GE H301 Series Bedienungsanleitung

High speed reciprocating compressors

H301 and 302 series operating manual

GE Oil & Gas

Document Revision Chart

The following chart lists the revisions made to this document tracked by version.

Revision Revision description 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.

H301/302 HSR Compressors | Rev. 2.2 | I

Contents

Acronyms ..............................................................

Lisf of Figures ..........................................................

List of Forms ..........................................................V

List of Tables..........................................................VI

Chapter 1: Getting Started ...............................1

Customer Service ......................................................1

Documentation ........................................................1

Request Access to the Website .....................................1

Compressor News Bulletins ........................................1

Operating Manuals ................................................1

Give Feedback.....................................................1

Parts ..................................................................2

Safety Advisories.......................................................2

Types of Safety Advisories..........................................2

Safety Symbols ....................................................5

Technical Support......................................................6

Training ...............................................................6

Warranty ..............................................................6

Chapter 2: Introduction ..................................9

H 301/302 Series Frame/Running Gear Assembly .......................9

H 30 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/Specications................. 21

Frame Specications ................................................ 21

Bearings and Running Gear .......................................... 22

Lubrication System .................................................. 24

Cylinder Nameplates................................................. 24

Piston Head End and Crank End Clearance............................ 25

Cylinder Sizes, Bores, Piston Diameters, Clearance and Weight ......... 25

Piston Ring and Packing Ring Clearances ............................. 27

Fastener Torque Values .............................................. 27

Fastener Torquing ................................................... 28

Hold Down Bolting ................................................... 30

Balance Weights .................................................... 30

II | H301/302 HSR Compressors | Rev. 2.1

Chapter 4: Installation ................................. 39

Access and Safety ................................................... 39

Vents and Drains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Secure the Skid and Foundation (Sub-Base) ........................... 40

Skid Leveling and Alignment ......................................... 41

Compressor Frame Leveling...................................... 41

Alignment ....................................................... 42

Maximum Allowable Drive Train Misalignment ................... 44

Driver to Compressor Free Coupling Alignment ................... 44

Compressor Crankshaft End Thrust Clearance .................... 45

Skid Hold-Down Bolting .............................................. 46

Recommended Bolt Size/Torque ................................. 46

Bolting Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Bolt/Fastener Tightening ........................................ 47

Piping ............................................................... 48

Process Gas Piping............................................... 48

Lubricating Oil Piping and Tubing ................................. 49

Compressor Valves .................................................. 50

Chapter 5: Operation .................................. 53

Maximum Allowable 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 Lubricator System Priming .............................. 58

Compressor Reapplication or Relocation Checklist ................ 58

Initial No-Load Rotational Test Run ............................... 60

Initial Load Run .................................................. 62

Operate the Compressor ............................................. 62

Start the Compressor ............................................ 64

Stop the Compressor ............................................ 65

Chapter 6: Lubrication ................................. 67

Frame And Running Gear Lubrication ................................. 67

Pressure Regulating Valves (PRV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Disassemble the PRV ............................................ 72

Inspect the PRV ................................................. 72

Re-assemble the PRV ............................................ 72

Crankcase Lubricant Selection ................................... 73

H301/302 HSR Compressors | Rev. 2.2 | III

Oil Viscosity ..................................................... 73

Non-Lube Cylinder Applications ...................................... 74

Cylinder Lubrication System .......................................... 74

System Installation .............................................. 75

Entrapped Air Removal .......................................... 75

Setup and Adjust Lubricator Pump ................................... 76

New Compressor Start-Up ....................................... 77

Cylinder Wall Oil Film Wipe Test .................................. 78

Guideline for Oil Film Wipe Test Results ........................... 78

Cylinder Lubrication Flow Rate and Cycle Indicator ............... 79

Rupture Disks.................................................... 80

Digital Cylinder Lube No-Flow Devices ............................ 82

Install Kenco NFS-3 No-Flow Switch .............................. 83

Chapter 7: Vibration ................................... 89

Types of Vibration.................................................... 89

Mechanical ......................................................... 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 Maintenance Checklist ................................100

Semi-Annual Maintenance Checklist .............................100

Annual Maintenance Checklist ..................................101

Optional VVCP Assembly Capacity Control .......................101

Adjust the Variable Volume Clearance Pocket (VVCP) Assembly....102

Connecting Rod Inspection Sheet – H Frame .........................109

Chapter 9: Troubleshooting ..........................111

Appendix A: H Series Tools ............................ A-1

Index ................................................ B-2

IV | H301/302 HSR Compressors | Rev. 2.1

Acronyms

PRV - Pressure regulating valve

VVCP - Variable voulme clearance pocket

H301/302 HSR Compressors | Rev. 2.2 | V

FIGURE 1 Safety symbols ....................................................5

FIGURE 2 H 301/302 H Series compressor components ..................... 10

FIGURE 3 Crankshaft rotation .............................................. 19

FIGURE 4 Cylinder nameplate .............................................. 24

FIGURE 5 Torque wrench with adapter at any angle except 90° right angle... 29

FIGURE 6 Torque wrench with adapter at right angle (90°) ................... 29

FIGURE 7 Maximum out of balance weight of opposing throws .............. 30

FIGURE 8 Sketch description of misalignment .............................. 43

FIGURE 9 Dial indicator arrangement....................................... 43

FIGURE 10 Inlet strainer ................................................... 49

FIGURE 11 Piping schematic ..................................... 63

FIGURE 12 Frame and running gear lubrication system ..................... 67

FIGURE 13 GE oil lter standard 1-105292 .................................. 69

FIGURE 14 PRV assembled and exploded parts illustration .................. 72

FIGURE 15 Typical lubricator pump with plunger shown at max stroke/ow.. 77

FIGURE 16 Rupture assembly ............................................. 81

FIGURE 17 Kenco NFS-3 No-Flow Switch ................................... 83

FIGURE 18 DNFT-LED Switch Assembly, with magnetic housing assembly.... 85

FIGURE 19 Vibration amplitude versus frequency chart..................... 92

FIGURE 20 Typical variable volume clearance pocket installed. . . . . . . . . . . . . . 102

FIGURE 21 Eective rod extension: amount pocket is open .................104

FIGURE 22 VVCP ange lubrication tting and threads .....................107

List of Figures

VI | H301/302 HSR Compressors | Rev. 2.1

FORM 1 Startup report ..................................................... 13

FORM 2 Pre-startup checklist............................................... 16

FORM 3 Post-Startup checklist.............................................. 17

FORM 4 Gas compressor record ............................................ 18

FORM 5 Compressor frame and cylinder data tag information ............... 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

List of Forms

H301/302 HSR Compressors | Rev. 2.2 | VII

TABLE 1 Frame specications .............................................. 21

TABLE 2 Dimensions and clearances........................................ 23

TABLE 3 Lubrication system ................................................ 24

TABLE 4 Cylinder sizes, bore, piston diameters, and clearances .............. 25

TABLE 5 Piston ring and packing ring clearances ............................ 27

TABLE 6 Pressure packing ring clearances .................................. 27

TABLE 7 Frame and crosshead guide support hold down bolting ............. 30

TABLE 8 2 stage counter balance weight part numbers...................... 31

TABLE 9 3-Stage counter balance weight part numbers ..................... 32

TABLE 10 3 or 4 stage CNG counterweights................................. 33

TABLE 11 Balance crosshead jam nut weight and part numbers ............. 34

TABLE 12 2 stage double acting piston with counterweights 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 lter upgrade.............................................. 69

TABLE 20 PRV size, part number and spring rating and information .......... 70

TABLE 21 Oil operating temperature vs. SAE viscosity ....................... 73

TABLE 22 Lowest ambient temperature vs. SAE viscosity .................... 74

TABLE 23 Part numbers for atmospheric rupture assemblies ................ 82

TABLE 24 Cylinder lubricants ............................................... 87

TABLE 25 Approximate frame and crosshead guide component weights ..... 96

TABLE 26 VVCP added clearance volume, travel and percent ...............105

TABLE 27 List of compressor conditions ...................................106

TABLE 28 Troubleshooting chart ..........................................114

List of Tables

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