GE H301 Series, Operating Manual

Page 1: ...High speed reciprocating compressors H301 and 302 series operating manual GE Oil Gas ...

Page 2: ...tion Date Author Approver 2 0 Updated safety information and made document usable online 3 9 2012 Luette A Jim H 2 1 Added piston head end and crank end clearance 7 10 12 Luette A Jim H 2 2 Update parts phone number efax website rearrange connecting rod form 7 25 13 Luette A Jim H 2012 General Electric Company All Rights Reserved ...

Page 3: ...0 Series Cylinder Assembly for H Series frames 9 Commissioning Report 10 Components of the H 301 302 Series 10 High Speed Reciprocating Compressor Startup Report 11 Startup Report 11 Pre Startup Checklist 14 Post Startup Checklist 17 Gas Compressor Record 18 Crankshaft Rotation 19 Chapter 3 General Data Specifications 21 Frame Specifications 21 Bearings and Running Gear 22 Lubrication System 24 Cy...

Page 4: ... Working Pressure MAWP 54 Rated Discharge Pressure 54 Cylinder Discharge Temperature Shutdown Settings 55 Shut Down Setting Recommendations 55 Discharge Temperature Calculations 55 Cylinder Temperature Shutdown Setting Formula 55 Compressor Relocation or Reapplication 56 Compressor Frame and Cylinder Information 57 Filling Crankcase Sump 57 Pre Lube Frame 57 Crankcase Oil Level 58 Cylinder Lubrica...

Page 5: ...cal 90 Inertia Unbalance 90 Pressure Pulsations 91 Torsional Vibration 91 Vibration Amplitude versus Frequency 92 Chapter 8 Maintenance 95 Component Weights 96 Frame and Frame Components 96 Preventive Maintenance 97 Record Keeping 97 Oil Analysis 97 Cleanliness 97 Inspect Gaskets and O rings 97 Recommended Maintenance 98 Daily Maintenance Checklist 98 Monthly Maintenance Checklist 99 Quarterly Mai...

Page 6: ...IV H301 302 HSR Compressors Rev 2 1 Acronyms PRV Pressure regulating valve VVCP Variable voulme clearance pocket ...

Page 7: ...t strainer 49 Figure 11 Piping schematic 63 Figure 12 Frame and running gear lubrication system 67 Figure 13 GE oil filter standard 1 105292 69 Figure 14 PRV assembled and exploded parts illustration 72 Figure 15 Typical lubricator pump with plunger shown at max stroke flow 77 Figure 16 Rupture assembly 81 Figure 17 Kenco NFS 3 No Flow Switch 83 Figure 18 DNFT LED Switch Assembly with magnetic hou...

Page 8: ...on 57 Form 6 Reapplication or relocation checklist 59 Form 7 Initial no load rotational test run checklist 61 Form 8 Initial load run checklist 62 Form 9 Daily maintenance checklist 99 Form 10 Monthly maintenance checklist 99 Form 11 Quarterly maintenance checklist 100 Form 12 Semi annual maintenance checklist 100 Form 13 Annual maintenance checklist 101 Form 14 Connecting rod inspection sheet 109...

Page 9: ...hts sour gas service 35 Table 13 3 stage counter balance weight part numbers 36 Table 14 Balance counterweights sour gas service 37 Table 15 Compressor frame thermal growth 44 Table 16 Hold down bolting torque range 47 Table 17 Discharge temperature calculations 55 Table 18 Cylinder discharge formula 56 Table 19 GE Oil filter upgrade 69 Table 20 PRV size part number and spring rating and informati...

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Page 11: ...orization only To request access 1 Go to the following link geoilandgas com hsr 2 Scroll down to the RELATED field at the bottom of the screen Expand the section called Websites 3 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 4 Follow the instructions in the e mail to confirm the request A GE empl...

Page 12: ...fety requirements of that country For details on safety rules and regulations in the United States contact your local office of the Occupational Safety and Health Administration OSHA the American National Standards Organization ANSI For information regarding Canadian or international locations contact your local or regional office of the International Standards Organization ISO The words notice ca...

Page 13: ...ng this information could result in SEVERE PERSONAL INJURY OR DEATH E X P L O S I V E CONTENTS UNDER PRESSURE FOLLOW APPROPRIATE PROCESS TO DEPRESSURIZE Complies with ANSI Z535 ISO 3864 OSHA 1910 145 f 7 Danger This symbol identifies information about immediate hazards Disregarding this information will result in SEVERE PERSONAL INJURY OR DEATH F L A M M A B L E FLAMMABLE GAS NO OPEN FLAME Complie...

Page 14: ...RATION OF THE MANUFACTURER S WARRANTY AND THE ADOPTION OF FULL LIABILITY ON THE PART OF THE USER CAN CAUSE INCIDENTS EVEN SERIOUS HARM Complies with ANSI Z535 ISO 3864 OSHA 1910 145 f 5 Excessive wear is not considered a material defect Normal wear items such as piston rings rod packing valves etc are not under warranty Complies with ANSI Z535 ISO 3864 OSHA 1910 145 f 9 On any field startup it is ...

Page 15: ...SIVE ASPHYXIATION PINCH POINT LIFTING HAZARD TOXIC AND POISONOUS SUBSTANCES FALLING DO NOT CLIMB ON EQUIPMENT SLIPPING AND FALLING GENERAL WARNING GENERAL DANGER ROTATING COMPONENT SEVER HAZARD PROJECTILE PERSONAL PROTECTIVE EQUIPMENT Figure 1 Safety symbols The safety advisories in this book are set against a black background so that they stand out When using these signs on equipment the backgrou...

Page 16: ...itial start up 2 All frame and cylinder assembly components received proper pre start maintenance checks and lubrication as stated in this manual 3 Starting and operating the compressor within the design limits and HSR Compressor specifications 4 Proper completion and return of the Startup report within 30 days after initial start up Send the completed report to GE Oil Gas ATTN Warranty Administra...

Page 17: ...H301 302 HSR Compressors Rev 2 2 7 ...

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Page 19: ...using 3 Distance pieces 4 Cover plates 5 Lubricating oil pump and filtration system 6 Cylinder forced feed lubricator system 7 Crossheads with pins 8 Crankshaft 9 Connecting Rods with Roller and Precision Bearings Options include 10 Non Lubricated cylinders 11 Sour Gas compliant configuration 12 Auxiliary Fan Drive not shown H 30 Series Cylinder Assembly for H Series frames Normally includes 1 Cyl...

Page 20: ... run checklist 5 Initial load run checklist 14 Figure 2 H 301 302 H Series compressor components 1 2 13 13 3 4 7 8 12 22 23 21 20 19 9 10 17 11 13 18 15 16 5 6 13 1 Concentric valve 2 HP liner 3 Suction valve cover 4 Packing lube inlet 5 Cylinder lube divider block 6 Main bearing 7 Crankcase breather 8 Crankcase 9 Crosshead 10 Crosshead liner 11 Packing case 12 Suction valve 13 Pistons 14 Suction ...

Page 21: ...der Package Startup Date Service Rep Contact Phone Driver Data Engine Motor MFGR Model Max Rated Horsepower RPM Applied Speed RPM Applied Horsepower Customer Name Phone Email Address City State Country ZIP Customer Unit No Unit Location Project Name Closest Town State Country Offshore Yes No Contact Person Contact Phone Application Information Application Injection Gathering Pipeline CNG etc Gas C...

Page 22: ...y Temperature at Filter Normal 150 170 F 185 F 85 C High Oil Temperature Shutdown Oil Cooler Coolant Temperature Inlet _____________ Outlet ______________ Cylinder Oil and Lube Rate Lube Cycle Time Seconds Stroke Break In Normal Contact oil supplier for frame and cylinder lubricant recommendations Driver Data Driver Speed RPM Engine Vacuum or Boost In Hg BHP Electric Motor Volts Amps KW Compressor...

Page 23: ... Clearances Throw CE HE 1 2 3 4 5 6 Crosshead to Guide Clearances Throw IB Middle OB 1 2 3 4 5 6 Piston Rod Run Out Throw Vertical Horizontal 1 2 3 4 5 6 Notes Alignment Axial Thrust Crankshaft Axial Thrust FACE COLD RIM 0 0 Crankshaft Axial Thrust FACE HOT RIM 0 0 Frame Serial No H301 302 HSR Compressors Rev 2 2 13 Form 1 Startup report ...

Page 24: ... ISO 3864 OSHA 1910 145 f 5 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 Complies with ANSI Z535 ISO 3864 OSHA 1910 145 f 5 D A N G E R O U S T E M P E R A T U R E S DO NOT TOUCH COMPRESSOR WHEN IN OPERATION Complies with ANSI Z535 ISO 3864 OSHA 1910 145 f 7 E L E C T R I C A L H A Z A R D DISCONNECT POWER Complies with ANSI Z535 ISO 3864 OSHA...

Page 25: ...ngs within specification and readings recorded 11 Have coupling flywheel adapter and drive coupling bolt torques been verified and recorded 12 Has compressor crankshaft axial thrust been checked and recorded Note Is drive coupling free floating when installed 13 Have piston end clearances been checked and recorded 14 Have the VVCPs been set to the desired clearance settings and stem jam nuts been ...

Page 26: ...y inlet debris screens 100 mesh been installed at the suction flange of each cylinder 36 Have the suction lines been blown out to remove water dirt slag etc 37 Has the gas piping been purged of all air for machines compressing a combustible gas 38 Have all critical fastener torques been checked and recorded Caution Loose fasteners may result in a safety hazard or equipment failure See Operators Ma...

Page 27: ...bout 10 greater than normal discharge temperature but not to exceed 25 F 14 C or cylinder s 350 F 177 C limit 7 Is the cylinder lubrication divider block s visual indicator pin moving or LED light flashing 8 Is pump set at maximum rate for break in Seconds stroke 9 Are there any oil or process gas leaks If yes then shutdown compressor and correct as required 10 Has piston rod packing begun to seal...

Page 28: ...CATION Throw stage number see Figure 3 1 2 3 4 1 Cylinder model series 2 Cylinder bore 3 Cylinder serial number 4 Stage number 1 2 etc 5 Crosshead light or heavy where applicable 6 Piston and rod assembly weight pounds 7 Weight added used for balance give number of pounds 8 Valve part numbers if not standard suction and discharge 9 Optional distance piece x if yes 10 Variable volume clear pocket x...

Page 29: ...H301 302 HSR Compressors Rev 2 2 19 Crankshaft Rotation The throw closest to the crankshaft drive end is the first throw Figure 3 Crankshaft rotation ...

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Page 31: ...30 series Rated speed RPM 1800 Minimum speed RPM 900 Units of measure Inches mm Stroke length 3 00 76 20 Piston rod diameter 1 1250 28 50 Crankcase mounting surface to the crankshaft center line 12 3125 312 735 Crankshaft drive end diameter 2 7035 68 669 Crankshaft taper of 1 50 inch per foot 1 50 38 1 Maximum horsepower KW per throw 100 74 57 2 throw frame and cylinder weights average lbs kg 2000...

Page 32: ... 200 3 002 76 251 Width 1 875 47 625 Wall thickness 0 187 4 7498 0 188 4 7752 Clearance range 0 002 0 0508 0 0045 0 1143 Maximum allowable clearance 0 007 0 1778 Connecting rod Connecting rod length CL to CL 8 50 215 90 Rod bearing bore diameter 3 423 86 944 3 424 86 970 Crosshead pin bearing bore diameter 2 0610 52 349 2 0615 52 362 Taper ovality out of round and barrel 0 0005 0 0127 Side clearan...

Page 33: ...with only the pin installed Group A 14 15 lb 6 4183 kg 14 20 lb 6 4410 kg Group B 14 21 lb 6 4455 kg 14 26 lb 6 4682 kg Group C 14 27 lb 6 4728 kg 14 32 lb 6 4954 kg Group D 14 33 lb 6 5000 kg 14 38 lb 6 5227 kg Crosshead liner sleeve Liner outside diameter 5 80 147 32 Liner bore inside diameter 5 125 130 17 5 126 130 20 Liner bore out of round 0 0015 0 0381 Liner bore out of round maximum 0 003 0...

Page 34: ...ar Low oil pressure Shutdown 30 Psig 2 0 bar falling Fahrenheit Celsius Normal operation hot 150 to 170ºF 65 to 76ºC High oil temp Shutdown 185ºF 85ºC rising Minimum oil viscosity 20 cSt 175ºF 80ºC Model RPM Oil flow Oil heat rejection H302 1 800 10 GPM 37 85 LPM 5 000 BTU Hour 1260 Kilo cal Hour Maximum oil pump output flow is at the rated speed listed above with a 160ºF 71ºC oil temperature Tabl...

Page 35: ...s Clearance and Weight The H301 302 cylinder size bore and piston diameter clearance and weight of the fixed clearance or VVCP assembly for lubricated cylinders are listed below Cylinder size inches mm Bore diameter inches mm Piston diameter inches mm Clearance inches mm Double Acting cylinder assembly estimated weight pounds kg Tandem Stepped cylinder assembly estimated weight pounds kg VVCP asse...

Page 36: ...9428 5 987 152 0698 0 013 0 3302 0 020 0 508 360 163 293 87 39 462 22 9 979 6 5 165 10 6 500 165 100 6 502 165 150 6 475 164 460 6 480 164 590 0 020 0 507 0 027 0 690 350 158 757 250 113 398 88 39 916 26 11 793 7 5 190 50 7 500 190 500 7 502 190 550 7 475 189 860 7 480 189 990 0 020 0 507 0 027 0 690 460 208 652 240 108 862 108 48 987 25 11 339 8 203 20 8 000 203 200 8 002 203 250 7 975 202 560 7 ...

Page 37: ...1 0 013 0 038 0 017 0 016 Table 5 Piston ring and packing ring clearances Pressure packing ring side clearance Cup depth Ring type Ring width Packing ring side clearance 0 375 9 525 0 377 9 576 Pressure breaker 0 369 9 372 0 007 0 177 0 375 9 525 0 377 9 576 BCD set 0 366 9 296 0 01 0 254 0 375 9 525 0 377 9 576 BD Packing 0 362 9 194 0 014 0 355 0 562 14 274 0 564 14 325 Oil wiper set 0 555 14 09...

Page 38: ...the fastener should be capable of being hand assembled with a minimum of force Generally fasteners should be installed with some radial clearance Avoid placing the fastener threads in shear or loaded against one side of the fastener s hole 4 Torque values are generally based upon the use of petroleum based lubricants with lubricant being applied to fastener s threads and seating surfaces Use of th...

Page 39: ...fastener applied torque and the wrench setting is as follows Tf x L Tw L A Figure 5 Torque wrench with adapter at any angle except 90 right angle Figure 6 Torque wrench with adapter at right angle 90 Example Tf bolt torque requirement equals 100 Ft lbs L Length of torque wrench socket drive to point of applied force equals 18 inches A Effective length of torque wrench adapter or extension equals 3...

Page 40: ...cking flange and valve cover bolting See GES089 for bolt diameters and torque All torque values are based on lubricated threads Use the suggested bolt diameter in packager s fabricated compressor pedestal skid All torque values are based on Molykote P 37 SAE 40 weight oil Complies with ANSI Z535 ISO 3864 OSHA 1910 145 f 9 Balance Weights The following weight tables provide the part numbers and wei...

Page 41: ...TWT NEEDED 5 406 6518 406 6518 409 2962 NO CTWT NEEDED NO CTWT NEEDED NO CTWT NEEDED 5 5 406 6518 406 6518 409 2962 NO CTWT NEEDED NO CTWT NEEDED NO CTWT NEEDED NO CTWT NEEDED 6 406 6518 409 2962 NO CTWT NEEDED NO CTWT NEEDED NO CTWT NEEDED NO CTWT NEEDED NO CTWT NEEDED 6 5 406 6518 409 2905 406 6486 406 6486 406 6486 406 6486 NO CTWT NEEDED NO CTWT NEEDED 7 5 406 6494 406 6486 406 6486 406 6486 4...

Page 42: ... x 4 7 5 x 4 8 x 4 8 x 5 H Series double acting piston assemblies w jam nut 2 5 3 3 5 4 4 5 5 5 5 NO CTWT NEEDED 6 NO CTWT NEEDED NO CTWT NEEDED NO CTWT NEEDED 6 5 409 2921 409 2921 409 2921 409 2921 409 2921 409 2921 7 5 409 2921 409 2921 409 2921 409 2921 409 2954 409 2954 420 9819 420 9819 420 9819 8 409 2921 409 2921 409 2921 409 2921 409 2921 409 2921 420 9819 420 9819 420 9819 409 2921 9 409...

Page 43: ...8 0861 408 0861 408 0861 408 0861 409 2979 420 9924 424 2930 424 2930 420 5670 409 6362 1 25 2 5CL 409 2979 409 2979 409 2979 420 9957 409 2979 1 5 2 5 409 7690 1 5 3 406 6486 Table 9 3 or 4 stage CNG counterweights Select the piston assembly from the top of this chart and the CNG piston assembly from the left side of this chart Follow the selections horizontally and vertically to find the counter...

Page 44: ...409 3932 3 79 1 72 409 6362 15 53 7 04 409 7690 2 87 1 30 420 5670 15 15 6 87 420 9802 2 07 0 94 420 9819 1 82 0 83 420 9924 3 54 1 61 420 9957 8 96 4 06 423 7940 14 14 6 41 424 1504 16 88 7 66 424 2930 8 72 3 96 427 3515 18 12 8 22 427 4350 3 76 1 71 427 6312 13 60 6 17 Standard crosshead jam nut CONSULT THE COUNTERWEIGHT CHART TO DETERMINE THE CORRECT COUNTERWEIGHT PART NUMBER BASED ON THE PISTO...

Page 45: ...DED NO CTWT NEEDED 6 409 2962 NO CTWT NEEDED NO CTWT NEEDED NO CTWT NEEDED NO CTWT NEEDED NO CTWT NEEDED 6 5 7 105620 6 105620 6 105620 7 105620 7 105620 NO CTWT NEEDED NO CTWT NEEDED 7 5 6 105620 6 105620 6 105620 5 105620 5 105620 5 105620 NO CTWT NEEDED NO CTWT NEEDED 8 7 105620 7 105620 6 105620 6 105620 6 105620 6 105620 6 105620 NO CTWT NEEDED 409 2962 NO CTWT NEEDED 9 8 105620 7 105620 7 10...

Page 46: ... 105620 3 105620 3 105620 3 105620 7 5 3 105620 3 105620 3 105620 3 105620 2 105620 2 105620 420 9819 420 9819 420 9819 8 3 105620 3 105620 3 105620 3 105620 3 105620 3 105620 420 9819 420 9819 420 9819 3 105620 9 4 105620 4 105620 4 105620 3 105620 420 9802 420 9802 420 9802 3 105620 3 105620 3 105620 10 11 105620 11 105620 11 105620 not possible to balance Table 11 3 stage counter balance weight...

Page 47: ... 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 3 79 1 719 1 105620 5 59 2 535 2 105620 5 80 2 630 3 105620 6 11 2 771 4 105620 6 59 2 989 5 105620 6 66 3 020 6 105620 6 92 3 138 7 105620 7 18 3 256 8 105620 7 45 3 379 9 105620 7 57 3 433 10 105620 8 72 3 955 11 105620 8 96 4 064 12 105620 9 24 4 191 13 105620 9 44 4 281 14 105620 10 15 4 603 Table 12 Balance ...

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Page 49: ...icient space and crane facilities or lifting access for efficiently removing reinstalling or servicing Compressor valves Major compressor components Major components in the gas piping system Cooling water system components if used including drains Consider personnel hazards such as moving parts high temperature and pressure and electrical power when determining space requirements Vents and Drains ...

Page 50: ...s or liquids must be piped away from the compressor either to skid edge or outside the building 3 If the process gas is heavier than air then vent and drain design must take this into account 4 In certain areas it may be necessary to install screens or sintered plugs over vents and drains to prevent blockage especially if the compressor may be shut down for an extended period of time Secure the Sk...

Page 51: ...ld be designed for use of anchor bolt capscrew length not less than 10 times the capscrew diameter Complies with ANSI Z535 ISO 3864 OSHA 1910 145 f 9 1 When installing the compressor frame onto the fabricated pedestal first use blocks or tapered wedges under the main skid and a level on top of the compressor pedestal to position the fabricated skid axially and longitudinally such that the bubble i...

Page 52: ...ment Checks Even though flexible coupling design allows for limited misalignment poor alignment can affect 1 Coupling component life 2 Main and thrust bearing wear 3 Package vibration levels and compressor axial thrust 4 Crankshaft bending and shaft seal wear 5 Power consumption efficiency and available compression horsepower HSR compressors can be aligned by several methods including dial indicat...

Page 53: ...Figure 9 Dial indicator arrangement Thermal Growth The compressor s cast iron frame thermally grows between ambient cold to normal hot operating conditions The expected vertical change from the bottom of the frame foot to the compressor s crankshaft center line position is shown in Table 13 These thermal growth figures may need to be prorated if the anticipated difference between cold and hot oper...

Page 54: ...ressor and its driver seldom have the same shaft center line height and operating temperature the drive train is often misaligned for its ambient cold condition Check the drive train s alignment and adjust as required during compressor installation and after startup for its normal hot operating condition Typically the compressor with its attached piping limiting it movement is considered the fixed...

Page 55: ...oat in an axial direction This movement accommodates thermal expansion and limited operational forces Drive train alignment is often offset cold so that it can be more closely aligned in its normal hot operating condition The driver either engine or electric motor position directly affects the thrust clearance of both the compressor and driver A driver placed too close or too far from the compress...

Page 56: ...re required to transfer and resist normal inherent reciprocating compressor shaking forces and couples into its skid Failure to install and maintain the compressor s mounting fasteners can result in equipment vibration drive train misalignment and compressor main bearing bore misalignment soft foot Reciprocating compressors develop unbalanced forces and couples due to the tolerances in the recipro...

Page 57: ...torque requirements 6 Use of the tabled values is based upon bolting materials with proof loads greater than 100 000 Psi 689 480 kpa Higher strength bolting material is preferred 7 Compressor frame foot bolting typically uses ASTM A193 B 7 threaded studs or Grade 8 bolts along with hardened steel washers and ASTM A194 nuts 8 Use Grade 8 or 9 bolts for all compressor mounting points 9 Verify the ho...

Page 58: ...der 4 Install an inlet gas scrubber s whenever wet or dirty gas is being compressed on the suction lines to each 1st stage or side stream stages 5 Piping should be connected to the compressor strain free in such a way that undue thermal or mechanical stresses are placed on the compressor 6 Install liquid separators with ample capacity and drainage to remove the condensate in the piping leaving the...

Page 59: ...re lube pump Does this go here Design and install all compressor lubricating oil piping as follows 1 Thoroughly clean all oil piping internally of weld slag mill scale and other construction debris before installation 2 Clean the inside of all removed or replaced oil tubing deburr its inside diameter ID and blow clean any debris before re installation 3 If using an electric or pneumatic motor driv...

Page 60: ...erent seat and guard materials valve plate materials plate lift and spring forces are frequently tailored to fit the actual operating conditions Tailored valves provide the end user with valve materials for optimum compressor performance and service life A computerized program selects the optimum tailored valve part numbers The following data is required for entry into the valve tailoring program ...

Page 61: ...H301 302 HSR Compressors Rev 2 2 51 ...

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Page 63: ...e Pre startup checklist items have been completed This checklist is designed to assist the technician for proper start up Complies with ANSI Z535 ISO 3864 OSHA 1910 145 f 9 H O T S U R F A C E DO NOT TOUCH THE COMPRESSOR WHEN IN USE Complies with ANSI Z535 ISO 3864 OSHA 1910 145 f 6 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 1...

Page 64: ...MAWP The MAWP hydrostatic test pressure is stamped into the cylinder nameplate of every cylinder If the cylinder nameplate is missing or illegible use the manufacturing numbers die stamped on the cylinder to identify it For replacement cylinder nameplates see CN 09 006 Rated Discharge Pressure The Rated Discharge Pressure RDP per API 11P and API 618 is calculated in one of two ways depending on th...

Page 65: ... 1910 145 f 9 The discharge temperature DT setting shuts the compressor down due to rising cylinder temperatures to prevent major damage Discharge Temperature Calculations Example 1 Example 2 ST 80 F 100 F SP 300 Psig 300 Psig DP 600 Psig 600 Psig ATM 14 65 Psig 14 65 Psig N 1 26 1 26 DT 167 F 191 F DTal 179 F 203 F DTsd 192 F 216 F Table 15 Discharge temperature calculations Cylinder Temperature ...

Page 66: ...ure in Pisa SP Inlet gas pressure in Psig at cylinder inlet flange N Ratio of gas specific heats Gas K value may also be used Default N value is 1 26 Table 16 Cylinder discharge formula The unit s operating conditions must not exceed the cylinder s Rated Discharge Pressure RDP Complies with ANSI Z535 ISO 3864 OSHA 1910 145 f 9 Compressor Relocation or Reapplication Each compressor is configured fo...

Page 67: ...p Compressors are shipped or relocated with lubricants drained It is recommended that the compressor sump be filled with single viscosity SAE 40 oil Before proceeding with any startup checks prime the lubricating systems for both frame and cylinders 1 Check the oil level in the crankcase 2 Add oil as required to the correct level DO NOT OVERFILL SUMP The crankshaft may hit an excessively high oil ...

Page 68: ...em by loosening the tubing fitting at each divider block inlet and outlet balance valve if used inlet and termination check valve inlet 2 Use a manual pump or manually stroke the cylinder lubrication pump forcing oil through the system 3 Visually observe oil flow from the tube fittings 4 When non foaming oil flows from the tube fitting re tighten each tubing fitting in flow sequence Compressor Rea...

Page 69: ...e rods are free of rust and rough spots in the area that passes through the packing Good Needed Cleaning 14 Check the integral distance piece packing vent and drain lines for obstructions 15 For sour gas applications confirm the presence of inert gas supply volume and pressure Adjust the regulator for proper flow volume and pressure to the distance pieces and packing cases 16 Slowly bar over the c...

Page 70: ... f 9 During a no load run operating above 900 RPM is not recommended as excessive inertia loads may occur For special cases get prior approval from the Packager Complies with ANSI Z535 ISO 3864 OSHA 1910 145 f 9 In order to reduce the inertia forces of constant speed electric motor driven compressors to acceptable operating levels the inlet and discharge pressures must be controlled immediately up...

Page 71: ...unctionality test of all the safety switch end devices If issues are found identify the cause and correct the problem 8 At the conclusion of the no load rotational test run remove the frame s top cover Use an infared temperature device to check all the main and connecting rod bearings for excessive heat If found identify the cause and correct the problem and repeat the entire test 9 Replace the su...

Page 72: ...re continuing the operation 3 Check the piston rod packing for excessive gas leakage 4 Adjust the cylinder lubricator pump to the maximum break in rate approximately twice normal rate 5 Observe the compressor vibration 6 Check the oil filter differential pressure indicator if used 8 Ensure proper crankcase oil level and adjust if required 9 Confirm the cylinder lubricator oil supply 10 Verify and ...

Page 73: ...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 Complies with ANSI Z535 ISO 3864 OSHA 1910 145 f 5 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 E X P L O S I V E COMPRESSED HYDROCARBON GAS AND AIR IS EXPLOSIVE CONFIRM ALL AIR IS PURGED FROM THE PROCESS GAS SYSTEM Complies with ANSI Z535 ISO 3864 OSHA 1910 1...

Page 74: ... bearings and cylinders 11 Start the compressor and run at not less than 700 low idle RPM when applicable 12 Immediately check for unusual noises low oil pressure and level and correct 13 Continue operating the compressor at reduced speed until the oil temperature reaches 100 F 39 C 14 Confirm the suction valve is open 15 Close the by pass load recycle valve s slowly 16 If using a suction control ...

Page 75: ...minimized load condition for a few minutes to cool down the package b Close the suction valve c Close the side stream valve if equipped d Close the discharge valve e Stop the compressor 3 Open the gas piping vent and blow down the gas pressure If maintenance requires open all gas lines or compressor cylinders vent all pressure to atmosphere before removing any valve covers or loosening any gas con...

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Page 77: ...e And Running Gear Lubrication Frame and running gear lubrication is a gear type positive displacement pump provides pressurized oil from the crankcase to the frame and running gear Figure 12 Frame and running gear lubrication system System Operation The lubricating oil is drawn from the crankcase sump by the frame oil pump and discharged into the packager installed oil cooler The frame oil pressu...

Page 78: ... front main bearing housing drive coupling end just upstream from the 1 drive end main bearing s oil supply connection Refer to the H302 compressor s General Arrangement drawing for details 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 tec...

Page 79: ...ilter assembly with element 405 047 405 047 N A 2 105739 Table 17 GE Oil filter upgrade Pressure Regulating Valves PRV Proper lubrication is critical to compressor frame operation The oil type viscosity grade cleanliness flow pressure and temperature of the oil are important factors Key components in the lubrication system are the internal or external oil pressure regulating valves PRVs The extern...

Page 80: ...sor frame sump below its minimum oil level Setting the Value H O T O I L 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 pre...

Page 81: ...installation If the crankcase oil is contaminated remove it immediately and either discard or reclaim it for future use Using reclaimed oil is entirely at the compressor owner s discretion but is strongly discouraged Consult with a lubrication engineer from the oil supplier as to the advisability of reusing oil Never put dirty or contaminated oil into a compressor Complies with ANSI Z535 ISO 3864 ...

Page 82: ... a Remove the cap B b Remove the O ring E c Remove the lock nut F d Remove the adjusting screw C e Remove the retainer D f Remove the spring G g Remove the piston I h Remove the stop ring H Not Recommended Special tooling is required to install new stop ring Inspect the PRV Inspect the valve bore and piston for wear and scoring Replace broken or damaged parts as required Clean all of the parts tho...

Page 83: ...bricant 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 Oil Viscosity Single viscosity SAE 40 ISO 150 weight oil is required in the crankcase year round regardless of the ambient temperature when the compres...

Page 84: ...from traveling in reverse direction Overpressure indicator rupture disk to prevent damage to the system by high pressure A no flow switch DNFT or Kenco is the current standard to trip the compressor in situations when oil flow is inadequate Cycle pin indicator to provide visual confirmation of system cycles Arrangements vary depending on the compressor configuration and the operating conditions of...

Page 85: ...r pump put the bottom of the oil supply tank at least 3 feet 1 meter above the lubricator pump inlet Consider oil flow and temperature when determining the line size and the height of the oil day tank Cold ambient temperature affects oil viscosity and can cause reduced oil flow to the pump inlet Cold ambient temperature affects oil viscosity and can cause reduced oil flow to the pump inlet The non...

Page 86: ...t all injection points g When all lines have been filled and tightened operate the pump for a few additional strokes and check for leaks or malfunctions Setup and Adjust Lubricator Pump All lubricator pumps on HSR compressors have a 375 9 52 mm maximum stroke length The effective stroke length is adjustable and determines the actual flow rate from the lubricator pump The plunger diameter maybe 25 ...

Page 87: ...e at least 4 plunger threads engaged in the base at max stroke Complies with ANSI Z535 ISO 3864 OSHA 1910 145 f 9 New Compressor Start Up Follow these steps to start up the compressor 1 Pre lube the compressor frame before startup 2 Set the adjustment on the lubricator pump plunger to the maximum output position 3 Start the compressor and operate for about 30 minutes allowing the oil to warm up 4 ...

Page 88: ...determine the lubrication rate by performing a cylinder wall oil film wipe test Due to differences in operating conditions process gas quality and manufacturing tolerances it is unlikely two otherwise identical compressors will have the same cylinder lubrication rates 1 Shut down the compressor according to standard procedures 2 Perform Lock Out Tag Out procedures F L A M M A B L E FLAMMABLE GAS N...

Page 89: ...setting the lubricator flow rate check the cylinders for proper oil film at approximately two day intervals during the first week and every six months thereafter Packing may be checked for proper lubrication by periodically examining the piston rods The piston rod surfaces should be bright and coated with a thin layer of clear clean oil Black and dirty oil scoring marks or heat discoloration on th...

Page 90: ... FINGERS INTO THE CYLINDER THROUGH A VALVE PORT UNLESS THERE IS SUITABLE BLOCK BETWEEN THE PISTON AND CYLINDER HEAD THIS WILL PREVENT THE CRANKSHAFT TURNING AND SUBSEQUENT POSSIBLE INJURY Complies with ANSI Z535 ISO 3864 OSHA 1910 145 f 9 After setting the lubricator flow rate check the cylinders walls and piston rod packing for proper oil film at approximately two day intervals during the first w...

Page 91: ...ating oil to the atmosphere to relieve the pressure and shut down the compressor The pressure at which the disk ruptures is a function of the aluminum disc s thickness and corresponding disc cap hole diameter There are 8 different thicknesses which are color coded to indicate the thickness and the rupture pressures Rupture disc pressure ratings are selected based upon the gas operating conditions ...

Page 92: ... N m Over tightening can cut into the disc reducing the rupture assembly s pressure rating Complies with ANSI Z535 ISO 3864 OSHA 1910 145 f 9 Both of the 0 125 inches 3 2 mm and 0 250 inches 6 35 mm disc caps can use the same disc thickness However the rupture assembly s pressure rating will be significantly different due to the change in the disc s exposed surface area Example a yellow 0 010 inch...

Page 93: ...ST be mounted either vertically terminal end up or at a minimum angle of 20 º off horizontal with terminal end at the high point This prevents water from accumulating around switch contact Complies with ANSI Z535 ISO 3864 OSHA 1910 145 f 9 1 A 25 micron sintered bronze or similar in line type filter should be installed ahead of the No Flow switch These are available from either KENCO or most manuf...

Page 94: ...sary ensure that adjustments are made while engine compressor No Flow switch are at their normal operating conditions The adjustment setscrew is located on bottom of switch housing Turn setscrew IN to decrease shutdown time and OUT to increase shutdown time Shutdown time can be determined by removing disabling lubricator pumping unit On multiple pump installations pumping at the same rate the sett...

Page 95: ...cants P E R S O N A L I N J U R Y WEAR APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT Complies with ANSI Z535 ISO 3864 OSHA 1910 145 f 5 F L A M M A B L E NO OPEN FLAME Complies with ANSI Z535 ISO 3864 OSHA 1910 145 f 7 Use the following oil specification as a guide only Determine the lubrication requirements based on the specific compressor gas analysis with the oil supplier engineer Complies with ANS...

Page 96: ...ases air ammonia hydrogen methane Type 2 Hydrocarbon gases such as butane propane natural gas butadiene ethylene and nitrous oxide Some liquids or condensables tend to wash away the lubricant If compounded oils with rust fortification properties are required consult the oil supplier engineer Type 3 Compressors where water carry over is a problem or where wet gases hydrogen sulphide and or carbon d...

Page 97: ...itor Yes Yes Yes Yes Carbon Residue Conradson 0 25 0 65 0 65 0 65 Pressures 1 000 2 500 Psig 69 to 172 bar SSU 210 F 100 C 70 85 85 110 70 85 85 110 SSU 100 F 40 C 600 950 950 1400 600 950 950 1400 Approximate SAE Grade 40 50 40 50 Compounded No Yes No Yes Yes Oxidation Inhibitor Yes Yes Yes Yes Rust Inhibitor Yes Yes Yes Yes Carbon Residue Conradson 0 65 0 65 0 65 0 65 Pressures 2 500 Psig 172 ba...

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Page 99: ...lies with ANSI Z535 ISO 3864 OSHA 1910 145 f 9 When vibration occurs first determine the type of vibration and its cause In general there are four types of vibration associated with reciprocating compressors 1 Mechanical 2 Inertia Unbalance 3 Pressure Pulsations 4 Torsion Vibration When unsatisfactory vibration amplitudes are detected take corrective actions immediately Notify the packager or GE i...

Page 100: ...bly with piston rings and crosshead jam nut Select and add balance weight s equal to the difference between the reciprocating weight of the opposing throws to the piston rod assembly having the lowest weight For applications having a blank throw add balance weight s to the blank throw crosshead The maximum out of balance weight between the opposing throws is 4 ounces 0 25 lb 0 113 kg See Balance W...

Page 101: ...ressor over a speed range and observe the cylinder vibration A drop in the vibration level after the piping is removed indicates pressure pulsations are present Fix pressure pulsations by installing Orifice plates Pulsation bottles or manifolds Piping supports Torsional Vibration Torsional vibrations are very difficult to detect without the use of special instruments If the compressor is in a tors...

Page 102: ...cond The X axis frequency measures in cycles per minute RPM The Y axis displacement amplitude measures in Mils peak to peak 1 10 100 100 1 000 10 000 Amplitude Mils Peak to Peak Frequency CPM Guidelines reference measurement at the outboard cylinder end Satisfactory Marginal Unsatisfactory 1 0 IPS 0 8 IPS 0 5 IPS Amplitude Mils Peak to Peak Figure 19 Vibration amplitude versus frequency chart ...

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Page 105: ...ntenance activities 2 Close valves blocking fuel and starting gas Turn off the electrical supply and ignition sources 3 Apply mechanical lockout device to prevent crankshaft rotation 4 Isolate the compressor from any compressed gas or rotational source 5 Close the compressor s suction and discharge lines isolation valves 6 Vent process gas from the cylinders by opening the blow down valve and vent...

Page 106: ...ing tools for maintenance activities Since actual weights may vary with design changes or optional extras always use an appropriate safety factor Use a crane to lift the compressor Compressor component weights approximate Frames assembled including crankshaft crossheads and connecting rods Weight lbs Kg H302 2 000 907 Crankshaft without flywheel or coupling adapter Weight Ibs Kg Crankshaft 69 31 3...

Page 107: ...lube oil flow rates lube oil consumption process gas flow rates fuel gas or electrical power consumption etc provide historical record of the package performance Additionally this data provides trend lines the operator may use for troubleshooting and projected major overhaul planning Oil Analysis A regular oil analysis program is recommended through the oil supplier Compressor oil change intervals...

Page 108: ...mpressor operates continuously so the time hour intervals are loosely tied to daily monthly quarterly semi annual and annual time intervals If maintenance is performed on hourly based time frames refer to the associated time interval column Daily Maintenance Checklist Maintenance checks daily Time interval Frame oil supply pressures 45 to 55 Psig 310 to 379 kpa adjust pressure regulating valve as ...

Page 109: ...e shutdown points will not allow operation in excessive rod load conditions 24 hours Unusual noises or vibrations 24 hours Scrubber level and drain operation 24 hours Check gas vents for leakage piston rod packing blow down and pressure safety valves PSV 24 hours Check vent lines for ice blocks when ambient temps below 40 F 4 C 24 hours Form 9 Daily maintenance checklist Monthly Maintenance Checkl...

Page 110: ...reen strainers 2 000 hours Form 11 Quarterly maintenance checklist Semi Annual Maintenance Checklist Maintenance check list 6 months plus daily monthly 3 months checks Time interval Compressor crankcase oil change or as recommended by oil supplier s monthly oil analysis Note Remove crankcase top cover and inspect internally for foreign material debris whenever oil is changed 4 000 hours Frame oil ...

Page 111: ...hours Calibrate and re certify accuracy of gauges and transmitters for all significant pressure and temperature points 8 000 hours Form 13 Annual maintenance checklist Optional VVCP Assembly Capacity Control Always review the use of a VVCP to change load conditions to verify acceptable compressor performance before adjustment Using a VVCP for capacity control has an impact on the compressor perfor...

Page 112: ... Assembly Do not adjust VVCP while the compressor is in operation Complies with ANSI Z535 ISO 3864 OSHA 1910 145 f 9 Failure to properly adjust and maintain VVCP can damage the compressor Complies with ANSI Z535 ISO 3864 OSHA 1910 145 f 9 See CN 06 004 This VVCP adjustments apply to all compressor cylinders using HE VVCP s Figure 20 Typical variable volume clearance pocket installed Authorized HSR...

Page 113: ...CAN HOUSE TRAPPED GAS Complies with ANSI Z535 ISO 3864 OSHA 1910 145 f 7 VVCP Adjustment Range Use the VVCP to adjust a cylinder s HE clearance The amount of change in clearance volume varies depending upon the position of the VVCP piston see Figure 20 The expected change in compressor flow and horsepower is a function of compression ratio and the gas properties VVCP adjustment can range from the ...

Page 114: ...104 Chapter 8 Maintenance Figure 21 Effective rod extension amount pocket is open ...

Page 115: ...6 3 045 125 79 9 00 228 60 53 49 28 03 711 962 3 045 162 87 10 00 254 00 67 24 28 54 724 916 4 475 300 89 Stepped bore diameter Inches mm Volume added per Inch of travel in 3 increase in clearance per inch of travel Inches mm VVCP travel distance Inches Max added volume in 3 4 00 101 60 7 08 18 78 477 012 3 405 24 11 5 00 127 00 11 06 18 78 477 012 3 405 37 66 5 50 139 70 11 06 15 52 394 208 4 367...

Page 116: ...5 ISO 3864 OSHA 1910 145 f 7 The adjustment of manual variable volume clearance pockets VVCP is applicable to all HSR compressor cylinders using head end HE VVCP s General Information The VVCP s piston ring is purposefully designed not to be completely gas tight This allows for minor gas and liquid migration across piston ring O ring This allows for easier VVCP piston adjustment when the cylinder ...

Page 117: ...m output showing desired VVCP setting in inches or 3 Tape measure 4 Large adjustable wrench to loosen VVCP jam nut and to turn VVCP stem 5 Grease gun to lubricate VVCP piston stem threads 6 Grease high quality heavy duty high temperature lithium 7 Molykote P 37 for VVCP jam nut and washer lubrication Figure 22 VVCP flange lubrication fitting and threads VVCP flange lubrication fitting Threads ...

Page 118: ...g of the VVCP stem piston may indicate that the jam nut is loose Complies with ANSI Z535 ISO 3864 OSHA 1910 145 f 9 7 Adjust the VVCP to the desired clearance position determined in step 2 Turn the piston stem clockwise CW to move the piston in and reduce clearance Turn the piston stem counter clockwise CCW to move the piston out and increase clearance Complies with ANSI Z535 ISO 3864 OSHA 1910 14...

Page 119: ... Rod Bolt Torque ft lbs Connecting Rod Eye ID 2 061 2 0615 Top A1 B1 Bottom A2 B2 Condition OEM torque must be applied to cap bolts to perform the crank pin check Connecting Rod Crank Pin OD BOD 3 423 3 424 Top C1 D1 E1 Bottom C2 D2 E2 Condition Crosshead Pin OD 1 4998 1 5000 F1 G1 F2 G2 F3 G3 F4 G4 Condition Roller Bearings OD BOD 2 0625 BOD 1 H1 I1 H2 I2 BOD 2 J1 K1 J2 K2 Condition 406 1569 100 ...

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Page 121: ...ses different than design unsuitable lubricant selection generally cylinders and packing lubrication valves not tailored for operating conditions or improper operations and maintenance It is important to use a compressor log sheet to record inter stage pressures and temperatures by stage on multi stage compressors When inter stage operating conditions vary from normal it indicates trouble with one...

Page 122: ...ercooler pressure below normal Valve breakage and wear abnormal Crankcase oil pressure low Elevated vibration amplitudes or frequencies 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 Sy...

Page 123: ...al Intercooler pressure below normal Valve breakage and wear abnormal Crankcase oil pressure low Elevated vibration amplitudes or frequencies 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 hi...

Page 124: ...wear excessive Delivery less than rated capacity Intercooler pressure above normal Intercooler pressure below normal Valve breakage and wear abnormal Crankcase oil pressure low Elevated vibration amplitudes or frequencies Water jacket or cooler dirty Dirt rust entering cylinder Cylinder head cooler dirty Packing rings worn stuck or broken Piston rod scored pitted worn Table 25 Troubleshooting char...

Page 125: ...g from cylinder end Damaged crosshead Loose crosshead balance weight Excess crosshead to guide clearance Excessively high crankcase oil level Improper lube oil selection Cylinder or frame vibration Discharge bottle wedges loose or improperly adjusted Compressor frame to cylinder or crosshead guide mounting bolts loose Bottle piping acoustical pulsations Drive train misalignment Excessive crosshead...

Page 126: ...Magnetic base Valve breakage or wear abnormal Liquid carryover Improper valve tailoring lift material springing assembly Solid abrasive debris entering cylinder with gas stream Excessive oil supply Off design operating condition Gas composition change Gas system resonant pulsation Incorrect center bolt torque Carbon coated valves Excessive cylinder lubricating oil Improper cylinder lube oil select...

Page 127: ...tion from liquid carryover Wiper packing leaks Worn packing rings Packing rings incorrectly assembled installed Packing not seated or properly run in Worn or scored piston rod Contaminants liquid or solid affecting packing rings Improper packing ring clearance side or end High discharge gas temperature Excessive compression ratio across cylinder back pressure from leaking suction valves or piston ...

Page 128: ... piston rings Incorrect compressor valve use valve not properly tailored for application Metered gas flow inaccurate or not counting upstream deductions for engine start fuel gas dehydration unit and other auxiliary equipment Crankshaft drive end seal oil leak Clogged top cover breather Back pressure from excessive cylinder packing leak Excessive seal wear due to incorrectly adjusted front cover E...

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Page 131: ...l 427 6176 Crankshaft Drive End Oil Seal Driver 407 7939 Crankshaft Gear Installation Driver 407 7922 Crankshaft Inner Bearing Driver 407 7914 Crankshaft Rear Main Bearing Driver 407 7906 Crankshaft Main Bearing Remover and Installer 407 7899 Includes 407 0915 Plate 407 0867 Driver 407 0915 Block 407 0689 Plate 3 4 All thread puller rod 3 4 Nuts 2 00 Piston Ring Compressor 405 8468 2 50 Piston Rin...

Page 132: ...cking ring 27 CNG counterweight 3 or 4 stage 33 commissioning report 10 components H Series 10 component weights 96 compressor configuration 56 data tag information 57 log book 97 operation safety advisories 62 reapplication 56 relocation 56 starting 63 start up 77 stopping 65 valves 50 Compressor News Bulletins website 1 connecting rod inspection 109 crankcase filling the sump 57 oil changes 72 o...

Page 133: ...ooting 111 lubricants list of cylinder 87 lubricating oil piping and tubing 49 lubrication frame and running gear 67 oil pump 74 system 24 lubricator system priming 58 M maintenance annual 101 daily 98 monthly 99 preventative 97 PRV 71 quarterly 100 semi annual 100 maximum allowable working pressure 54 out of balance weight 30 mechanical vibration 90 misalignment maximum allowable 44 monthly maint...

Page 134: ...2 types of 2 warning 3 semi annual maintenance 100 settings cylinder discharge temperature shutdown 55 pressure 68 specifications bearings and running gear 22 frame 21 start the compressor 63 stop the compressor 65 support technical 6 system pressure decrease 70 increase 70 T technical support 6 email 6 temperature shutdown setting formula 55 thermal growth 43 torsion vibration 91 training 6 train...

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Page 136: ...3 683 2400 F 1 713 683 2421 For complete contact information please refer to our website geoilandgas com hsr The information contained herein is general in nature and is not intended for specific construction installation or application purposes GE reserves the right to make changes in specifications or add improvements at any time without notice or obligation GE the GE Monogram and imagination at...

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