRVs are not pressure relief valves. PRV in this context refers to pressure regulators. PRVs are not a positive shut- off valve, and bypass a minimal amount of oil all the time. Complies with ANSI Z535, ISO 3864, OSHA 1910.145 (f) (9) Crankcase oil Changes Check the crankcase oil level every 24 hours and before every start-up to ensure proper levels.

  • Page 82: Disassemble The Prv

    Valve body (valve bore inside) acorn Nut adjusting Spring Retainer o-Ring lock Nut Spring Stop Ring Piston PRV assembled and exploded parts illustration Fi gu Re 14 C O M P R E S S E D S P R I N G F O R C E SHUTDOWN COMPRESSOR BEFORE DISASSEMBLING THIS VALVE.

  • Page 83: Crankcase Lubricant Selection

    Complies with ANSI Z535, ISO 3864, OSHA 1910.145 (f) (5) Crankcase lubricant Selection GE does not recommend specific brand and type of lubricants. Most oil manufacturers market oils with an additive package suitable for lubricating this type of compressor. Contact the local oil supplier/expert for suitable lubricants.

  • Page 84: Non-Lube Cylinder Applications

    The oil viscosity depends upon the ambient temperature when the compressor is started cold. Lowest ambient temperature °F (°C) SAE viscosity number 40°F (4°C) and above 40°F (4°C) and below 40 with crankcase heaters or supplemental heat Lowest ambient temperature vs. SAE viscosity Table 2 0 Non-Lube Cylinder Applications Non-Lube applications require piston rings and rod packing specific materials.

  • Page 85: System Installation

    Never replace a divider block valve with one of a different size number and/or letter. The block change affects all oil routed through the divider block assembly. Changing one block size may cause catastrophic failure. Complies with ANSI Z535, ISO 3864, OSHA 1910.145 (f) (9) System installation The cylinder lubricator pump is cam driven off the compressor crankshaft’s speed reduction gear train located in the compressor’s auxiliary end housing.

  • Page 86: Setup And Adjust Lubricator Pump

    Loosen tube nuts at all injection points. (Cylinder and packing.) Loosen the tube nut at divider block and loosen the four socket head screws at the inlet end of the block. Loosen a connection in the manifold block located on top of the pump unit, and the inlet connection to the no-flow switch.

  • Page 87: New Compressor Start-Up

    Max. Stroke Min. Stroke Loosen locknut to adjust plunger stroke FiguRe 15 Typical lubricator pump with plunger shown at max stroke/flow Screw plunger out of the base to increase stroke/flow, or in to decrease stroke/flow. Complies with ANSI Z535, ISO 3864, OSHA 1910.145 (f) (9) Leave at least 4 plunger threads engaged in the base at max stroke.

  • Page 88: Cylinder Wall Oil Film Wipe Test

    After operating for 200 to 300 hours, determine the lubrication rate by performing a cylinder wall oil film wipe test. (See "Lubricator cycle time and oil feed rates" for the calculation) Cylinder Wall oil Film Wipe Test Check the inside bore of each cylinder for proper lubrication by wiping the cylinder wall with a two-ply clean tissue from the 12 O'clock to 6 O'clock positions.

  • Page 89: Cylinder Lubrication Flow Rate And Cycle Indicator

    Too much oil Oil strains through both plies of tissue paper. Oil may be pooled at bottom of cylinder bore, discharge passages, valves, or covers. Return compressor to service and reduce cylinder lube rate (increase cycle time) by 10 to 20%. Perform cylinder oil film wipe test again in 200 to 300 operating hours.

  • Page 90: Rupture Disks

    When operating at the maximum rated speed, the typical oil flow rate for reciprocating compressor cylinders is 0.30 pints (0.14 liter) per day (PPD) for each inch (25.4 mm) of cylinder diameter. The oil flow rate for pressure packing is 0.6 pints (0.28 liter) per day (PPD) for each inch (25.4 mm) of piston rod diameter.

  • Page 91: Figure 16 Rupture Assembly

    activates, shutting the compressor down. Remove the blockage before starting up the compressor. It is necessary to have a properly sized and working atmospheric rupture assembly installed in all lubricating divider block systems. Never remove, modify, or plug an atmospheric rupture assembly since equipment damage can result.

  • Page 92: Digital Cylinder Lube No-Flow Devices

    0.250 inches (6.35 mm) 0.125 inches (3.2 mm) Medium pressure High pressure Replacement rupture discs rupture disc assembly rupture disc assembly Rating Rating Thickness Part # Part # Part # Color (PSI) (PSI) (Inches) 1-PS-5804 51-PS-5804 Black 0.006" 2-PS-5804 1150 52-PS-5804 Green 0.008"...

  • Page 93: Install Kenco Nfs-3 No-Flow Switch

    An example of an electronic no flow device (ENFD) is DNFT ® www.noflo.com Examples of mechanical no flow devices (MNFD) that are used are Kenco ® Lincoln ® www.kenco-eng.com www.graco.com install Kenco NFS-3 No-Flow Switch Kenco NFS-3 No-Flow Switch FiguRe 17 Switch MUST be mounted either vertically (terminal end up) or at a minimum angle of 20 º...
  • Page 94 lube-line check valve or point of lubrication. The "NFS-4", "NFS-5" and "NFS-9" No-Flow switches for Ajax are provided with brackets for mounting to one of the screws which hold the cast cover to the cylinder near the cylinder check. Connect No-Flow switch contact wire to magneto or alarm/shutdown switch. Connect line from lubricator to inlet port on No-Flow switch.

  • Page 95: F I Gur E 18 Dnft-Led Switch Assembly, With Magnetic Housing Assembly

    DNFT-LED Switch Assembly, with magnetic housing assembly FiguRe 18 Disconnect all wiring prior to welding on the compressor or skid. Complies with ANSI Z535, ISO 3864, OSHA 1910.145 (f) (9) Cylinder lubricants P E R S O N A L I N J U R Y WEAR APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT.
  • Page 96 The gas type, quality and operating conditions being compressed, determine the viscosity and type of oil used to lubricate the cylinders and piston rod packing. Use quality, properly inhibited oil. See “Table 22”. The oil should have good wetting ability, high film strength, be of low carbon content, good chemical stability, and be resistant to sludging.

  • Page 97: Table 24 Cylinder Lubricants

    0.65% 0.65% 0.65% 0.65% Pressures 2,500 Psig (172 bar) and above: CONTACT THE OIL SUPPLIER AND GE. * Can contain 3% to 10% (acid less tallow or animal fat) or special compounding to resist water-wash. Cylinder lubricants Tabl e 22...

  • Page 99: Chapter 7: Vibration

    Pressure Pulsations Torsion Vibration When unsatisfactory vibration amplitudes are detected, take corrective actions immediately. Notify the packager or GE if unable to correct the problem. See “Figure 19” for satisfactory, marginal, and unsatisfactory levels of vibration. All reciprocating compressors have inherent vibration. All components have a natural vibration frequency which maybe amplified by the operating conditions of the compressor.

  • Page 100: Mechanical

    Mechanical Possible causes of excessive mechanical vibration include: • Loose hold-down bolting • Loose distance piece to cylinder or frame bolting • Loose cylinder support • Possible frame distortion • Improper distance piece support • Improper discharge bottle support • Drive coupling misalignment •...

  • Page 101: Pressure Pulsations

    Pressure Pulsations Pressure pulsations are caused by piston motion, which generate the basic fundamental pulsation frequency corresponding to crankshaft speed, gas properties, and the flow pattern of the gas through the valves and piping. The pulsation level is the product of piston speed and fluid density times the speed of sound.

  • Page 102: Vibration Amplitude Versus Frequency

    Vibration Amplitude versus Frequency “Figure 19” shows how vibration amplitude decreases as frequency increases. • The diagonal lines are in velocity measured in inches per second. • The X axis (frequency) measures in cycles per minute = RPM. • The Y axis (displacement amplitude) measures in Mils peak to peak. Amplitude (Mils Peak-to-Peak) Guidelines reference measurement at the outboard cylinder end.
  • Page 103 H301/302 HSR Compressors | Rev. 2.2 | 93...

  • Page 105: Chapter 8: Maintenance

    Chapter 8: Maintenance Safety must always be the paramount consideration in the operation AND maintenance of a reciprocating gas compressor. S E V E R E I N J U R Y THE DRIVER (ENGINE, ELECTRIC MOTOR, ETC.) MUST BE STOPPED AND IF NOT UNCOUPLED FROM THE COMPRESSOR, RESTRAINED TO PREVENT COMPRESSOR ROTATION WHILE MAINTENANCE IS BEING PERFORMED.

  • Page 106: Component Weights

    Refer to Chapter 3: General Data/Specifications. E X P L O S I V E TO AVOID A POTENTIALLY EXPLOSIVE AIR/GAS MIXTURE, THE ENTIRE GAS SYSTEM MUST BE PURGED WITH GAS PRIOR TO START UP AND OPERATION AND AFTER PERFORMING ANY MAINTENANCE..

  • Page 107: Preventive Maintenance

    Preventive Maintenance Record Keeping Maintenance and Repairs – Compressor Log Book All operating compressors require periodic maintenance. Establish a maintenance program in conjunction with any recommended startup and initial operations checks. The program should be reviewed at regular intervals and modified as required to address any special situations or concerns.

  • Page 108: Recommended Maintenance

    Select and use appropriate sealants and O-ring lubricants compatible with the gasket and O-ring materials to: (1) improve sealing and life of the gasket or O-ring material and (2) aid in the removal of the gasket or O-ring during disassembly. Complies with ANSI Z535, ISO 3864, OSHA 1910.145 (f) (9) Always use OEM O-rings of the specified material and durometer hardness to ensure reliable leak free connections.

  • Page 109: Monthly Maintenance Checklist

    Compressor operating conditions - compressor RPM, suction/discharge 24 hours temperature and pressure by cylinder. Valve cover temperature – each suction and discharge valve by cylinder. 24 hours High cylinder discharge gas temperature shutdown, lesser of 10% or 25°F (14°C) above normal discharge temperature of each cylinder Note: 350°F 24 hours (177°C) shutdown, max allowable gas discharge temperature.

  • Page 110: Quarterly Maintenance Checklist

    Quarterly maintenance Checklist Maintenance check list – 3 Months Time interval (plus daily/monthly checks) Check frame crosshead guide mounting bolts for tightness, shim and re- 2,000 hours torque as required to eliminate any “soft foot” found. Examine the external frame and cylinder fasteners for loose or broken bolts. 2,000 hours Check discharge bottle supports for snug fit adjustment, with compressor 2,000 hours...

  • Page 111: Annual Maintenance Checklist

    annual maintenance Checklist Maintenance check list- 6 months Time interval (plus daily/monthly/3 months/6 months checks) Check drive alignment, coupling (rim and face) including axial thrust. 8,000 hours Check critical frame running gear clearance – main, connecting rod and thrust, if readings outside tolerance limits, repair or replace affected 8,000 hours components as required.

  • Page 112: Adjust The Variable Volume Clearance Pocket (Vvcp) Assembly

    Rod Loading. Compression ratios. Discharge Temperatures. Please contact GE if you have questions concerning the installation or use of a VVCP as a capacity control device. adjust the Variable Volume Clearance Pocket (VVCP) assembly Do not adjust VVCP while the compressor is in operation.
  • Page 113 Performance parameters to check, includes volumetric efficiency, gas temperatures, driver power limitations, crosshead pin reversals, interstage pressures, system torsional response, compressor valve dynamics and process gas acoustical affect. The added cylinder clearance may significantly change process gas pressures and require valve modifications (usually spring changes) to achieve optimum valve life for long-term operation.

  • Page 114: Fi Gu Re 21 Effective Rod Extension: Amount Pocket Is Open

    Effective rod extension: amount pocket is open Fi gu Re 21 104 | Chapter 8: Maintenance...

  • Page 115: Table 26 Vvcp Added Clearance Volume, Travel And Percent

    % increase in Double Acting Volume added per clearance per inch of VVCP travel Max added bore diameter Inch of travel (in. ^3) travel distance Inches volume (in. ^3) Inches (mm) Inches (mm) 3.00 (76.20) 4.92 23.19 (589.026) 3.405 16.75 3.50 (88.90) 7.08 24.53 (623.062)

  • Page 116: Table 27 List Of Compressor Conditions

    F L A M M A B L E FLAMMABLE OR TOXIC PROCESS GAS MAY LEAK FROM THE VVCP PISTON STEM WHENEVER THE JAM NUT IS LOOSENED. THE SEAL WASHER UNDER THE JAM NUT IS USED TO SEAL GAS FLOW ACROSS THE STEM THREADS. EXERCISE ALL NECESSARY SAFETY PRECAUTIONS WHEN TOXIC OR POTENTIALLY EXPLOSIVE GAS/AIR MIXTURES ARE PRESENT.

  • Page 117: F I Gur E 22 Vvcp Flange Lubrication Fitting And Threads

    Required Materials and Tools When adjusting a standard HE VVCP on an HSR compressor cylinder, use: VVCP clearance in “Table 26” or graphs. Performance program output showing desired VVCP setting in inches or %. Tape measure. Large adjustable wrench to loosen VVCP jam nut and to turn VVCP stem. Grease gun, to lubricate VVCP piston stem threads.
  • Page 118 Adjust the VVCP Inspect the cylinder’s HE for any special spacers, between the VVCP and the cylinder. Clearance spacers may have also been installed under some or all of the suction and discharge valves. In certain high clearance applications a special HE compression clearance spacer may have been added to the cylinder’s “base”...

  • Page 119: Connecting Rod Inspection Sheet - H Frame

    Crosshead Pin OD – 1.4998"/1.5000" Condition Crosshead Pin Roller Bearings OD (BOD) – 2.0625" BOD 1 BOD 2 Condition Roller bearings oD F o R m 1 4 Connecting rod inspection sheet GE imagination at work H301/302 HSR Compressors | Rev. 2.2 | 109...

  • Page 121: Chapter 9: Troubleshooting

    Chapter 9: Troubleshooting Minor situations can occur during the operation of a HSR Compressor that requires trouble shooting. Often these situations can be attributed to gas contaminants (liquid and solids carryover), actual conditions different from design (improper adjustments), unsuitable lubricant selection, or operating personnel unfamiliar with the compressor and its setup.
  • Page 122 Symptoms Possible cause Discharge pressure above normal Discharge pressure below normal Operating speed less than normal Inlet pressure below normal Intake clogged Dirty valves Valves worn or broken Valves not seated in cylinder Incorrect valve Valve incorrectly assembled Gaskets leak System leakage excessive Piston rings worn,...
  • Page 123 Symptoms Possible cause Foundation bolts loose Piston to head clearance too small Piston or piston nut loose Bearings need replaced Liquid carry-over Lubrication inadequate Lubrication excessive Oil viscosity incorrect Wrong type oil Oil filter plugged Water inlet temperature to high Ambient temperature too high Cylinder, head, cooler...

  • Page 124: Table 28 Troubleshooting Chart

    Symptoms Possible cause Water jacket or cooler dirty Dirt, rust entering cylinder Cylinder, head, cooler dirty Packing rings worn, stuck or broken Piston rod scored, pitted, worn Troubleshooting chart Table 2 5 114 | Chapter 9: Troubleshooting...
  • Page 125 Situation Potential common causes Compressor will not rotate • Cylinders gas pressure loaded • Piston end clearance improper, piston hitting head-end head or crank-end head • Foreign, incompressible material in cylinder • Mechanical seizure in running gear (crankshaft, bearings, connecting rod, crosshead, packing/piston rod, piston) Cylinder noise or knock •...
  • Page 126 Situation Potential common causes Crankcase oil level high/low • Cold oil / insufficient head pressure • Oil makeup system isolation valve closed or strainer plugged • Oil makeup system out of adjustment or leaking High oil filter differential pressure • Filter media plugged •...
  • Page 127 Situation Potential common causes Excessive packing leakage • Worn packing rings • Packing case bolts loose • Packing rings incorrectly assembled/installed • Improper lube oil selection and associated lube rate • Contaminants (liquid or solid) affecting packing rings • Packing not seated or properly run-in •...
  • Page 128 Situation Potential common causes Inadequate compressor output • Unit recycle vent or scrubber dump valve open or leaking flow • Compressor speed lower than rating • Compressor suction pressure lower than rating • Cylinder head end VVCP unloader improperly adjusted •...

  • Page 131: Appendix A: H Series Tools

    Appendix A: H Series Tools Crosshead Jam Nut Wrench*......... . . 406-6412 Piston Nut Spanner Tool*.

  • Page 132: Index

    Index Index 3 or 4 stage 33 commissioning report 10 components H Series 10 component weights 96 Symbols compressor configuration 56 3 or 4 stage CNG counterweight 33 data tag information 57 log book 97 operation safety advisories 62 access reapplication 56 to website for documentation 1 relocation 56...
  • Page 133 feedback 1 oil pump 74 parts 1 system 24 technical support 6 lubricator system priming 58 warranty 6 maintenance fastener torque values 27 annual 101 feedback daily 98 email to send 1 monthly 99 filling crankcase sump 57 preventative 97 fixed clearance cylinder head 9 PRV 71 form...
  • Page 134 post startup checklist 17 bearings and running gear 22 prelube frame 21 frame 57 start the compressor 63 pressure stop the compressor 65 maximum allowable working pressure (MAWP) support technical 6 pulsations chart 92 system pressure rated discharge 54 decrease 70 settings 68 increase 70 troubleshooting low oil 111...
  • Page 135 H301/302 HSR Compressors | Rev. 2.2 | 5...
  • Page 136 The information contained herein is general in nature 50127 Florence, Italy and is not intended for specific construction, installation T +39 055 423 211 or application purposes. GE reserves the right to make F +39 055 423 2800 changes in specifications or add improvements at any [email protected] time without notice or obligation.

This manual is also suitable for:

H302 series

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