GE H301 Series User manual

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.
©2012 General Electric Company
All Rights Reserved

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

H301/302 HSR Compressors | Rev. 2.2 | 1
Chapter 1: Getting Started
Customer Service
Send any request for parts, technical support and/or service should be sent to
High Speed Reciprocating (HSR) compressors at [email protected]. All requests
for parts or service should include:
1. Compressor frame/model size
2. Frame serial number
3. Cylinder serial numbers
4. Cylinder bore diameter
5. Part description and part number (P/N)
6. The date the part is needed. If a breakdown has occurred and a part is
required immediately to return the compressor to service, note it in the parts
request
7. Customer’s Purchase Order (PO) number
8. Description or problem if service is required
9. Your contact information
Documentation
High Speed Reciprocating (HSR) compressors provide several types of
documentation: Compressor News Bulletins, operating manuals, parts books, etc.
The website is http://supportcentral.ge.com/products/sup_products.asp?prod_
id=51671
Request Access to the Website
Access to the website is through authorization only. To request access,
1. Go to the following link geoilandgas.com/hsr
2. Scroll down to the “RELATED” eld at the bottom of the screen. Expand the
section called “Websites.”
3. First time users select “HSR support site registration”, ll 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 conrm the request. A GE employee will
then complete the authorization process.
Compressor News Bulletins
Compressor News Bulletins (CN) provide the latest technical information for GE
and Legacy (Gemini, Energy Industries, and Chicago Pneumatic) reciprocating
compressors. CN is available on the HSR compressor website. http://
supportcentral.ge.com/products/sup_products.asp?prod_id=51671
Parts Books and Operating Manuals
Parts books and operating manuals are available on the HSR compressor website
http://supportcentral.ge.com/products/sup_products.asp?prod_id=51671
Give Feedback
Please send feedback for any documentation to HSR[email protected]
Give Feedback
need more information?
Let us know by sending an
e-mail to the address below.
HSR[email protected]
Customer Service
Available 24 hrs
1-832-978-9780
[email protected]

2 | Chapter 1: Getting Started
Parts
Assistance for parts is available 24/7 365 days a year.
E-fax: [phone]
E-mail: [email protected]
Phone: [phone]
Safety Advisories
The following safety precautions are published for your information. GE Oil & Gas
does not, by the publication of these precautions, imply or in any way represent
that they are the sum of all dangers present near HSR Compressors. These
compressors are mostly used for compressing ammable 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
requirements. All requirements of the Federal Occupational Safety and Health
Act must be met when GE Oil & Gas products are operated in areas that are
under the jurisdiction of the United States of America or Canada. GE Oil & Gas
products operated in other countries must be installed, operated and serviced in
compliance with any and all applicable safety requirements of that country. For
details on safety rules and regulations in the United States, contact your local
oce 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 oce of the International
Standards Organization (ISO).
The words “notice,” “caution,” “warning” and “danger” are used throughout this
manual to highlight important information.
Be certain that the meanings of these alerts are known to all
who work on or near the equipment.
Complies with ANSI Z535, ISO 3864, OSHA 1910.145 (f) (9)
This manual is best when viewed online. If printing out the
manual, ensure that it is a color copy so that people are
notied by the color in the safety advisories.
Complies with ANSI Z535, ISO 3864, OSHA 1910.145 (f) (9)
Types of Safety Advisories
Notice
This symbol identies information, which is NECESSARY TO THE PROPER
OPERATION, MAINTENANCE OR REPAIR OF THE EQUIPMENT.
Safety advisories
NECESSARY TO THE PROPER
OPERATION, MAINTENANCE OR
REPAIR OF THE EQUIPMENT
Parts
24/7 365 days a year
E-fax: [phone]
Email: oilandgas.hsrparts@
ge.com
T [phone]

H301/302 HSR Compressors | Rev. 2.2 | 3
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 identies information about hazards or unsafe practices. Disregarding
this information could result in MINOR OR MODERATE PERSONAL INJURY.
PINCHPOINT
DO NOT PUT HAND OR FINGERS NEAR THE INSIDE
OF THE CYLINDER.
Complies with ANSI Z535, ISO 3864, OSHA 1910.145 (f) (6)
Warning
This symbol identies information about hazards or unsafe practices. Disregarding
this information could result in SEVERE PERSONAL INJURY OR DEATH.
EXPLOSIVE
CONTENTS UNDER PRESSURE, FOLLOW APPROPRIATE
PROCESS TO DEPRESSURIZE.
Complies with ANSI Z535, ISO 3864, OSHA 1910.145 (f) (7)
Danger
This symbol identies information about immediate hazards. Disregarding this
information will result in SEVERE PERSONAL INJURY OR DEATH.
FLAMMABLE
FLAMMABLE GAS, NO OPEN FLAME.
Complies with ANSI Z535, ISO 3864, OSHA 1910.145 (f) (5)
DANGER
FAILURE TO OBSERVE SAFETY REGULATIONS AND/OR
REMOVAL OR MODIFICATION OF SAFEGUARDS WILL NULLIFY
THE WARRANTY AND MAKE THE USER FULLY LIABLE.
Complies with ANSI Z535, ISO 3864, OSHA 1910.145 (f) (5)
Safety advisories
Could result in MINOR OR
MODERATE PERSONAL INJURY
Could result in SEVERE
PERSONAL INJURY OR DEATH
Will result in SEVERE PERSONAL
INJURY OR DEATH

4 | Chapter 1: Getting Started
DANGER
SUBSTITUTION WITH NON-ORIGINAL SPARE PARTS OR PARTS
OTHER THAN THOSE RECOMMENDED BY THE MANUFACTURER
IS THE FULL RESPONSIBILITY OF THE USER AND CAUSES
IMMEDIATE DECAY OF THE GUARANTEE. THE MANUFACTURER
DISCLAIMS ALL LIABILITY FOR DAMAGE TO PERSONS AND/
OR THINGS ARISING FROM THE USE OF NON-ORIGINAL
SPARE PARTS. IN ADDITION, NON-COMPLYING WITH THE
PRECAUTIONS OR SAFETY REGULATIONS AND/OR REMOVING
OR CHANGING ANY SAFETY GUARDS, AS WELL AS THE
EXPIRATION 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 eld 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.
Complies with ANSI Z535, ISO 3864, OSHA 1910.145 (f) (9)

H301/302 HSR Compressors | Rev. 2.2 | 5
Safety Symbols
Caution, warning and danger use a variety of safety symbols to depict the specic
risk. These symbols are used throughout this manual.
DANGEROUS
TEMPERATURES
ELECTRICAL
HAZARD
AIR GAS INLET
PRESSURE
MOVING PARTS
CUT AND CRUSH
HIGH PRESSURE FLAMMABLE EXPLOSIVE 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 background is safety white with a black
border and black text.
Complies with ANSI Z535, ISO 3864, OSHA 1910.145 (f) (9)

6 | Chapter 1: Getting Started
Technical Support
Technical support is available 24 hours/7 days a week; when you
need it.
E-mail: [email protected]
Phone: [phone]
Training
Training is available three times a year. The schedule is posted on the
HSR website http://supportcentral.ge.com/products/sup_products.
asp?prod_id=51671.
Warranty
The warranty is eective when:
1. An authorized representative of GE Oil & Gas – High Speed
Reciprocating (HSR) gas compressors or the authorized packager
is present at the initial 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 specications
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 Administrator - HSR Compressors
4425 Westway Park Blvd.
Mail Stop #3
Houston, TX 77041 USA
[email protected]
Technical Support
Available 24 hrs
1-832-978-9780
[email protected]
Warranty
GE Oil & Gas
ATTN: Warranty Administrator
- HSR Compressors
4425 Westway Park Blvd.
Mailstop #3
Houston, TX 77041 USA
[email protected]

H301/302 HSR Compressors | Rev. 2.2 | 7

H301/302 HSR Compressors | Rev. 2.2 | 9
3
2
1
3
4
1
5
9
9
8
7
6
8
6
4
3
6
5
Chapter 2: Introduction
GE Oil & Gas designs, manufacturers and supplies HSR Compressors to customers,
qualied 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:
1. Frame with integral crosshead guides
2. Main (precision) bearings and bearing housing
3. Distance pieces
4. Cover plates
5. Lubricating oil pump and ltration 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 conguration
12. * Auxiliary Fan Drive
* - not shown
H 30 Series Cylinder Assembly for H Series frames
Normally includes:
1. Cylinder
2. *Fixed clearance cylinder head (if no VVCP)
3. Piston with rings
4. Piston Rod
5. Piston Rod packing
6. Valves and valve covers
7. *Tailored valves
Optional clearance devices include
8. Variable Volume Clearance Packet (VVCP) assembly
9. *Valve spacers
* - not shown

10 | Chapter 2: Introduction
Components of the H 301/302 Series
The components of the H series compressor are displayed in “Figure 2 H 301/302”.
Commissioning Report
For HSR compressor commissioning, whether new or after repairs or re-
application, complete the commissioning report to ensure proper operation. The
commissioning report includes 5 forms:
1. “Startup report”
2. “Pre-startup checklist”
3. “Post-Startup checklist”
4. “Initial no-load rotational test 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
1516
5
613
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 valve chair
15. Variable Volume Clearance
Pocket (VVCP) assembly
(optional)
16. Discharge valve cover
17. Piston rod
18. Oil pan
19. Auxiliary cover
20. PRV valve
21. Main lube pump
22. Auxiliary fan drive (optional)
23. Crankshaft
24. Distance Piece
7
24
14
3