obZ85i ‘e @ GE Power Systems Oil & Gas compressor ews Subject: Ring, Compressor/Rider (C/R) Group: Cylinder Assy. Number: 01-001 Sub Gp: Piston & Ring Gp Date: Feb. 1, 2003 Series: 89 ‘The piston rings in the 4 ¥% - 5 Y (2500 PSIG) and the 5 ¥% - 6 ¥% (2200 PSI) cylinders have been changed to the compression/rider (C/R) type piston rings (G00 - 100067) from the compression type piston rings (x00 - 1000000). Cylinders shipped after January 1, 2001, and serial number 8964296 and up, will have the compression /rider piston rings. The rings (x00-100000 and 200c-100067) are not interchangeable. Taras [waren | Teli Toa es sueses | une | t-nerer exssuosr | esssnone | zee-noag | ene. isi00851 e @ GE Power Systems Oil & Gas compressor {jews Subject: Gasket, Seat,Vaive Group: Cylinder Assy. Number: 01-003 Sub Group: Cover & Holder GP Valve seat gaskets are now available In two thicknesses. The .062” thick gasket can be used where more spaced Is desired between the valve and head. 7 The 062" thick gasketls the standard gasket I cylinders shipped starting the, second quarter of 2004. The .031” thick gasket will still be avallable a item. Gasket Part Number 2031: Thick _| .062" Thick Valve Size Cylinder Size 50-14367 | 50-100078_| H52RX Inlet 25-3.0 '53-14367 | 53-100078 | H52RX Discharge e ‘47-14367 | 47-100078_| HGORX Inlet 3.25 -3.75, 11-14367__[11-100078 | H6ORX Di: 4.75 -5.5 1-01-20048 | 13-100078 | 64CET & H70RX Inlet 4045, 575-65, 30-375, 1-20882 14-100078 | 64CET & H70RX Discharge arene 1-20122 | 16-100078 | 77CT & H79RX Inlet 6.75-7.5 1-01-30121 | 18-100078 | 77CT & H79RX Discharge 5.5-6.25 '56-14367 | 56-100078 _ | 77Ct inlet (SPC1) & Hi000cT Disc 63-14367__ | 63-100078_| 77CT Discharge (SPCL) 7.75-85 59-14367__[59-100078 | Hi00CGT inlet 5.5 ~ 6.25 (3600 psi) 15-14367 | 15-100078 | 1270GT & H127CGT Inlet 9.0-10.5 35-14367 | 35-100078 | 1270GT & H127CGT Discharge | _7.0- 7.5, 10-11 61-14367__ | 61-100078 | 137CHT Inlet 10-11 (95p) - 62-14367 | 62-100078 _| 137CHT Discharge 41-14367 | 41-100078 _[ 148CHT & Hi48CHT Inlet 11.0-13.0 44-14367 | 44-100078 _[148CHT & 148CHT Discharge | 8.5— 9.5, 12- 13.5 The sealing surface on the cylinder for the cover gasket (soft iron or O-ring) will be in a different position when replacing a .031” gasket with a .062” gasket. The new sealing surface must be clean and free of marks, rust and dirt. The new sealing surface is i more critical when an O-ring is used. ‘Gas Compressors002851 GE Power Systems Oil & Gas compressor [ews Subject: Indicator, cycle, magnetic Group: Divider Valve Assy Number: 01-005 Sub Group: Cylinder Lube GP The cylinder lubrication system has been changed to eliminate one point of possible oil leaks. A magnetic cycle indicator has replaced the cycle pin indicator on the divider valve assembly. No more cycle pin packing and o- rings to leak and replace. The magnetic cycle indicator is a fully enclosed stainless steel housing with a highly visible bright color cycle indicator. The indicator will be phased in on the M, H and B frames in the third quarter of 2001. The indicator was phased in on the A, D, E and F frames in the first quarter of 2000. : The indicator is available for field replacement and repair as listed: Part number Frame Divider Valve Manuf. 4-100077 ADE, F Lincoin 2.100077, M,H,B Dropsa Gas CompressorsGE Power Systems compressor (jaws Satie Fame Nanenancr RSL KGS ina Fame GP Recommended Spare Parts Lists (RSPL) GE Gemini has developed an array of compressor frame maintenance RSPL kits designed to simplify ordering and shipping of all items needed to perform specific maintenance or repair procedures. The objectives of Gemini RSPL kits are: * Minimizo Customer's time required to order parts Assurance that all parts are included for a given repair procedure Include small hardware, gaskets and seals with major parts in RSPL kits Expedite parts shipment by having RSPL kits pre-packaged ‘A combination of various RSPL kits may be ordered for frame overhaul cece RSPL kits are designed for the following frame maintenance and repair procedures: PM Preventive Maintenance Bearing Replacement Crosshead Replacernent Gasket / Seal Replacement Oil Cooler Replacement Oil Pump Replacement ' ‘Throw Replacement (Internal Moving Parts) Front Cover Shaft & Gears for H302, M301 & M302 frames End User time and cost savings are derived from competitively priced RSPL kits. RSPL kit prices are less than the total price of individual parts within the kit. The application and content of each frame RSPL kit is described on the reverse side of this Compressor News Bulletin. Please Contact GE Geminl for additional Information at (361)693-3206 — Paul Orta.002851 Kit# KitName — Model Kit Description Ki PM DEF-All —Oilfiter element and © ring seal Ka Crosshead —_D-All Shoes, shims crosshead pin & caps. Body NOT included Ki7 Throw Dall Xhead Ass'y, conn rod Ass'y, shims, Xhead pin & caps 25 Bearing —-D-2throw Main, conn rod & thrust bearings, Xhead pin bushings 26 Gaskel/Seal 0-2 throw Gaskets, O' rings and oil fter element K27 Oil Cooler D-2 throw Gaskets, ©’ rings, fitter element and standard cil cooler 28. Oil Pump _—_D-2 throw Gaskets, ©’ rings, filter element and frame oil pump K8 — Gasket/Seal_D-4 throw Gaskets, 0’ rings and oil fiter element K11 OilCooler D4 throw Gaskets, ©’ rings, filter element and standard oil cooler 13 Oil Pump - D-4throw Gaskets, ©’ rings, fitter element and frame oil pump 19° Bearing —-D-4 throw Main, conn rod & thrust bearings, Xhead pin bushings Kis Throw EA Xhead Ass'y, conn rod Ass'y, shims, Xhead pin & caps K3_ Crosshead E8F-All_ Shoes, shims, Xhead pin & caps. Body NOT included K5 Bearing E-2 throw Main, conn rod & thrust bearings, Xhead pin bushings 7 Gaskel/Seal_ E&F-2 throw Gaskets, 0 rings and oll fer element K10 Oil Cooler E8F=2 throw Gaskets, O' rings, filer element and standard oll cooler Kid. OilPump — E8F-2 throw Gaskets, O' rings. filter element and frame oil pump K2 Bearing E-4throw Main, conn rod & thrust bearings, Xhead pin bushings K6 — Gaskel/Seal E-4 throw Gaskets, ©’ rings and oil fit element K9_— Oil Cooler EBF-4 throw Gaskets, O' rings, filer element and standard oll cooler 12 OilPump —EBF-4 throw Gaskets, O' rings, fiter element and frame oil pump. K23 Oil Cooler E&F-6 throw Gaskets, 0” rings, filer element and standard oil cooler K24 Oil Pump _—_E&F-6 throw Gaskets, 0” rings, filer element and frame oil pump 22 GaskelSeal E&F-6 throw Gaskets, O' rings and oil fter element K42 Bearing 6 throw Main, conn rod &thrust bearings & Xhead pin bushings K16 Throw F-All Xhead ass'y, conn rod assy, shims, Xhead & pin caps Ké3. Crosshead F-All Shoes, shims, Xhead pin & caps. Body NOT included K18 Bearing 2 throw Main, conn rod & thrust bearings & Xhead pin bushings 20 Bearing —F-4 throw Main, conn rod & thrust bearings, & Xhead pin bushings K21 Bearing ——F-6 throw Main, conn rod & thrust bearings, & Xhead pin bushingsKitt 29 30 36 39 «40 K35 32 33 KitName PM Bearing Gasket/Seal Oil Cooler Oil Pump Crosshead (Light) Crosshead (Heavy) Throw (Light) Throw: (Heavy) Bearing Gasket/Seal Oil Cooler Oil Pump PM Bearing GasketSeal il Pump Shaft & Gear Crosshead Throw Pkgicase Pkg Only PM Bearing: Gasket/Seal Oil Pump Gasket/Seal PM Bearing Crosshead Oil Pump Shaft & Gear Pigicase Pkg Only Throw Gasket/Seal Model ACA A2 throw A-2 throw A-2 throw A2 throw A-284 throw A284 throw A284 throw A-28 4 throw Ad throw A-4 throw A4 throw A-4 throw 302 302 302 302 302 302 & 304 302 & 304 302 & 304 302 & 304. 304 304 304 304 301 M301 & 302 M301 & 302 M301 & 302 M301 & 302 M301 & 302 M301 & 302 M301 & 302 M301 & 302 M302 Kit Description Oil fiter element and O' ring seal Main, conn rod & thrust bearings & Xhead pin bushings Gaskets, 0’ rings and cil fter element Gaskets, O' rings, fiter element and standard oil cooler Gaskets, 0’ rings, fiter element and frame oil pump Xhead Ass'y, Xhead pin, caps & gaskets Xhead Ass’y, Xhead pin, caps & gaskets Xhead Ass'y, conn rod Ass'y, Xhead pin & std caps Xhead Ass'y, conn rod Ass'y, Xhead pin & std caps. Main, conn rod & thrust bearings & Xhead pin bushings Gaskets, O' rings and oil filter element used within Gaskets, O' rings, fiter element and standard oil cooler Gaskets, ©’ rings, filler element and frame oil pump Oil fiter element Main, conn rod & thrust bearings & Xhead pin bushings Gaskets, 0” rings and oil fier element Gasket, ol fiter element and frame oil pump Gears, shafts, pins & keys for front cover assembly Xhead Ass'y, Xhead pin, gaskets & O' rings for 1 Xhead Xhead Assy, conn rod Ass'y & Xhead pin Rod packing, packing case assembly & gaskets Rod packing & gaskets Oil fiter element Main, conn rod & thrust bearings & Xhead pin bushings Gaskets, 0’ rings & oil fiter element Gasket, oi fiter element & frame oil pump Gaskets, © rings and oil fier element Cilfiter element Main, conn rod & thrust bearings & Xhead pin bushings Xhead Ass'y, Xhead pin, gaskets & O' rings for 1 Xhead Gasket, filter element frame oil pump Gears, shafts, pins & keys for front cover assembly Rod packing, packing case assembly & gaskets Rod packing & gaskets, Xhead Ass'y, conn rod Ass'y & Xhead pin Gaskets, ©” rings & oil fiter elementGE Power Systems compressor (ews : Date: May 13,2002 Series: All New Preservation Procedures for Frames and Cylinders GE Gemini has revised its preservation procedures to allow for outdoor ‘storage for up to 6 months before re-preservation is required! The most noticeable change in the preservation procedure is the red “preservation tag” that is attached to every unit. This tag identifies when the unit was initially preserved and when It must be re-preserved. Other features of the new preservation procedure are: 4) Mobilarma 624 lubricating oil containing’ rust preventatives is used during nodoad testing. Mobilarma 524 oil provides superior rust and corrosion prevention and antioxidation characteristics. 2) NOX-RUST 502 petroleum based rust preventative is applied to all interior surfaces of the frame, including the crankshaft. NOX-RUST 502 is miscible with lubricating oils and does not need to be removed prior to packaging and start-up. 3) 3M 4811 Preservation Sealing Tape is used.on the crankshaft and flywheel, If Present, to prevent corrosion. The tape is applied to the piston rod of’ cylinders that are shipped loose. 4) The Oil Fill Cap on D, E, and F frames is now shipped loose in the tool box that accompanies each frame. This prevents moisture from entering the fram 5) Desiccant bags are placed in front of the crosshead in each guide. Desiccant bags are also attached to the blind flanges for the cylinder suction and discharge passages. ANY ROTATION OF THE CRANKSHAFT COULD CAUSE THE DESICCANT BAGS TO BREAK, CONTAMINATING THE FRAME AND CYLINDERS.C7 The following steps must be performed prior to packaging: Compressor Frame Inspection and Preparation: 1) Remove all frame covers and remove the desiccant bags. Remove the sealing tape from the breathers, crankshaft and oil fill cap. Inspect the inside of the frame for corrosion and moisture. Remove all traces of moisture with lint free cotton rags. 2) Any corroded parts must be removed from the frame before attempting to remove any corrosion with abrasive media such as emery cloth, crocus cloth or Scotchbrite. Failure to do so will result in contamination of the frame with abrasive particles that will result damage to the frame. 3) The frame oil should be changed after one hour of operation if the frame has been stored outside for more than 6 (six) months. Compressor Cylinder inspection and Preparation: 1) Remove the suction and discharge blind flanges from the cylinder and remove the desiccant bags. 2) Remove the sealing tape from the piston rod. 3) _ Inspect the inside of the cylinder for corrosion and moisture. e 4) Remove all traces of moisture with cotton rags. Any corroded parts must be removed from the cylinder before attempting to remove any corrosion with abrasive media such as emery cloth, crocus cloth or Scotchbrite. Failure to do so will result in contamination of the cylinder with abrasive particles that will result in damage to the cylinder. 5) Oil the cylinder bore with the dil to be used for cylinder lubrication. Replace the valves, valve retainers and valve caps, Please Contact GE Gemini for additional Information j JAGOMPRESSOR NEWSICN 02-007 - NEW PRESERVATION PROGEDURE.DOGGE Power Systems Oil& Gas ‘Gemini ‘Subject: Cylinder Maintenance RSPL Kits Group: CYLGP’s Number: 02-008 Sub Group: Cylinder Date: May 29, 2002 Series:___D, E and F Series Recommended Spare Parts Lists (RSPL) GE Gemini has developed an array of compressor cylinder maintenance RSPL kits designed to simplify ordering and shipping of all items needed to perform specific maintenance or repair procedures. The objectives of Gemini RSPL kits are: e Minimize Customer's time required to order parts ' © Assurance that all parts are included for a given repair procedure e Include small hardware, gaskets and seals with major parts in RSPL kits e Expedite parts shipment by having RSPL kits pre-packaged ‘A combination of various RSPL kits may be ordered for cylinder overhaul RSPL kits are designed for the following Cylinder maintenance and repair procedures in ‘addition to Preventative Maintenance: © Rod Packing Replacement © Rod Packing Gase with Packing Piston Ring Kits with O-Rings Liner Replacement Valve Replacement Valve Internals Repair Piston and Rod Assembly Variable Volume Clearance Pocket Seals End User time and cost savings are derived from competitively priced RSPL kits. RSPL kit prices are less than the total price of individual parts within the kit. The application and content of each cylinder RSPL kit is described on the reverse side of this Compressor News Bulletin. Please Contact GE Gemin! for additional information at| os.21-02 -JCompressor Newe-CN02-008-Cylndor Maintenance RPL Kits Page ots.GE Gemini Cylinder Kit Part Numbering System , (Wo Spaces Between Characters) Rod Packing Replacement Kit* Example/Template: KRP,_E , 12.0-16.6 , Available Kits Do Not Include Distance Piece Models v Ly cylinder Bore Diam. Range > See Table “A" For Choices Kit Rod Packing 5 the Model (D:E.F) Example KitIncludes: Part QTY Description 22-2107 1 Gasket-Aluminum Pkg Case to Cylinder 272-PS-2988 1 O-Ring False Head to Cylinder 216-PS-2988 4 O-Ring False Head to Packing Case 10-PS-6058 4 —_—Pressure Packing-TEICI 10-75-4288 -2-—_—Pressure Packing-TFEICI 10-PS-4338 «2 -~—_—~False Head Oil Wiper Per Packing-Ci 4.026114 2 Gasket-Cross Head Door Rod Packing Case With Packing Example/Template: KPC, CE, 420-465, Available Kits Do Not Include Models with Distance Piece ¥ Ly cyinder Bore Diam. Range > See Table “At” For Choices Kit Packing Case EE me Model (0.6,F) Example Kit Includes: Part # QTY Description 22-2107 1” Gasket-Aluminum Pkg Case To Cylinder 11-026744 1 Packing Case Pressure 272-PS-2088 1—_O-Ring - False Head to Cylinder 216-PS-2988 — 4-—O-Ring- False Head to Packing Case 11-PS-6058 4 ~—_—Pressure Packing - TFE/CL 11-PS-4288 = 2-—_—Pressure Packing - TFE/CL 11-PS-4338 ©—-2-—_“False Head Gil Wiper Packing - CL 1-026114 2 Gasket - Cross Head Door * Must Order Separately Head End “O" Ring Per Cylinder Range as Required See Table “A2" Piston Ring Kit With O-Rings* Exemple/Template se DEF, 62 Ly cylinder Bore Diam. > See Table “B- For Choices KitPiston Ring toda! Example Kit Includes: Part # QTY Description 2042-10067 '§ ~——Rings-2 Pc CFT - 6.25" Diameter 445-PS-2987 1 O-Ring - Cylinder Head GE Gemini Parts Sales: Contact Parts Specialist For: Paul Orta Special Valves. NACE Hardware Legacy Models ‘Other Cylinders Not Listed * Must Order Separately the Head End O-ring Per Cylinder Range as Required - See Table *A2" 05.21.02 -!AGompressor News-CN02-008.Cyindor Maintenance RSPL Kits Page 20f5002851 GE Gemini Cylinder Kit Part Numbering System Liner Repl it Kit* (No Spaces Between Characters) Example/Template: KCL, DEF, 127, v ‘ Ly cylinder Bore Diam. See Table “B° For Choices Kit Cylinder Liner pame Model Example kit Includes: part QTY Description 81-PS-830 1 Dowel 5.031718 1 Liner- 12.75" D.E & F - 50,60 & 70 Frames Valve Replacement Kit Example/Template: KVR, DEF, 120-137 v Ly cylinder Bore Diam. Range > See Table kit Valve Replacement Model Exemple Kit Includes: Part # QTY Description 1-01-5141 4 Inlet Valve Assembly 41-100078 4 Gasket - Seat - Soft Steel 260-PS-2987 8 O-Ring Cover to Cylinder 406-3301 8 O-Ring Cover to Studs 1-01-5142 4 Discharge Valve Assembly e 441000078 4 Gasket Seat - Soft Steel Scope: Complete Set of Standard Inlet and Discharge Valve Assemblies, Seat and Cover Gasket For One (1) Cylinder Ive Internals Repair Example/Template: _KVI, _DEF, 12.0 -13.7 12.0437, Ly cylinder Bore Diam, Range > See Table “C" For Choices a kavave manos yy Example Kit Includes: part # QTY Description 55141 2 Valve Plate - MT Meterial 111-01-55100 2 Wafer Spring 14-01-03262 48.—_Closing Springs (16 Inlet 32 Discharge) 41-400078 1 Gasket - Seat - Soft Stee! (Inlet) 44-100078 1 Gasket - Seat - Sof Steel (Discharge) 260-PS-2987 2 O-Ring - Cover to Cylinder 2 406-3301 ‘Scope: (O-ring - Cover to Studs Plates and Springs to Repair 1 Inlet and 1 Discharge Valve, ‘Seat and Cover Gasket Included GE Gemini Parts Sales: Paul Orta Contact Parts Specialist For: ‘Special Valves. NACE Hardware Legacy Models Other Cylinders Not Listed * Must Order Separately the Head End O-ring Per Cylinder Range as Required - See Table “A2 05-21-02 -INCompressor News-CN02.008-Cylinder Maintenance RSPL Kits Page SotPi id Rod AssembI Exemple/Template: iston Kit Piston Rod ‘Assembly Part # 4.026875 9.484245 5-PS-16 4-611-386 4.011387 2.403164 2.102929 2067-1000067 460-PS-2987 1.026114 NOTE: Example Kit Includes: ary Nokeneesee Ki et Frame Model (D5,06,E5,66,E7,F5,F6,F7) GE Gemini Cylinder Kit Part Numbering System (Cont'd) (No Spaces Between Characters) Available Kits Do Not Include Distance Piece Models Cylinder Bore Diam. > See Table “B" For Choices Description Piston Rod 2.25" Diameter Piston Nut ‘Set Screw Bushing - Piston - HE Bushing - Piston - CE Piston Hub (HE & CE) 12.6" Diameter Carrier Ring - 12.5" Diameter Rings Combo - 2p¢ CFT - 12.5" Diameter ‘O-Ring - Cylinder Head Gasket - Cross Head Door Piston Rod Assembly is Fully Assembled and Torqued. ie DEF, - Part # 2-1000063 248-PS-2987 5-100014 1-PS-254 Example/Template: 45-65 Kit Variable Clearance ary 1 1 1 1 Example Kit Includes: Variable Volume Clearance Pocket Seals Gylinder Bore Diam. > See Table “D* For Choices Qescription Ring O-Ring Seal Thread Seal Grease Fitting GE Gemini Parts Sales: Contact Parts Specialist For: Paul Orta ‘Special Valves e NACE Hardware pauroraGps gecom Legacy Models Other Cylinders Not Listed 0521-02 -!8Compressor News-CN02-008.Cyknder Maintenance RSPL Kits Page 4 0F5e GE Gemini Cylinder Kit Part Numbering System (Cont’d) Table “A” (Rod Packing) ‘Table “B (Piston Rings, Liners and Table “C” (Valve Kits) Piston Rod Assembly Kits) D.E or F All Strokes D.E or FAll Strokes Cylinder Rar in) ‘Gylinder Bore (in) Cylinder Bore Ranges (in DSOI60 5.5-11.2 inc. 14.75NL 55 100 55-65 ne 70NL 120-165 87 102 67-77 inc. 8.25 NL 60 == 105, 85-97 ine 10.25NL aa eee 62 107 10.0-11.2 ine. 14.75 NL # 65 11.0 12.0 - 13.7 inc. 14.25 NL. FSOIGO/70 5.8-11.2 ine. 11.75 NL Clair Ti) 14.0- 18.0 120-165 70 125 185-165 qe : 75 130 77 135 65 140 a7 145 so 180 92155 95 160 e 165 Table “A1” Packing Gase Table “A2” HE “0” Ring For Table “D” (wvGPs) With Packing Packing and Piston Rod D.E or F All Strokes Part # D.E or F All Strokes Cylinder Bore Ranges (in) Cylinder Bore Ranges (in Cylinder Bore Ranges (in) *45-5.2inc SSTLEONL 441-PS-2087 45-65 oO Rear TeM -85-BSkc rom 445-PS.2087 67-97 me. s025N ioataes 67-77inc 825. 448-PS.2987 10.0 ~13.7 ne. 11.7560 85-97 ine 1028M. — 482-PS-2987 140-165 ES0I60/70 5.5-6.5 nc 70M. 100-112 ine 125M. 455-PS-2987 G7-11.2ie14.75N 12.0137 ne 425K 460-PS-2987 120-165 140-150 466-PS-2987 F50I60/70 5.5 -6.5 inc. 7.0NL ares Beadle = 11.2 ine Stee een NOTE: 1. Designation above Refer to Cylinder Designs with MAWP up to 2200 PSIG and are Only Include Those For Which Kits are Available... See Parts Specialist for Other Sizes or Pressure Ratings 2. 114 and 3/4 inch Bores are Truncated in the Nomenciature to .2 and .7 Respectively. 3. Valve Kits are '95 Series Cylinder Models Except 5.5-6.5 in Bore Cylinders and are Designed for Standard Valves Only GE Gemini Parts Sales: Contact Parts Specialist For: Paul Orta Special Valves. NACE Hardware [email protected] Legacy Models Other Cylinders Not Listed ie Pipeline and Other Sizes 05-21-02 J8Compressor News:CN02-008-Cylindor Maintenance RSPL Kits Page Sof5002851 GE Gomini 2707 North Loop West, Sufte 200 Houston, TX 77008 @ GE OIL AND GAS compressor (2.5 Low Lift Valves Group: D,E,F 03-004 ‘Sub Group: All A 03 95 Ser id ‘A quick solution to impact related valve problems is to convert the cylinder to low lift valves. Although it is expected that some performance will be sacrificed with this approach, this, approach has been proven to be an effective method of solving impact related valve problems. Below is a listing of the low lift valves currently available for the 89 & 95 Series of watercooled, linered cylinders sold with the GE Gemini Model D, E, and F Frames (formally designated 550, 650, 565, 665, 765, and DH). Low lift valve options for the remaining cylinder sizes will be relayed at a later date. MAWP (Psig) Bore Diameter # Valves Valve Type _Per End BSEa | — SOD Ota | OTTO ROTRET | TOSS rare | iso wor arsow | ansows | oreo | cessor ases | tooo act ors | xagssiat | xcorssrae | xansntea woorto | i250 arc 4 Xovsoure | Jeossoun | xorsoure | Xonsoure wzoi3s| soo vaacr__s__—Xarasrar | xossorat | xovanvas | xossotes standard | towiin Inet Vave_} net Valo Discharge charge Valve Valve ce | Tow Valve Nomenclatu: X-01-XXXXX = Standard Valves X-03-XXXXX = Low-Lift Valves X-05-XXXXX = NACE Valves The use of the “03” digits in the valve part number indicates a low lift valve. GE Oil & Gas 2707 North Loop West, Suite 200 Houston, TX 77008 713-803-0900 (Switchboard) 713-603-0499 (Fax) wwiw.gepower.com\Gemini weww.gepower comlgil&gas Valve Impact Force is a function of mass and acceleration, by reducing the distance the-compressor valve plate travels, the time upon which the valve is. . allowed to accelerate prior to contacting the damper spring is reduced. Low Lift Valves can affect compressor capacity and horsepower. Please contact GE.Gemini for a performance estimate. Low Lift valves are priced competitively, and available on short notice. Contact the GE Ger for price and delivery. parts department Emergency Phone Numbers: Parts: 832-978-6233 Service: 832-978-9780 oe ‘Compressor News\CNO3-004 Low Lit ValvesGE 1333 West Loop North, Suite 800 Houston, Texas’ 77027 U.S.A. OIL & GAS ete mye i compressor (jaws Subject: © PRODUCT UPGRADE NOTICE Group: Frame Number: 03-005-1 Sub Group: Date: June 12, 2003 Series: D, E&F Date: june 12,2003 Series: DEF Crankshaft Upgrade - Model D, E, and F Frames As part of the GE Oil & Gas commitment to deliver quality products to our Oil & Gas customer, we are pleased to announce the following product improvement, The crankshafts for the D, £, and F series of compressor frames will now be offered with integral counterweights. When our current inventory of crankshafts. with “bolted: on” counterweights is fully utiized, all future crankshafts will have “integral” counterweights, We ‘anticipate thet all new crankshafts shipped from GE Oil & Gos - Oshkosh will have integral counterweights by Fall 2003 Both the "bolted on” and “integral” counterweights designs are fully interchangeable, Also, both crankshaft designs are fully warranted by GE Oil & Gas, per the terms of our applicable Packager or distributor agreement There is no anticipated change in price related to this product improvement. if you have any ‘questions, please don't hesitate to contact the GE Oil & Gas- Gemini team. Regards Crankshaft with integral Counterweights Colman de Jong Director of Sales and Marketing - Gemini GE OI & Gos 2707 North Loop West, Suite 200 Houston, TX 77008 713-803-0444, 713-803-0499 (Fox) [email protected] www.geoilandgas.com '¥you hove ony questions concerning this procedure, please contact GE's Technical Hotline 24 Hour Assistance Phone Numbers: Parts: 832-978-6233 Technical Service: 832-978-9780 oes (Compresser NowsiCN 03-008-4e @ GE ENERGY 2707 North Loop West, Suite 200 Houston, TX 77008 OIL AND GAS USA compressor ews Subject: Discharge Temperatures Group: All Number: 04-002 SubGroup: All The following clause has been added to all of our operations manuals: Cylinder Discharge Temperature ‘Shut Down Setting Recommendations The purpose of the discharge temperature switch setting is to shut the unit down e due to rising temperature of a given cylinder before major damage results, Discharge temperature shut down set point of each cylinder is as follows: The discharge temperature shut down set point of each cylinder must be set at 10% but NEVER more than 25 degrees F. above the highest NORMAL. daily discharge temperature of that cylinder. Due to changing operating and ambient conditions, itis the operator's responsibilty to daily check, justify, confirm and adjust (as may be required) all safety shut down devices. ‘The maximum allowable operating temperature on the cylinders is 350 degrees F. on hydrocarbon gases. 24 Hour Emergency Phone Numbers: Parts: 832-978-6233 Tech Service Support: 632-978-9780 @ www.geoilandgas.com eee Compressor Newson 64-002GE Energy GE Energy Ot 8.6, ne 2707 North Loop West, Suite 200 Oil & Gas Houston, Texas 77608 USA com pressor [ews The attached recommendations for the maintenance of GE Oil & Gas high speed reciprocating compressors is being added current GE Gemini Operation and Maintenance manuals. !fyou have any questions concerning this procedure, please contact Geminis Technical Hotline. GE Oil & Gas Emergency Phone Numbers: Parts: 1832.978-6233, Service: 832.978.9780 GE Oi & Gas Gemini High Speed Reciprocating Campressors ~ Headquarters Sates, Parts, Service Customer Service 207 North Loop West, Suite 200 Houston, TX 77008 Tel. 1-713-603-0960 (Switehboara) Fax 17-713-803-0498 wn. geoilandgas.com 1 OF 4 Compresscenewscn orang “SeGE Energy GE. Ena O18 Gas, re. 2707 North Loop West, Suite 200 Oil & Gas Houston, Texas 77008 USA Gemini Compressors - All Models Recommended Maintenance All operating compressors require a periodic maintenance program, It should be established 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. A compressor maintenance logbook should be kept on each unit. The logbook allows for detailed records, so that maintenance costs, troubleshooting and trending can occur. An operator's log sheets should be routinely reviewed by qualified personnel, to determine ‘compressor any maintenance or performance trends. The frequency of a compressor's maintenance intervals is determined by a number of factors, including its physical operating environment, actual operating conditions and the degree of gas contaminants. If performed and documented properiy, a unit's maintenance history will be well documented should any troubleshooting situations arise. A regular compressor oil analysis program is recommended through the oil supplier, ‘even if the crankcase sump is sweetened with makeup oil due to cylinder lubrication use. Compressor oil service change intervals are based upon your oil supplier's specific analysis recommendations. If the oil supplier recommends a more frequent oil change interval than Geminis, then his recommendations should be followed. Ifa situation develops that contaminates the crankcase sump, the compressor oll should be changed as recommended, with the problem's cause determined and corrected. The following typical maintenance program Is offered as a basic guide only, and may be expanded due to actual operating conditions. Time intervals begin with the startup of the unit. This program assumes the compressor operates continuously, 80 the time hour intervals are loosely tied to daily, monthly, quarterly, semi-annual & annual time intervals If maintenance. is performed on hourly record micrometer readings based time frames, refer to the associated time interval column. FOF 4 Compressor NewsCN OF.008GE Energy GE_Enorgy O18 Gas, Inc. f 2707 Noth Loop West, Suite 200, Oil & Gas Houston, Texas 77008 USA. Maiitefance CRSCe= Dall) HSER Frame oil supply pressure, 45 to 55 psig, adjust pressure regulating valve as required when unit at normal operating speed & temperature. | 24 hours Note: 30 psig falling pressure, minimum Low Oil Pressure Shutdown. Frame oil supply temperature, adjust cooling water flow as required Pa hous Note: Maximum 185°F - high temp shutdown, 180°F Minimum. Cooling water flowitemperature, for oll cooler & cylinder cooling 2a Rous Frame oil level, mid-evel of sight glass - hot 24 hours Gil fiter differential pressure, filer housing pointer or gauge(s) 24 hours Note: Change fiter element fcfferential pressure exceeds 10 psid Cylinder lubricator Box cycle fime, seconds/cycle (Max 100 seticycla) | 24 hours Note: See job book for unit specific break-in & normal lube rates Cylinder lubricator oil supply level, separate day tank used 2a hours ‘Compressor Leaks — oil, gas or water, correct as required 24 hours, ‘Compressor operating conditions compressor RPM, 24 hours suction/discharge temperature & pressure by cylinder Valve cover temperature — each suction & discharge valve by oyinder_| 24 hours High cylinder discharge gas temperature shutdown, lesser of 10% or 25°F above normal discharge temperature of each cylinder 24 hours Note; 350°F shutdown, max allowable gas discharge temperature Process gas pressure shutdown set points — high/low settings fo be aS close as practical to actual operating conditions, Set points are typically 10% above and below normal operating pressures. Confirm 24 hours hile pressure shutdown points will not aliow operation in excessive rod load conditions. ‘Unusual noises or vibrations: Da hours ‘Scrubber level & drain operation 24 hours ‘Check gas vents for leakage — piston red packing, blow down & 24 hours pressure safety valves (PS\ (Check vent lines for ice blocks, when ambient femps below 40°F. 2a hous, eaeeeaL 720 hours ‘Normal panel & gauge operation 720 hours Verity cylinders lubricating oil presence, i oyinder operating pressure ‘eater than 3500 psi (verify lubrication fim adequate with 2 cigarette | 720 hours Paper swab test along oylinder wal) ‘Grease VVCP unloader stem threads 720 nours, ‘Check cylinder lube line check valves for high temp and/or leakage "720 hours: 3 OF4 Compressor Newscnce-oo6 "=@ GE Energy G.E. Energy Oil& Gas, Ine 2707 Noth Loop West. Suite 200 Oil & Gas Houiton, Texas 77008 US.A [hime Interval Zs | Check frame & crosshead guide mounting bolts for fghtness, “shim & 2000 hours fe-torque as required to eliminate any “soft foot" found. External frame & cylinder fasteners, for loose or broken bolts 2000 hours ‘Check discharge bottle supports snug fit adjustment, with unit 2000 hours stabilized at normal discharge temperatures Drain pulsation bottles liquids, inlet and discharge 2000 hours ‘Remove and inspect process gas a screen strainers (if used) 2000 hours Tineareral Compressor crankcase oil, ‘change. OF: 28 recommended by = ‘supplier's monthly oil analysis 4000 hours Note: Remove crankcase top cover & inspect intervals for foreign materialidebris whenever oll is changed Frame oil filter, change or ff differential pressure exceeds 10 psid 4000 hours Inspect cylinders’ valve for damaged or broken components, rebuild or 4000 hours: replace as required (lean crankcase breather ooo RUS ee Checks Annuals ee Sma oiecoe significant pressure & temperature points @ Check drive alignment, coupling (rim & a ineluding axial thrust. ‘8000 hours ‘Check eriical frame running gear clearances — main, connecting rod & | 8000 hours thrust, if readings outside tolerance limits, repair or replace affected ‘components as required ‘Check critical crosshead pin/bushing & guide clearances, record ‘8000 hours micrometer readings. If readings outside tolerance limits, repair or replace affected components as required. Replace pin roller bearings, ifso equipped, Inspect cylinders’ valve for damaged or broken components, rebuld or | 6000 hours replace as required Inspect cylinder bores for wear or damage, record micrometer ‘8000 hours readings Pull cylinders piston rod assembly — clean & inspect for wear, replace | 6000 hours worn or damaged components as required Rebuild packing cases ‘8000 hours Record clearances between crosshead & guide bore, by throw 4000 hours Pressure (leak down) test cylinder’s lubrication distribution block(S) ‘8000 hours assemblies, replace oF repair as required Inspect "no-flow” on cylinder lubrication distribution lube blocks for 8000 hours roper operation Change or re-cerfy process pressure safety valves (PSV) ‘8000 hours Calibrate and re-certify accuracy of gauges and transmitters, for all "8000 hours ‘Compressor Newsicn 04.006 See GE Energy eee cee ie Oil & Gas "amon Teae 17608 USA compressor (jews Subject: Trouble Shooting Group: All Number: 04-007 Sub Group: All Date: 17 Sept 04 Series: A The attached trouble shooting procedures have been added to the current GE. Gemini Operation and Maintenance Manuals. Ifyou have any questions conceming this procedure, please contact Gemini's Technical Hotline. GE Oil & Gas Emergency Phone Numbers: Parts: 832-978-6233 Service: 832-978-9780 GE Oil & Gas Gemini High Speed Reciprocating Compressors ~ Headquarters Soles, Parts, Service Customer Service 207 North Loop West, Suite 200 Houston, TX 77008 Tel. +1-713-803-0900 (Switchboard) Fax +1-173-805.0499 www.geoilandgas.com 1 of7 Compressor NeweiGN 04.007GE Energy GE Energy O18 as, ne fs 2701 Noth Loop West, Sue 200, Oil & Gas Houston, Texas 77008 US.A GE Gemini High Speed Reciprocating Compressors — All Models Compressor Trouble Shooting Minor situations can occur during the operation of a GE Gemini compressor that Fequire trouble shooting. Otten these situations can be attributed to gas. contaminants (liquid & solids carryover), actual conditions different from design (improper adjustments), unsuitable lubricant selection, or operating personnel unfamiliar with the compressor and its setup. These difficulties can usually be addressed with personnel training, proper lubricant selection, proper compressor adjustments, correction of adverse operating conditions, or replacement of minor parts. Major situations may also occur, generally during longer periods of operation Often these situations can be attributed to use of the compressor for purposes different than design, unsuitable lubricant selection (generally cylinders & packing lubrication), valves not tailored for operating conditions, or improper operations and maintenance, |tis important to use a compressor log sheet to record interstage pressures and temperatures by stage on multi-stage compressors. When interstage operating conditions vary from normal it indicates trouble with one of the stages. Generally, when the interstage pressure suddenly drops look at the lower pressure cylinder. If the interstage pressure suddenly rises look at the higher pressure cylinder. The following trouble shooting cause and effect is offered as a basic guide only. It lists the more common issues with their most probable causes. It may be expanded to address specific package designs and actual operating conditions Situation Potential Common Causes Compressor Gylinders gas pressure loaded Will Not + Piston end clearance improper, piston hiting head end head or Rotate crank end head * Foreign, incompressible material in cylinder + Mechanical seizure in running gear (crankshaft, bearings, connecting rod, crosshead, packing/piston rod, piston) Cylinder Noise + Piston loose on rod Or Knock «Piston end clearance improper, piston hitting head end head or crank end head * Loose crosshead batance weight ‘+ Damaged crosshead or excessive clearance ‘+ Loose crosshead pin or pin caps * Loose packing case or false head + Broken or leaking valves * Worn or damaged piston rings or wear Band * Valve improperly seated or damaged seat gasket ‘Cylinder incompressible contaminants, liquid or solid carryover 3 2 of7 Compressor NewsiON 04-007GE Energy GE Energy O18 Gas, ne fs 2707 North Lop West, Sue 200, Oil & Gas Houston, Texas 77008 USA GE Gemini High Speed Reciprocating Compressors — All Models Compressor Trouble Shooting Situation Potential Common Causes Frame Noise Loose crosshead pin or pin caps Or Knock * Loose or wom main, crankpin or crosshead bearings ‘Knock coming from cylinder end + Loose crosshead balance weight + Damaged crosshead + Loose crosshead pin or pin caps + Improper lube ol selection Cylinder or ‘+ Compressor frame or crosshead guide mounting bolts loose Frame + Discharge bottle wedges loose or improperly adjusted + Drive train misalignment + Bottle/piping acoustical pulsations ‘+ Excessive crosshead guide clearance (crosshead stap) Low oil + Low oil level ‘Supply + Oil pump faiture Pressure ‘* Oil pump cavitation from excessively cold oil * Oil pressure regulating valve improperly adjusted *Oil fiter element — ditty, restricted or collapsed ‘Low oil pressure switch setting too low + Defective pressure gauge * Oil foaming - high ol level being struck by counterweights * Internal running gear leakage - excessive bearing clearance High Oil * Cold oil Supply * Oil pressure regulating valve improperiy adjusted Pressure * Defective pressure gauge Low/High Oil '* Cooling water supply restricted Supply * Cooling water isolation valves closed Temperature * Temperature control valve temperature incorrect, ‘improperly, installed or stuck Crankcase Oil —_* Oil makeup system isolation vaive ciosed or strainer plugged Level High/Low — « Oil makeup system out of adjustment or leaking ‘* Cold oil / insufficient head pressure High Oil Filter + Filter media plugged Differential * Cold weather / high oil viscosity Pressure ‘+ Oil contaminated with water (condensed during shutdown) * Oil pressure gauge(s) reading improperly _ ££e GE Energy eae ; ja oacmmnes oan Oil & Gas Houston, Texas 77008 USA GE Gemini High Speed Reciprocating Compressors — All Models ‘Compressor Trouble Shooting Situation Potential Common Causes "No-flow” Lube line blockage of crushed tubing, causing rupture disk to Shutdown, blow-out Cylinder Lube» Rupture disk cap torque excessive, scored disk lowers rupture pressure setting * Incorrect rupture disk or fiting for application + Inadequate lube oil supply to pump ‘+ Faulty high pressure oil pump feeding distribution blocks + Distribution block failure + DNFT failure * Oil injection point check valve blockage or failure Valve Breakage © « Liquid canyover or Wear '* Improper valve tailoring — lift, material, springing, assembly Abnormal ‘* Solid abrasive debris entering cylinder with gas stream ‘* Excessive oil supply '* Off design operating condition + Gas composition change * Gas system resonant pulsation Carbon Coated — + Excessive cylinder lubricating oil Valves + Improper cylinder lube oil selection ‘+ Oil carryover from inlet scrubber or from previous stage ‘* High temperatures from leaking or broken valves + Excessive temperatures due to high compression ratio across cylinder + Excessive temperatures due to high inlet gas temperature to cylinder Packing Over inadequate lube oil supply rate, break-in versus normal rates Heating + Lubrication supply failure ‘+ Inadequate packing water coolant flow. if so equipped ‘+ Improper lube oil selection and associated lube rate ‘= Worn packing rings + Contaminants (liquid or solid) affecting packing rings + Improper packing ring side or end clearance fon rod wear ~ scored, tapered or out of round + Excessive piston rod run out 2GE Energy GE Energy O18 Gas, ne 2707 Norn oop West Sate 200 Oil & Gas Houston, Texas 77008 USA GE Gemini High Speed Reciprocating Compressors — All Models ‘Compressor Trouble Shooting Situati Potential Common Causes Excess Worn packing rings Packing + Packing case bolts loose Leakage + Packing rings incorrectly assembled/nstalled + Improper lube oil selection and associated lube rate ‘+ Contaminants (liquid or solid) affecting packing rings ‘* Packing not seated or property run-in ‘+ New packing installed on worn rod or damaged packing case ‘Improper packing ring side or end clearance ‘* Piston rod wear — scored, tapered or out of round, + Excessive piston rod run out Piston Rod or —_» Cylinder or piston wom or scored Packing Wear —_« Oil dilution from liquid carryover Excessive ++ Improper cil supply — excessive or inadequate ‘Inadequate lubrication — incorrect oil type, viscosity or amount + Solid abrasive debris entering cylinder with gas stream ‘+ Piston Rings Worn, Stuck or Broken’ Ring, Piston, _ Piston Rings Worn, Stuck or Broken Liner & Cylinder + Cylinder or piston worn or scored Wear Excessive — « Oil dilution from liquid carryover + Inadequate lubrication — incorrect oil type, viscosity or amount * Solid abrasive debris entering cylinder with gas stream Piston Rod Oil» Wom packing rings Wiper Packing + Packing rings incorrectly assembled/installed Leaks * Packing not seated or properly run-in ‘+ Worn or scored piston rod ‘= Contaminants (liquid or solid) affecting packing rings ‘* Improper packing ring side or end clearance _— 2GE Energy GE. Energy O18 Gs. re Oil & Gas 2707 North Loop West, Suite 200 Houston, Texas 77008 US.A. GE Gemini High Speed Reciprocating Compressors — All Models Compressor Trouble Shooting Potential Common Causes Excessive compression ratio across cylinder — back pressure from Gas Temperature leaking suction valves or piston rings of next higher stage cylinder High Discharge Gas Pressure Inadequate Compressor Output Flow Crankshaft Drive End Seal Oil Leak * High cylinder suction gas temperature + Reduced cylinder suction pressure - flow restriction, inlet strainer Screen debris, suction pressure control valve or inlet scrubber restriction ‘+ Leaking discharge valves or piston rings ‘+ Fouled intercooler piping + Improper lube oil selection or rate # Change in cylinder mode of operation, from single acting (SA) to double acting (DA) ‘+ Excessive compression ratio across cylinder - back pressure from leaking suction valves or piston rings of next higher stage cylinder ‘Downstream line obstruction or isolation valve closed ‘+ Unit recycle, vent or scrubber dump valve open or leaking ‘* Compressor speed lower than rating + Compressor suction pressure lower than rating ‘+ Cylinder head end VVCP unloader improperly adjusted * Suction pressure gauge reading higher than actual * Incorrectly calibrated gas flow meter + Damaged or incorrectly installed orifice plate in gas flow meter ‘+ Leaking vaive around gas flow meter + Liquid drop out between stages of compression ~ + Downstream line obstruction or isolation valve closed + Damaged cylinder valves + Damaged piston rings + Incorrect compressor valve use, valve not properly tailored for application ‘+ Metered gas flow inaccurate or not counting upstream deductions for engine startfuel gas, dehydration unit and other auxiliary equipment ‘+ Clogged top caver breather + Back pressure from excessive cylinder packing leak + Excessive seal wear due to drive coupling misalignment + Excessive seal wear due to incorrectly adjusted front cover 6 of7 ‘Compressor NewsiCN 04-007GE Energy ron SE FONE Ges re ; 07 Nori Locp Vest Sut 203 Oil & Gas Houston, Texas 77008 USA GE Gemini High Speed Reciprocating Compressors — All Models Compressor Trouble Shooting Potential Common Causes. Faulty or improperly adjusted pressure safety valve (PSV) ‘+ Back pressure from leaking suction valves or piston rings of higher stage cylinder downstream ‘+ Downstream line obstruction or isolation valve closed +s Discharge line check valve restriction - sticking or damaged ‘* Gas cooler tubing restriction fouled or exceeds flow capacity — 2GE Energy GE. Energy O18 Gas. re. 2707 North Loop West, Suite 200 Oil & Gas Houston, Texas 77008 USA compressor (aws Subject: “Hold Down”Bolts Number: 04-011 All Frames All ‘The GE Gemini compressor installation and maisitenance manuals are being modified to include the following information. ‘The attached table lists the hold down bolting sizes and minimum torquing requirements recommended for (GE Gemini reciprocating compressors. High strength studs and bolts are recommended to secure the ‘compressor frame feet and crosshead guide to the compressor skid. Proper hold down bolting selection, installation and torque are required to transfer and resist normal inhecent reciprocating compressor shaking forces and couples into this skid, Failure to install and maintain compressor mounting fasteners can resuit in equipment vibration, drive train misalignment and compressor main bearing bore misalignment. Reciprocating compressors will develop unbalanced farces and couples due to the tolerances in the reciprocating weights and the offset of the compressor throws. The resulting unbalance results in the presence of horizontal and vertical forces and horizontal and vertical couples. The compressor skid and foundation must be designed to dampen and transfer these shaking forces originating from the compressor into the skid and foundation. Secure mounting of the compressor frame and crosshead guide to the skid is necessary to minimize the vibrations associated with these forces. Note: Bo't lengths extending only through the compressor mounting foot & Kbeam may not be sufficient to prevent loosening. All hold down bolts must be periodically checked for tghtness, and retightened as required Bolting Requirements 1. The compressor frame's hold down bolt is typically 1/8" smaller in diameter than the mounting foot hole opening, unless otherwise specified 2. The length of hold down boting should be as long as possible and stressed using a torque value appropriate with the batting material The following “Compressor Hold Down Botting” table lists the minimum frame foot and crosshead guide bolting sizes and torque requirements. Use of the tabled values is based upon bolting materials with proof loads greater than 100,000 psi Higher strength bolting material is preferred, Compressor frame foot bolting typically uses ASTM A193 GR B-7 threaded studs or Grade 8 bolts, along with hardened steel washers and ASTM A194 nuts. Hold down botting used for M&H model compressor mounting and all models’ crosshead guide ‘Suppor is recommended to be Grade 8 or 9 bots. Tighten the mounting fastener to stress its material to a value greater than 55% of its proof load rating. A higher strength bolting material will result in torque values higher than those listed. 8. Hold down bolt torque value, ‘sof foot deflection and proper crosshead guide support shimming verifications must be made at startup and periodically during the compressor's normal operation. Bolt Fastener Tightening 1. Fastening hardware's threads and contact surfaces are to be clean and free of burrs or dings. This includes bolt, stud and nut threads, along with washer, nut, bolt head and associated contact surfaces, 2, Threaded fasteners are to be installed free turing, with minimal hand force. eee eee mene eee 1 OF 2 compressor NewsCn o4-011@ GE Energy Oe ce ora ce 2707 North Loop West, Sute 200 Oil & Gas Houston, Texas 77008 USA 3. Torque values are based upon the use of a petroleum lubricant applied to both the threads and seating surfaces. Use of the compressor sump’s SAE 30 or 40 WF oll is preferred, Caution: Friction reducing lubricants, such as molybdenum disulphide or Never-Seez, are not to be Used unless specified. Friction reducers using the specified torque values can result in excessive fastener stresses, 4. Fasteners should be installed with some radial clearance. Avoid placing the fastener threads in shear or loaded against the fastener's opening in the feet or skid 5. Use a calibrated torque wrench, and a torque multiplier as required 6. Incorporate hold down bolting torque verification and soft foot checks inlo your routine compressor maintenance program Frame Foot Crosshead Guide to Suppor GE/Gemini Hole | Recommended | Torque Torque Reciprocating | Diameter | Boltor Stud | Range. tb-t| Bolt Size _|_Range, Ib-t Compressor inch Size Min [Max] inch TPL [Min | Max Model ch - TP iY Threaded |“5/8"- 77 UNC | 160] - NA fees boit hole, Gi Threaded [~3/"-T0UNC [250] NA - p> bolt hole @ a 8" 7-8 420 | -460_| 5/877 UNC | 100 | 120 5 T 71-8 | 280 | 300 |“3/a"- 10 UNC | 200_| 220 “Dazz 74 Tae 4-10"-7 | 845 | 880 | 3/4710 UNC | 200 | 220 [_ D602 7 607 1-3/8 1a -7 845 [880 _|/3/4"- 10 UNC _|~200 [220 5047608 | 7-172" 4-3/8"-6 [1100 | 1140 | 3/4" 10 UNC | 200 | 220, E 12" 4-3/8"=6 [1700 | 1140 | 3/4" 10 UNC | 200 | 220 FE 172" 4-3/8"= 6 |1100 [1140 |-3/4"— 10 UNC | 200-| 220 1-3/8" 7-318"—6 sume | (44mm) | (35mm) __| 1400 | 1140] 4-38"-6 | 1100 | 1140 Reciprocating Compressor Hold Down Bolting Table Notes: 1. Larger compressor frame feet have a “through bolt” hole that can accommodate an all- thread fastener, hardened washer & nut 2. M&H compressor frames incorporate threaded bolt holes, bottom iocated, for ‘compressor mounting, These units do not have an additional crosshead guide end ‘support. Use Grade 8 or stronger bolts to mount the framelguide combination to the skid, eee eee 2 OF 2 Compressor Newscn O4 011GE OIL & GAS £046 605, 1335 West Loop Noth suite 800 Houston, Texas 77027 USA compressor ews Subject: “Rupture Discs” Group: Frames Number: 05-003 Sub Group: Lubrication Date: 23 June, 05 Series: All Operating Manuals for high-speed reciprocating compressors are being modified to include the following information, Cylinder Lubricator System - Over Pressure Protection A thorough understanding of the cylinder and packing lubrication system can improve compressor rliobilty, ‘and prevent damage to components, The Basic System Figure #1 represents 0 typical cylinder (and piston rod packing! lubrication system, Oilis pressurized by o lubricctor pump, then fed through stainiess st2el tubing to @ divider Block ossembly that meters the ol to the cylinder bore(s| and pressure packing. & typicol system includes ‘+ Check vaives,to prevent oil from traveling in reverse direction ‘+ Overpressure indicator rupture cisk to prevent damage tothe system by high pressure, * Aino flow switch, [ONFT or Kenco ore our current standards) io rip the compressor in situations when flows inadequate, + Cycle pin indicator to provide visual confirmation of system cycles. ‘Arrangements will vary depending on the compressor configuration, ond with the operating system's conditions ‘of service. Contact the Technical Services hotline with specific questions about your system. System Function: Ifa blockage occurs in the divider blocks, lube lines, check valves or injection points, the system will Increase Pressure to overcome the blockage, Excessive system pressure is limited by the use of an over pressure Protection device (rupture disk located between the pump dischorge and the distribution blocks. When the oll pressure exceeds the roting of the rupture disk, a charge of lubricating oilis released. Without ol flow, the ‘ubrication “no flow" switch will activate, normaly shutting the unit down, cece ottobre sano a ee Figure #1: Typical Cylinder Lubrication System Schematic cee Compressor NewsiCN 05.003,GE OIL & GAS 6086 os In 1535 West Loop North, Suite 600, Houston, "ence. 77027 USA, compressor (jews Important Itis necessary to have a properly sized ond working atmospheric rupture ossembly instolled in all lubricating divider block systems. Never remove, modify or plug on atmospheric rupture assembly since equipment damage con result. The exclusive use of genuine OEM componentsis recommended (see Tobe 1. Trouble Shooting Typical causes of Lubrication blockage in divider biock systems oe 4. Crushed or pinched a tubing lines 2. Contamination blockage - crt or foreign material affecting systern components 3. iror gos inthe system - con cause system lockup. inadequate lubrication or intermittent (phantom) lubicotion shutdowns Blocked of injection points) Improperly driled ol passoge Incorrect magnetic housing assernbly instaliotion,cousing divider block pistons] to over travel and jam, Details: ‘Atmospheric rupture assemblies contain on aluminum disc, which is sized and designed to rupture ct o designated pressure, venting lubricating oll to the atmosphere, The pressure ot which the disk ruptures Isa function of the aluminum disc's thickness and corresponding fitting cop hole diameter, The different discs are ‘color coded to indicate the relieving pressures. Rupture disc pressure ratings ore selected based upon the gas. ‘operating conditions and MAWP of the cylinder {and packing casel being lubricated. Table 1 ists rupture disc ‘ossemblies for both 1/8" and" cop holes, along with replacement dises by color thot can fit ether assembly Medium Pressure Assemblies ‘Medium pressure (less thon 3500 psilrupture assemblies typically use a 1/4” (0.250 inches, 64 mmlcop hole. see Figure #2, High Pressure assemblies High pressure (greater than 3500 psi rupture assembles typically use o 1/8" 0.125 inches, 32 men) cap hole, see Figure #2, ‘ — NOTE: @ Torque Cap to no more e@ e@ Color Coded Rupture Disks than 3 ft-lbs (36 in-lbs). Figure #2: Rupture Assembly, with either a {" medium pressure or 1/8" high pressure cop, 20F 3 Compressor NewsiCN 06-003@ = GEOILSGAS ania 1535 West Loop North, Suite 800 Houston, Texas 77027 USA, \\ fe al WV a) 4" Medium Pressure! 1/8" High Pressure Replacement Rupture Discs Rupture Disc Assembly Rupture Disc Assembly Porte Re Port # Rating, Part # Color Thickness Pst PSI Inches 1-PS-5808 900 NA Black 0.006" 2-PS-5808 1150 N/A Green 0.008" 3PS-5806 —-1480=«12-PS-5808 3700 Yellow 0.010" 4-75-5808 «1750 ——«13+PS-§804 4600 Red 0.012" 5-75-5808 2050 «14-PS-5804 5500 Orange 0.014" 6-75-5808 2350-«—15-PS-5804 6400 Aluminum 0.016" 8-P5-5806 2950 «16'PS-5804 7300 Blue 0.020" 9-75-5804 «5250. -—17-PS-$804 «8400«««58-PS-5804 Purple 0.022" Table 1: Part Numbers for Atmospheric Rupture Assemblies supplied by Lincoln St. Louis Coutions 1. To effectively seal the iting without damage to the dsc, the rupture assembly cop must be torqued to no ‘more than 3 ft-lbs (36 in-Ibsl Over tightening ofthis cop con cut into the aluminum dsc and reduce the fitting’s rupture pressure rating for that disc thickness, 2, The some aluminum disc thickness can be used with both 1/8" ond %" hole caps. However, the rupture assembly's pressure rating will be significantly different due to the change in disc's exposed surfoce oreo. @ Example: A yellow (0,010" thick disc wll rupture at 1450 psiin the " hole cop. but 3700 psiin the 1/8 hole cap. Individual arrangements can vary depending on the conditions of service, and Specific compressor ‘orrangement, Contact GE Oil & Gas customer service with any specific questions regarding your compressors. If you hove ony questions concerning this procedure, please contact GE's Technical Hotine 24 Hour Assistance Phone Numbers: 832-978-6233, 832-978-9780 30F3 Compressor News!CN 05-003GE 1333 West Loop North, Suite 200 OIL&GAS Houston, Texas 77027 USA compressor (|\\ Subject: Oil Filter Upgrades Group: Frame Number: 05-006, Rev 2 Sub Group: Lubrication ES, F, F! GE Oil & Gas has upgraded its ol fitration fiter element standard offering and associated options as a product improvement for al of the following frames. The fiter head now comes equipped with two plugged 0.25" NPT taps (side mount) for‘fiter differential pressure monitoring ‘+ All Frames — FESO Series, FE65 Serios + AILD, DS, E, ES, F, FS Series il fitration is vital for successful operation of a compressor and deserves special attention The standard canister type fiter housing is a 4 Non-bypassing design that uses a replaceable, full flow cartridge type filler element. The fiter canister assembly bolts to the ol distribution manifold. internally the fiter element has top and bottom o-ring type ‘seals. The top seal fits over a steel tube, while the bottom seal has a formed metat cap that’s held in place with a col spring. {the fiter housing’s formed metal end plate (PN 124827) or spring (PN 124826) are wom or damaged, always replace with OEM Components. Failure to do so could allow unfitered oil to bypass the {iter elements, which could damage the compressor, ‘This Compressor News describes the new standard 10 micron filers elements used on the 9” & 18" fiter housing assembles. it also details the new 18" fer conversion option for these frarnes. The 18° fiter ‘element can be provided as an option with new equipment, or as a retrofit to the standard 9° housing with ‘minimal component changes. An 18” canister can replace @ standard 8" canister, utilizing the samme o-ring, internat cap & spring. Always check for adequate package clearance required for maintenance purposes, See attached sketch. Note: if water or condensate is allowed to collect in the bottom of this canister, erosion or corrosion of the spring and plate can occur ‘The optional 18° fiter element is a one-piece element design, with twice the surface area as a standard 9° element. The increased fiter surface area can be beneficial infield applications where extended change intervals, or decreased cold weather startup differential pressure is desirable. The fiter head assembly now has two fiter differential pressure indicators, the existing pointer plus two ew 14" NPT tapped ports for gauges. The pointer utlizes a spring loaded piston to measure differential pressures, and requires the following differential pressures to move the pointer (visual indicator] to the colored regions as follows: ‘+ 420 Psi differentiol is required to move the pointer to the green / yellow line. ‘+25 Psi differentials required to move the pointer to the yellow / redline + 430 Psi differentials required to move the pointer to the full red limit. FOF 2 compressor NewsiGN 05.006GE 1535 West Loop North, Suite 800 Houston Texos 77027 USA OIL & GAS compressor (> Note: The actual ol fiter element has a collapse pressure rating of 150 psid ‘The 9" fiter element willbe interchangeable with the 9° legacy oil filer elements, All new 9" & 18° fiter elements have @ nominal fitration rating of 25 microns, and are made of pleated synthetic media, We also Offer the option of @ 10 Micron fiter for applications where increased fitration capabiliy is desired. ‘Std 9" fiter housing assembly (Optional 18° Fiter Assembly, Note: Anew DS, ES or FS frame will ship with a 9" fiter installed, The 18° canister and fiter element must ship foose, since it extends approximately 8 to 9" below the compressor frame's mounting feet. Filter Options - Table 4 “Old 9” Oil Filter__[ New 9" Oli Filter__| New” Oil Filter | Status ‘Obsolete Optional ‘New Standard, Media Type. Cellulose ‘Synthetic ‘Synthetic Nominal Rating (microns) 25 25 10 [Old Part Number | “New Part Number | New Part Number Filter Element TEPS-2203 25Z-PS-2203, 102-PS-2203 Filter Assembly With Element 9.PS.2203 9Z-PS-2203, 422-PS-2203 Filler Canister 34-PS-2203 34:PS-2203 34-PS-2203, New 18" Oil Filter_| New 18 Oil Filter _| Status Optional Optional Media Type ‘Synthetic Synthetic Nominal Rating (microns) 25 10 7 New Part Number | New Part Number Emer canaiet 35-PS-2203 35PS2203 7Z-PS-2203 162-PS-2208 ilter Assembly | With Element 182-PS-2203 192-PS.2203 jeplacoment Plate 124827 2A827 Replacement Spring 120828 120828 Replacement o-ring kit (1) H-PS-2208 41-PS.2208 (1) Canister & differential pressure pointer o-rings included 20F2 (Compressor NowstCN 05.008GE OIL & GAS Ge018 Ges, te +1839 West Loop North, Sute 800 Houston, Texas 77027 USA compressor (ews ——— Subject: Rotating Inertial Data Group: Frame Number: 05-007 ‘Sub Group: All Date: 16 June, 2005 Series: DS (D), ES (E), FS (F) Many GE Oil & Gas’ high speed reciprocating compressors are driven by Waukesha engines. When the engine is equipped with an ESM controller. the compressor inertia data is requited. This compressor news provides rotating moment of inertia dota far its 0S 0}, €S (6) ond FS (F) compressor models |n 2004 Woukesha Engine introduced its Engenius ESM Engine System Manager controller that is being used on variety of large horsepower engines driving GE reciprocating compressors. This ESM conteoller requires the moment of ine‘tio, os on input value, associated withthe driven equipment or “load” itis driving. In the case of _gos compressors, the criven equipment includes both the recipracoting compressor and its dive coupling. Listed below in Toble 1 are the GE compressors’ rotating moment of inertio values, At some point Waukesha ‘may include these values, along with other compressor OEM dato, in its ESM manual. The ESM manual expicins how to calculate and input driven equipment inertial dote inte its controler, Please refer to Woukesha ESM documentation or contact your coupling supplier forthe couplings moment of inertia value Ifyou have any questions about your Waukesho engine or its ESM controller, please contact Waukesha or one of its outhorized distributors. ‘Waukesha Engine 1000 W. St Poul Avenue Waukesha, wi 53188 USA Phone: 262-547-3311 Emoit www waukeshaengine dresser.com bead ‘Compressor NéwsiCN 05.007002851 @ GEOIL&GAS £018 Gas, ne 1393 West Loop North, Suite 600 Houston, Texas 77027 USA. compressor [ows Compressor Rotating Moment of inertia. Manufacturer Model Ret Tbfin-sec! igh 3502 & 0502 1500 a7 2 (05504 & 0504 1500 34 % 5 5 7 [03602 & D502 1200, 16 2 3604 6 D608 1200 42 5 3502 6 E502 1500 65 75 F502 6 F502 #5504 & £508 1500 5 iz F350 6 F504 £5506 & E506 1500 w 35 7 eet ne TE ee) T5602 & £602 1200 38 86 5602 & F602 €5608 & E604 1200 1 Ts F3604 & F604 #5606 & €606 1200 705 ie e 3606 & F606 nie epee ee aS ©5702 6 £702 1000, 35 62 F5702 & F702 E5706 G E708 O00 Ti Ts |__F5704 86704 £5706 & E706 i000 Tes wz S706 & F706 i Table T: Compressors rotating moments of inertia - oppronmote values Ifyou have any questions concerning this procedure, please contact GE's Technical Hotline 24 Hour Assistance Phone Numbers: Parts: 832-978-6233, Technical Service: 832-978-9780 Ee SEES EEE 20F 2 Compressor Newsicn 05.607GE OIL & GAS 199 West tcp No, Suto 850 Houston, Texas 77027 USA compressor [120 | Subject: Coupling Adapter Frame Number: 05-008, rev 3 SubGroup: All Date: 26 Oct 07 Series: D, DS, E, ES, F, FS The attached procedure replaces Compressor News 04-004. Two additional diameters of oversize coupling adapter bolts & associated reamers have been added to the tables included in this procedure. This updated bulletin was developed to assist with coupling installation for GE Oil & Gas model D, DS ,E, ES and F, FS compressor frames. This procedure is also often applicable to many of the earlier “FE” compressor frames. The attached cross-reference sheet will assist with identification of your frame. |Fyou have any questions conceming this procedure, please contact GE's Technical Hotline DS Series Frames] [ES Series Frames | {_ FS Series Frames Curent] Legacy | [Curent] Legacy | [Current] Legacy 08422 |FE 4500-2] | E5502 |FE s85C-2| | FSs02 FE sesDH saa |Fe 4500-4] | ess04 |Fe s8c-a| | Fssce | FE 56s0H-4 oss02 |Fe 5500-2| | ess0s re sesc-6| | Fssos | FE s6s0H.6 ss0é [Fe 5500.4) | es60 |FE 6asc-2) | Fseoe | Fe essDH.2 602 |FE 6500-2] | es6o4 re 6asc-4| | Fs6oe | FE 68sDH.4 8608 |FE 6500-4] | Ese0s |re essc-e| | Fs60s | Fe 6650H.6 E8702 |FE 7esc-2| | Fs702 | re 7650.2 es704 |e 765¢-4| | F704 | FE 7e5DH-4 estos |Fe 7esc-s) | Fsvos [Fe 7esDH6 24 Hour Technical Assistance: 832-978-9780 (Phone) 24 Hour OEM Replacement parts: 1-866-565-2303 (Phone) 1-513-774-4018 (Fax) Parts Webpage: wwiw.parisdirect gexpro.com Email address for replacement parts inquiries: oilgasstreambox gexpro.com GE Ol & Gas GE High Speed Reciprocating Compressors ~ Headquarters ‘Saies, Parts, Service Customer Service 1333 Wost Loop North, Suite 600 Houston, TX 77027 Tol, +1-713-803-0900 (Switchboard) Fax +1-713-803-0499 www. geollandgas com 10f6 Compressor Newsich 05:08, ev 3GE OIL & GAS £018 Ges, ne. 1333 West Loop North, Suite 800 Houston, Texas 77027 USA GE High Speed Compressor Crankshaft Flange Adapter Procedure for Installation of Coupling Flange Adapter & Bolts DS, ES & FS Compressor Frames This coupling adapter bolt installation procedure is applicable to GE compressor current frame models DS, ES and FS. Itis to be used for the initial coupling bolt installation or whenever an oversized bolt replaces a standard bott. ‘Some crankshafts (DS, ES & FS models and their earlier models D, E, F, FESO and FE6S Series) come standard with a machined coupling flange, see Figure 1.” This flange is an integral Part of the compressor crankshaft and will accommodate various coupling designs. A drive ‘coupling adapter is an optional component, available from GE. The coupling adapter may be installed on the crankshaft at the factory, to match a specific coupling chosen by the Packager. Additionally, there are times when the adapter must be installed by the Packager or in the field. Every time the bolts are replaced, a new oversized hole, and new oversize bolts should be used. The existing flange and adapter bolt holes are enlarged by use of a special stepped feamer. Specific bolts-are matched with the corresponding hole diameter (refer to table on the ‘next page). Proper ft between the bolt and hole is critical, The coupling adapter is then installed, with the Packager or Customer furnishing the specified coupling assembly (shim, spider, hub or engine/motor adapter). Please contact GE if you have questions concerning the use or installation of a coupling adapter. Note: Please notice the difference in bolt diameters between the initial (standard) and field replacement (oversize) bolt hole reaming sizes, Caution: ‘Sharp steel metallic burrs may be present, Use proper personal protective equipment and tooling to prevent injury. Warning: Failure to propery install and torque coupling adapter bolts can result in serious equipment damage. Required Materials & Tools For the installation of a standard coupling adapter to a GE compressor crankshaft flange, the following specialty items will be needed: - Magnetic base drill press, 3/4” or larger chuck preferred. ~ Three 3/4" (0.75") diameter studs, 9” long with nuts and washers = Hammer, 16 Ib. minimum, ~ _ Drift punch (1” to.1.5" in diameter x 6” long), steel ~ Torque wrench & Adapter to fit a 11/16" nut, ~ Pilot drill & stepped reamer to match the body ofthe fitted bolt being used, standard or oversize, see the following table. 20f6 Compress Hew 05-008 3e GE OIL & GAS GE 01802 re, 1383 West Loop Nort, Suto 860 Houston, Texas 77027 USA GE High Speed Compressor Crankshaft Flange Adapter Procedure for Installation of Coupling Flange Adapter & Bolts DS, ES & FS Compressor Frames [ ‘DE DS Frames Bok Pan # T Govping | Adapter | Slandsrd Sze [T"Oversze | 2" Ovenae [I Overae | Nut | Hardened | Bot Sae(ypical |Pat# —[oses'tn |ossete | taste | tosr% | Pane | Warner | ayy Designation cose xs4e | tooox | roax | tose Pan tong 3.48°1onq__| 3.48°Iong_| 348" long 07606 | aRBTA 70/700 | 15A622 751750 —[ 473-0407] 114209 423.9053 | 427-6309 | 427.6000 | 110009 | s-100063 | 6 120/800 | 180591 85 /650_—_| 158023 62/905 [160379 ETF EESTFS Frames Bon Part ae Couping | Adapter Siang ze | 2" Ovemae |FGvente | Nt | Hardened | Bot Seetugca) | Pate” [SORT [i"Ovenze 72° Overie [IOwemae | Nt , | Hadoned | pot Designation osesto | toorx | rox | s08ax Pane 0.966" ae" | 448" tong | 448" long | 448" ong Jeng e wor e00 | Waar 701700 15A822 eres] HATE! rsao0s | azreat0 | azr-esi1 | s1aove | e-to00es | 12 307600] 1SAG01 35,7850] 16AS79 321925 16AR7O Body FRBON size Pict Bri Sze ‘Stepped Reamer Description ‘Standard ‘Siaight uted, stepped reamer with a major Size e168" diameter of 0.966" 0.965" (0.3537) ‘The stepped ream should have a 0.952" 0.953" pilot to iameter x long, | _ 0.966 Reamer part# 357-9514 TF Oversize Sifaigh uted, stepped reamer wih a major o.9e" eae" diameter of 1.000". ‘ (0.984) ‘The stepped ream should have a 0.983" / 1.000" 10.964" pilot diameter x 1" ong Reamer part# 427-5654 2nd Overs Siraight futed, stepped reamer witha major 1031" +1164" lameter of 1.032" to (016) ‘The stepped ream should have a 1.015" 1.032" 1.016" pilot diameter x 1" long, Reamor part# 1-104498, 31d Oversize ‘Straight futed, stepped reamer with @ major 1.062" 11132" diameter of 1.063". to (1937) ‘The stepped ream should have a 1.091" / 1.063" 1.032" plot diameter x 1" long e Reamer part# 1-104499 30f6 Compressor News\eW05-008 1 3e GE OIL & GAS E018 as, ne 1939 West Loop North, Suite 800 Houston, Texas 77027 USA, GE High Speed Compressor Crankshaft Flange Adapter Procedure for Installation of Coupling Flange Adapter & Bolts DS, ES & FS Compressor Frames Installation Procedure 1, Remove any preservatives from the crankshaft flange and adapter with a solvent / de-greaser. 2. Clean and deburr the mating surfaces, pilot diameter & faces, of the crankshaft flange and coupling adapter. 3. Mount the coupling adapter to the crankshaft flange. 4. Confirm that the adapter piate's male pilot fits properly into the crankshaft hubs female counter bore. Verify that the two mating faces are fully in contact with each other. 5. Rotate the coupling adapter relative to the crankshaft ange, to optimize unreamed bolt hole alignment, see note below. Punch mark the two flanges’ OD to indicate flange bolt holes alignment for proper reassembly. Note: Align the mating holes on the adapter with the holes in the crankshaft. if one hole(s) of either the crankshaft lange or coupling adapter is larger or smaller then the other, center the smaller hole to the larger hole as closely as possible. 6. Remove adapter to confirm NO burrs have been ‘pulled’ between the adapter and e crankshaft mating surfaces. 7. Reinstall the adapter plate following above steps 2 thru 5. 8, Install the three (3) %" studs, evenly spaced, to hold the adapter securely on the crankshaft during subsequent steps. 9. Tighten the three studs evenly to hold the adapter securely in place on the ‘crankshaft, 10. Use the magnetic dril to pilot drill one of the holes to the diameter required for that bolt size, see table above. Note: Be sure to use a drill that has been properly sharpened so the resulting hole will Not be oversized. 11. Clean the drilled hole of all of the cuttings and lubricate with cutting of 12. Use the magnetic drill to match ream one hole set, adapter to flange, using the stepped reamer for the bolt size selected for installation. 18. Clean the reamed hole of all ofthe cuttings and lubricate with ol 14, Drive the coupling bolt through the match reamed hole until it seats solidly against the coupling adapter. Note: The head of the GE supplied bolt has coarse knurled splines (anti-rotation) that must be driven into the coupling adapter’s counter bore. A properly installed bolt will have its head recessed approximately 0.200" below the surface of the coupling adapter, see Figure 2. Caution: Make sure the bolt has bottomed in the coupling adapter’s counter bore. @ Replacement mounting hardware must include a new nut and new hardened washer. 40f6 Compressor News\ON 05-008, re 3GE OIL & GAS Ge O18 Gas, te 1399 West Loop North, Suite 600, Houston, Texes 77027 U.S.A GE High Speed Compressor Crankshaft Flange Adapter Procedure for Installation of Coupling Flange Adapter & Bolts DS, ES & FS Compressor Frames Warning: Failure to properly install and torque coupling adapter bolts may result in inadequate bolt preload and subsequent equipment damage. 15. Lubricate the bolt threads and mating nut face with oil (SAE 30WT or 40WT) 16. Install a hardened washer and lubricated nut, then tighten the nut to 80 ft. bs, 17, Repeat steps 10 through 16 on the hole approximately 180° opposite from the first hole 18. Remove the 3/4°studs that were used to temporarily hold the coupling adapter in place 19. Repeat steps 10 through 16 for the remaining bolt holes. 20. Final torque for all bolts is 200 to 220 f. Ibs. Apply final torque in three incremental steps (i. 80, 150 and 200 f-Ibs). When torquing boits, avays use the following cross patter’s alternating tightening sequence. Bolt Tightening Sequence — 12 Bolt Pattern Bolt Seating Verification 1. Using the hammer and drift punch, sharply strike each bolt head one time. 2. Re-torque each bolts nut to determine ifthe bolts have reseated in the coupling adapter. Caution: Any bolt that has a reduced torque value has not properly seated in the adapter. Drive that bott until it firmly seats and re-torque the nut to 200 to 220 ft. Ibs. 5 of6 Comoressor Newel 05-068, 0603GE OIL & GAS GE O18 Gas, Ine. 1893 West Loog North, Suite 860, Houston, Texas 77027 USA, GE High Speed Compressor Crankshaft Flange Adapter Procedure for Installation of C oupling Flange Adapter & Bolts DS, ES & FS Compressor Frames Z COUPLING ADAPTER NG Boor FIT DIAMETER — CRANKSHAFT. W/COARSE KHURLEE HEAD FIGURE 1: COUPLING AD/ ; ZZ Z| HARDENED WASHER IAPTER.& HARDWARE o% porn eS Baur HEAD REZESSCO. Hy ADAPTER FIGURE 2: COUPLING ADAPTER HAF COUPLING ADAPTER - CRANKSHAFT BOLTING \RORARE PROPERLY INSTALLED 6 of 6 ‘Compressor NewsleW 05-0081 3GE OIL & GAS Gé 018 Gas, re 1333 West Loop North, Sute 800 Houston, Texas 77027 USA, compressor {jews Subject: — DNFT Magnetic Assemblies Group: All Frames Number: 05-009 Sub Group: Lubrication Date: 17 June, 2005 Series: All This compressor news is written to assist Packagers ond customers instoll the correct digital no-low timer {DNFT-LED) switch and associated magnet assembly on the compressor’s cylinder lubrication distribution block system. Failure to install the correct magnet assembly will result in a blown rupture disc after the divider block Piston locks up and stops oil flow, triggering « no-flow shutdown. Refer to Compressor News #05-003 for rupture disc detail The DNFT-LED iso micro-processor bosed switch thats used to sense a no-flow or slow-flow condition on lubricating oil going to cinder or piston rod packing. see Figure #1. The DNFT-LEO manufacturer itercture ‘refers to several electrical opprovol ratings, including CSA, NEC, Class | Division |, Groups. A B.C D. The some ONFT-LED switch may be used for ll ofthese classifications. To apply the DNFT switch propery, the magnet ssembly must be matched to the proper divider block manufacturers include Lincoln, DROPSA, Trabon, etc), See Figure #2 ‘The ONFT-LEO switches con be used as both an olarm and o shutdown, depending upon how the switches ore utllzed. Eoch ONFT-LED switch must be wired separately. The ONFT-LEO contains an amber colored light- emitting diode (LED| as a cycie indicator, to provide o visual indication thot the system is functioning, This LED is ‘ypically used to manually monitor the cycle time Iseconds/strake} of the distribution black system, The Gemin| Supplied DNFT-LED is typically shipped loose in the toolbox, for packager installation and adjustment. ‘Adjustment instructions are included in the DNFT-LED box, The DNFT-LED works in conjunction with c magnetic pin, which cycles in time with the divider block piston ‘movement - flashing the'LED to indicate o completed divider block cycle. The DNFT-LEDis intemally powered, ‘operated with o field replaceobielthium battery. f battery voltage drops below its minimum power level, the DNET-LEO goes into o shutdown mode. The compressor cannot be restarted with o non-functioning DNFT-LED tnt the battery power is restored. ‘When @ DNFT-LED is instolled on a GE high speed reciprocating compressor. there are several magnetic ‘ossembiies avilable depending upon the manufacturer of distribution block used Listed in Table 1 ore the distribution block manufacturers, GE Compressor Models and associated OFNT-LED port numbers for the correct switch assembly forthe instalation, The name of the distribution block manufacturéris usually stamped on the face of each divider block the manufacturer of ONFTS. Whitlock instrument has detailed DFT information ond troubleshooting guides ovoilable on-line. This information con be found on Whitlock instrument's website (waw.nofla.coml. adgitional informtion and troubleshooting of divider block lubrication systems ond DNFTS is also available from C.C Technology, Inc, at their web site (awwcct nul Please call GE Oil & Gos with any questions you may have, 10F2 Compressor NewsiCN 05.009@ GEOL&GAS cone 1338 West Loop North, Suite 600 Houston, Texas 77027 USA, compressor ()aws Distribution Block ‘Compressor ONFT-LED part #, [Magnetic Housing Monufacturer Model includes magnet | Assembly Description assembly Lineoin St Louis ADSIOL ESE FSIA 427-4837 Tincoin o-ting seal, extended nose, 7/16" ~ 20 TP threads 2 DROPSA B,H&M, W27-4820, Dropsa 4" 6SP threads Table 1: Typical ONFT-LED part numbers by compressor model Notes: (2) DNFT part number includes the correct mognet housing assembly requited for that monufacturer. (2 7/16" - 20 TP threads are also used on magnetic assemblies whose nose design only fits Trabon blacks PORN tree 09.66% te 28 OE nnn o.oo Figure #1: Digital No-Flow Timer (ONFT-LED) Switch ‘Assembly, including magnetic housing assembly Urea 0g Sat ‘ended Neat ce me-20 Figure #2: Magnetic Housing Assemblies Caution: ONFT must be nstolled with the correct, magnetic assembly for each divider block ‘manufacturer.@ Ge OIL & GAS 002851 41333 West Loop North, Suite 800 Houston, Texas 77027 U.S.A. compressor (12\/S | Subject: Upgraded Frame Number: 05-013 Rev 2 Date: __29 Feb 07 GE Oil and Gos has upgraded the running gear of the “F* crosshead, crosshead pin, ond connecting rod. Frames in earty 2008. and ore identified with the designation “FS” Group: Frames ‘Sub Group: All Series: LFS frame. These upgrades include changes to the Containing these upgraded camponents began shipping frame, All new frames being shipped from GE Oil & ‘Gas contoin these upgraded components, These upgrades are ¢ further expansion of the upgrades ovalloble for the Chicago Pneumatic ond Energy Industries “FES65DH, FEGESDH, and FE76S0H" frames, Building on technology from its proven Nuovo Pignone APIE1S process compressors, GE Oil & Gas has uparaded the running geor to provide greater robustness. The u ES ond FS Teodition Series of high-speed compressors, ipgraded frames ore now identified as the GE Oil & Gas, DS, « Upgrade Summary-F to FS Connected Rod and Crosshead Connecting Rod: (1) Cap Alignment pin has been added, also, the pin is offset to ensure proper cap installation (2) Bolts are 12.point capscrew type with hardened washers. (3) Clamping force of the connecting rod cap ‘has been increased with the upgraded ‘components and an upgraded attachment procedure. (4) Tri-Metal bearings, babbit coated bronze bearings with steel backs are now standard, Crosshead: {5) Single piece forged stee! crankshaft with Integral counterweights. (6) Adjustable aluminum shoes have been replaced with babbitied integral shoes. (7) FS crosshead is now a single piece ductile iron casting (8) FS crosshead pin is increased from 3.875" inches to 5.25" in diameter, increasing pin surface area over 183%. (8) The “F" piston rod locking pin device has been discontinued, The fame upd oo eters eroded ing of he ses fone om bt cenpeessen od @ vote esther ure creosote combente sesame tom TOF 2 compressor tensiCn 05:13GE 1533 West Loop North, Suite 800 Houston, Texas 77027 US.A, OIL & GAS r fews SWS) ‘Summary of FS Frome Ratings ane Sar Sa] FSI FSTE | PERG] FRESE] FST] FSR FSG FTO fer troy Bee (fees | sea ote | erate] erate deeaee | need ae Seow “incre st eaten feo ee we etl feet fer ts. ra nx ie | v0 | sco | soo | azo | sco | 500 | eo | sow fun ene moo | 20 | ben | deo | dio | to | ram | taco | Joo sx od Loses coos Sonprsion e |e] ef ola] ew] ol om | « Season s/s |)e]/o)5)8)/e)ele ad Dla -mches ze | 5 | os | 2s | os | os | as | Sef 2 Grants Sata Sains a | és | as | as | as | as. | as | a8 | es ren eng Whee as | 3a | as | os | oe | ce | sa | fs | a-tnenes, es | ss | os | es | os | ce | os | te | at inches a | se | is | oe | se | ce | se | S| [econesing Rod testy: enes se | sz | sm | se | ie | ie | ts | o& | 2 [canning os ering Leng wehes a] EY SE |) Se | a | ss | se 1 82 [goonied Gace ches aiweteisetaltatlelsts Items of importance: Proper throw balancing of the compressor frames critical to sofe and smooth operation. The FS sunning geor has o different weight tbefore balance adjustment) thon the “F* running gear. To prevent. vibration, this weight must be accounted for when boloncing the frame, The nominal crosshead weight of the FS frome is 128.01 lbs. This represents an increase of 12.11 Ibs over the F crosshead weight of 11539 Ibs. F and FS frame bolance weights oré interchangeable. ‘+ Proper running geor cleorances are critical to safe ond smooth compressor operations. Due to the change in running geor dimensions and materials, the recommended FS frame clearance specifications ‘ore not the some as those applicable to the F frame, consult the FS operations manucl ‘+ Proper connecting rod cap bolt torque is crticol to safe compressor operation, The four connecting rod ‘cap bolts hove « recommended torque of 165 ftlbs plus an adcitional 99 degree rotation, ‘+ New special tools - A connecting rod cop removal tool port number 427-6200 and connecting fod cap tightening 90 degree gouge 427-6292, Details and instructions on the proper procedures and settings forthe above points can be found in the FS frome ‘operations and maintenance manual, or contact the Technical Assistance hotine - 832-978-9760. ‘Attached is o parts listing for the FS connecting rod and crosshead, these items con be purchased ina kt form ‘95 port number: Kit907. This kitincludes the ports necessary for one throw of running gear upgrades, including the crankoin bearinas. (FS Throw Ri Pon wimier ROOT Weems 1.70 hem [Description Be ROD ASSY.CONW ESS BUSHWIO feme2S_ 0.103307 _TIeAPScREW i207, 125-128 DES CONN — 20m 2 diosa a ares 9 NA 1103305 Se Seer | CROSSHEAD GROUe FS Fram —]eaP cROSSHEAD 1103300 © ssso1 a ‘360-100062 WASHER FLAT. HARDENED. 625 STL ~ "7-105 [CROSSHEAD, sa [an Se FE sarc HI] 15 ne Sa ae Sarre Tae —— 1S aoe CComprossor NewelCN 05-013,GE 1333 West Loop North, Suite 800 Olé Gas Houston, Texas 77027 U.S.A. NAW compressor (ac Subject: Crankshaft Counterweights Group: Frame Number: 06-002 Sub Group: Maintenance Date: __11Jan 06 Series: EF 1 2004, GE Oil and Gos began providing “single piece" crankshafts for the “E" and "F frame os described in Compressor News CN-03-005-1. Since then, crankshaft with integrat counterweights are the stondard for the ‘new ES and FS series of compressor fromes. These improvernents are further expansion ofthe “E* upgrades valloble for the Chicago Pneumatic and Energy industries "FES65, FE66S, and FE765" frames described in Compressor News CN-02.006, Crankshafts with either the “bolted on” or the “integral” counterweight designs tre fully interchangeable ESSeriesFrames___| [FS Series Frames Current, Legacy Current ‘Legacy £5502 | E502 or FES6SC-2 | [S502 | F502 orFE SESDH-2 fs504 | Es04orreS6sC-4 | | Fs504 | . F504 or FE S6SOH-4 e506 | E506 orFES6sC-6 | | Fs506 | F506 0rFE SE50H-6 es602 | e60z0rFEe6sC-2 | | Fs602 | F602 or FE 6ESOH-2 3604 | £604 oF FE 665C-4 F604 | ~ F604 or FE 685DH-4 £606 | E606or FE G6SC-6 | | FS606 | F606 0° FE 6ESDH-6 €s702 | e70zorFE76sC-2 | | Fs702 | Fr020rFE7650H-2 Es70% | E704orFE765C-4 | | FS704 | F704 or FE TESDH-4 es7os | e706 orFe765¢-6 | |_£5706 | F706 or FE 7650H-6 GE Oil 6 Gos does not recommend removal of the counterweights, On the rare occasion when counterweights ‘must be removed for service needs, proper re-installation of the counterweights is erical. Improper installation of the counterweight hardware con result in severe compressor damage. Hf you have any concern or questions ‘regarding the counterweight installation on your E, or F series compressor. contact the GE Oil ond Gos high speed reciprocating compressor technical support hotline immediately, 832-978-9780, Whenever the counterweights ore removed, they must be reinstalled using the new counterweights and hardware shown in Table 1 below. Also, itis critical that the counterweights ore installed in strict adherence to the attached maintenance procedure. The redesigned counterweights have specially roughened surfaces thot mote to the crankshaft. Adcitionally, the counterweight bolting hardware uses Superbolt® nuts to control bolt preload, The counterweight replacement procedure {1-103545, attached) applies to the following list of ‘Compressor crankshafts by model and stroke, One replacement kits required per crankshaft Typical crankshaft with "Bolt On" counterweights TOF 2 compressor NewsiCh 06-002e GE 1333 West Loop North, Suite 800 oH iy compressor (05 VAY SD Model ‘Stroke ‘Crankshaft Part # ‘Maintenance Replacement Kit * Inches Portit Throws Table I: Field Cronkshaft Counterwaight Replacement Kits Ifyou hove any questions concerning this procedure, please contact GE's Technical Hotline 24 Hour Assistance Phone Numbers: Parts: 832-978-6233, e Technical Service: 832-978-9780 20F2 ‘Compressor Newstn 06-002GE 4333 West Loop North, Suite 800 Houston, Texas 77027 USA. OIL & GAS Maw WIR compressor (ics Subject: ONFT LED, Model 506 Group: All Frames. Number: 06-003 Sub Group: Cylinder Lubrication Date: 11Jan06 Series: All This compressor news is written to inform Packagers and Customers on proper installation and wiring of the digital no-flow timer (DNFT] LED, model 506 switch. Failure to install and wire the DNFT correctly will resuit in on inadequately protected compressor lubrication system, ‘The DNFT-LED is a micro-processor based switch thatis used to sense 0 “no-flow’ or “slow-flow’ condition in lubrication oil going to cylinder or piston rod packing, see Figure #1. The ONFT-LED manufacturer literature refers to several electrical approval ratings, including CSA, NEC, Class I Ovvision |, Groups, 8, C, D. The some ONFT-LEO switch may be used for all of these classifications. To ‘opply the DNFT swatch properly the magnet assembly must be matched to the proper divider block {manufacturers include Lincoln, OROPSA, Trabon, etc). see CN# 05-009 The DNFT-LED switches can be used os both on alarm and a shutdown, depending upon how the switches ore utilized. Each DNFT-LED switch must be wired separately, see Figure #1 for typical "Normally Open’ or "Normally Closed’ configurations. NOTICE: WHEN MORE THAN ONE DNFT IS INSTALLED ON THE COMPRESSOR, EACH DNFT MUST BE WIRED TO A SEPARATE ALARMCIRCUIT ON THE CONTROL PANEL, ANNUNCIATOR OR PLC. THIS WILL SIMPLIFY TROUBLESHOOTING THE LUBRICATION SYSTEM AND DNFT. The DNFT-LED contains an amber colored light-emitting diode (LED! as a cycle indicator, to provide a visual indicotion that the system is functioning, This LED is typically used to manually monitor the cycle time (seconds/stroke) of the distribution block system. The GE supplied DNFT-LED is typically shipped loose in the toolbox, for packager installation ond agjustment, Adjustment instructions are included in the DNFT-LED box ‘The DNFT-LEO works in conjunction with a magnetic pin Figure #4, which cycles in time with the divider block piston movement - flashing the LED to indicate o completed divider block cycle. The DNFT-LED is internally powered, operated with o field replaceable lithium battery. IF bottery voltage drops below its minimum power level, the DNFT-LED goes into a shutdown mode. The compressor cannot be restarted with a nonfunctioning ONET-LED until the battery power is restored A the manufacturer of ONFTs, Whitlock Instrument has detoiled DNFT instollation, mointenance information and troubleshooting guides available on-line, This information can be found on Whitlock {nstrument’s website iwunw.nofla,com). Additional information and troubleshooting of divider block lubrication systems and DNFTSis also available from C.C. Technology, Inc. at their web site (onwor ect OF 2 compressor NewsiCN 06-003GE {933 west Lop Hort, Sula 00 fo Houston, Tenas 77027 USA, compressor (ows sae og wen woe a = cevneec ovens rountencomecron Fe hae reine nee cs DNFT-LED 000506 Sienna WIRING LEGEND OPEN LOOP MODE | CLOSED LOOP MODE neo 4 Vo 7 Seer \ Dees) sgaer DBR tera o00508 my ForuntwosSuaton a00s06 my FSnuieeseuon Figure #1: Digital No-Flow Timer (ONFT-LEO} Switch Assembly, with NO and NC switch wiring diagrams ELETRICAL TESTING OF DNFT ALARM CIRCUIT NORMALLY OPEN - Attach ohmmeter to red wires. Meter should read 10 mega-ohms in operation ‘ond less than 10 ohms in alarm stote. 2, NORMALLY CLOSED - Attach ohmmeter to orange wires. Meter should read less than 10 ohms in operation and infinity in alarm state, Piease call GE Oil & Gas with any questions you may have. GE Oil & Gas High Speed Reciprocating Compressors 24 Hour Assistance: Parts: 832-978-6233, Technical Service: 832-978-9780 2OF 2 Compressor NewsiCN 05.003@ Ge 1333 West Loop North, Suite 800 Houston, Texas 77027 USA. OIL & GAS ee compressor {ews Subject: Volume Pockets Group: ‘All Cylinders Number: 06-004 SubGroup: All Date: _11 Jan 06 Series: All ‘The attached procedure outlines the adjustment of manual variable volume clearance pockets {WvcPs|, and replaces CN 04-010. This VWCP adjustment procedure is applicable to all GE compressor ‘gylinders using head end [HEI VCPs. Failure to properly adjust and maintain WCPs, can result in damage to the compressor. Capacity Control The WCPis an optional capacity control device used to adjust the head end clearance of the cylinder. Most compressor cylinders can be equipped with WWCPs, by replacing the fixed clearance HE cylinder head, Reciprocating compressors are positive displacement devices, compressing a specific volume of gas with each piston stroke, The operating conditions can vary across a range of pressures, temperatures, flows and gos mixes, depending upon the actual field applicotion. The use of a VCP is one method of e ‘copacity control that can be used to efficiently adjust the compressor throughput and power. The WGP is designed to add o variable amount of volumetric clearance to a compressor cylinder. As the piston approaches the cylinder HE, gas tronped in the WWCP clearance volume and does not exit the cylinder. As the piston travels back toward the crank-end of the cylinder, this trapped HE gos re- expands into the cylinder bore. Please contact GE if you have questions concerning the installation or use of @ VWCP as a capacity control device. vvcp Assembly VCP Piston ‘Stem and Jam Nut ver e nis Figure #1 - Typical Variable Volume Clearance Pocket (Installed) 10F4 ‘Compressor NewsiCN 06.004GE 1333 West Loop North, Suite 800 OIL &GAS Houston, Texas 77027 U.S.A. compressor [120s Authorized GE high speed reciprocating packagers are provided with performance prediction software which allows them to chéck the entire performance operational envelope, Contact GE Oil & Gas for your local authorized packager location con contact, Caution: The use of a WCP to change load conditions should always be reviewed to verify acceptable compressor performance before adjustment. Using a VWCP for capacity conta will have an impact on compressor performance characteristics os well os horsepower and flow. Performance parameters to check, includes volumetric efficiency, gas temperatures, driver power limitations, crosshead pin reversals, interstage pressures, system torsional response, compressor valve dynamics ond procéss ‘gos acoustical affect. The added cylinder clearance may significantly change process gas pressures ‘and require valve modifications (usually spring changes} to achieve optimum valve ife for long-term ‘operation ‘Warning: Improper adjustment to or servicing of WWCPs, in hazordous or toxic gas service, can present asofety hazard. WCP Adjustment Range ‘The WCP is used to adjust o cyinder’s HE clearance. The amount of change in clearance volume will vary depending upon the position of the WP piston, see figure #2, The expected change in compressor flow and horsepower is a function of compression ratio ond the gos properties. VCP adjustment can range from the He's fixed clearance (WCP fully closed, 0% travel to maximum clearonce iVWCP fully open, 100% travel. Clearance is often calculated in cubic inches, WCP position is commonly communicated to equipment operators in “inches of travel’. A cross reference can be found by consulting your GE High Speed Reciprocating compressor operations and parts manu! Jam Nut VVC P Piston over Sea Sealing Ring Washer 8 a Z Y LT ‘Manual Drain Plug Figure # 2 Effectivé Rod Extension: Amount pocket is open, in inches = B- A Consult your latest GE High Speed Reciprocating Compressor Parts Manual for specific cylinder clearance data, 24 Hour Assistance Hotline: Parts: 832-978-6233 Technical Service: 832.978.9780 20F4 ‘Compressor NewsicN 06-004GE 1333 West Loop North, Suite 800 Houston, Texas 77027 U.S.A. OIL & GAS compressor )\2\/5 Variable Volume Clearance Pocket (VVCP) Adjustment Procedure The adjustment of manual variable volume clearance pockets ICP} is applicable to all GE high speed ‘reciprocating compressor cylinders using head end (HE) WCPs. The VUCP clearance volume may be agjusted with the compressor running or stopped. ifthe compressor cylinder is pressurized, VVCP adjustments can be made ifthe following precautions are oddressed: Operating Condition Description ‘Compressor shut down with gas pressure ‘Compressor shut down ond de-pressurized ‘Compressor running ot iow idle and de-pressurized ‘Compressor running at low idle with inlet pressure and bypass / recirculation volve ‘open 5. ‘Compressor sunning at reduced speed on line with re-circulation valve closed. 6 ‘Compressor running online ot normal operating conditions GErecommends all VCP adjustments are made under above operating conditions 1, 2or 3. However,if VUCP adjustments under above operating conditions 4, 5, or 6 ore required, then the following minimum precautions are recommended. CAUTION: Flammable of toxic process gas may leak from the VWCP piston stem whenever the Jom nut is loosened. The seal washer under the jarm nut is used to seal gas fiow across the stem threads, Exercise all necessary safety precautions when toxic or potentially explosive gos/air mixtures are present. WARNING: Whenever the process gos contains hydrogen sulfide (HS) or other toxic gases under 1 circumstances should you adjust the VCP during compressor operation, General information The VWCP's piston ring is purposefully designed not to be completely gas tight. Ths allows for minor {Gos and liquid migration across piston ring / O-ring, Ths allows for easier VWCP piston adjustment when the cylinder is pressurized, Gas tropped in the VCP housing will slowly vent across the VCP piston ring or O-sing during'cylinder de-pressurization. However, accumulated liquids, debris or rust ‘around the WWCP's piston con trap gas in the housing, substantially increasing WCP gas depressurization time, WARNING: . Co NOT remove or loosen any gas containment bolting, or the WWCP housing bottom drain plug, until gas trapped in the housing has fully vented, WCEP Adjustment - Required Materials & Tools ‘When adjusting a standard HE WCP on a GE compressor cylinder, the following items will be needed ‘9 WCP clearance tables or graphs Performance program output showing desired WCP setting in inches or %. Tope measure Large adjustable wrench to loosen WCP jam nut & to turn WWCP stem Greose gun, to lubricate WCP piston stem threads Greose - high quality, heavy duty, high temperature lithium Anti-seize, for WCP jom nut & washer lubrication eococe ‘Compressor Newsicn 06-006GE 1333 West Loop North, Suite 800 Houston, Texas 77027 U.S.A. OIL & GAS compressor (wows: Sw WP Adjustment PrdMedure 1. _ Inspect the cylinder’s HE for any special spacers, between the WCP and the cylinder: in certain high cleorance applications a special HE compression clearance spacer may have been added to the cylinder’s "base" cleorance. 2. ‘Determine the desired WCP stem extension dimension “os-is" on the cylinder and "as- tequired" from WCEP charts or performance runs. 3. To set the VCP at the desired percentage (9) open position, fully close the WWCP, and then. fully open it, counting the number of turns to the full open position, Fully close the WP. Multiply the totol number of tums by the desired percentoge open, and open the VCP the ‘resulting number of tus. 4. During WWCP adjustment, exercise all necessary safety precautions. 5. Apply stem thread lubricating grease compatible with the process gas through the WCP flange lubrication fitting 6 Prior to adjustment, loosen the WCP stem jam nut. NOTE: Some chattering and / or light knocking of the WCP stem/piston may be experienced during WWCP stem adjustment with the jar ut loosened. 7. Tominimize gas leakage across the seol washer during stem adjustment, loosen the WCP ‘stem jam nut no more than one hal turn from its tightened position. & Adjust the VCP in oF out to the desired clearance position determined in step 2, while ‘maintaining the half-turn jom nut position in step 7, NOTE: 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, 9. After adjustment, securely tighten the VCP jam nut against the VWCP thread seal washer, Using torque values shown in Table 1. TToble 1: VCP Jam Nut Recommended Torque Threaded Rod Size Jom Nut Torque, ibs | T-8UNC 200 ft-lbs a-i/2" - UNC 2.3/4" - UNC 600 ft-lbs 2°-4acme CAUTION: Foilure to maintoin proper VWCP jam nut torque can result in vibration of the VWCP piston in it's housing, ond possibly lead to a fatigue failure ofthe pistor/stem connection. Piston Jam nut tightness should be checked on a doily basis. 30. Reapply grease to the VCP stem threads through the flange lubrication fitting 11. After final UCP adjustment and Jom Nut tightening, verify there is no gas leakage from the WCP stem seal washer area, If leaks are detected, replace stem seol washer, or provide other repairs as required 12, _ Reset high/low process gos shut down points (pressure ond discharge temperature) to proper set points FOF 4 compressor NewsiCN 08.004GE 1355 West Loop North, Suite 00 Oil & Gas Houston, Texas 77027 USA. AIG compressor jaws Subject: Oil Pressure Regulating Valve Group: All Frames Number: 06-009 Sub Group: _Lubrication : 21 Mar 21 ries: A,B,D, EFS Proper lubrication is critical to successful compressor frame operation. The type (grade). cleanliness, flow, pressure, and temperature of the oil are all important factors in proper lubrication. The overall compressor lubrication system is described in the appropriate GE High Speed Reciprocating Compressor Operations, and Maintenances Manual, ‘An important component in the frame lubrication system is the oil pressure regulating vaive. This compressor news is written to provide operators of GE High Speed Reciprocating compressors with the details on the Fulfo oil pressure regulating valves (PRV), see Figure #1. These valves are standard equipment on A.B, D, DS, E, ES, F, FS frames and are used as an oil backpressure control device. The PRV valve is not considered a relief valve, since in normal operation the PRV valve is open, bypassing cl. The PRV is typically adjusted during normal operating conditions to maintain consistent oil supply pressure to the #1 main bearing connection. Since the #1 main bearing oll supply connection is furthest from the ‘pump, itis recommended that the Packager install alow oil pressure shutdown switch at this iocation. ‘With this arrangement, operation with inadequate oil pressure and flow to the bearings can be prevented. Proper operation of the PRV is necessary for correct oil system operation during cold and normal {hot) operating conditions, therefore proper installation, maintenance, and setting of the pressure regulating valve is important vo coencsce ou sire aaa oct vase acct Hants ice re Hea ee | Fr-4 {QI lo SORE BFE Figure #1: Typical Compressor Frame Lubrication Schematic * cooler ncrmaly suposed by GE on A 8, OS, ES, and FS frames 10F3 ‘Compressor NowsioN 05-000eed eaee gee geee ed eaee Seeger gece geese gE SSPEC ATT @ GE alah ccaeae Oil & Gas : een compressor (aws APPLICATION ‘The Futlo “V" Series valves used on GE Oil & Gas compressors are %4", 3/4” or 1" and operate efficiently ‘with compressor lubricating oll of any viscosity, controling pressures between 30 and 100 psig. The PRV has a cast iron body with threaded FNPT inlet/outlet connections, a hardened steel piston & an adjustable spring range of 30%# to 100# (see Figure #2), Pressure Regulating Valve Partit NPT Size & Spring Rating Compressor Mode! ‘BW-PS- 1284 3 ENPT, 30# to 1008 ‘ASS2/A354 DS504/604 4W-PS-1284 2314" FNPT, 30# to 1008 ESIFS 504/604/704 ESIFS 06/606/706 G50-1534 T-FNPT, 308 to 100% ALB Frames. ‘SW-PS-1284 TFNPT, 30# to 100# DS502/602 ESiFS 02/602/702 INSTALLATION Prive cat mtd nan soso, bu arent te aay os par cf conpesa fare Sum Te Ps seugned orice oaresolvoue pertcibawn an Gotan rend Sats ol etches Te ake sured connons pees ese Soran rte posse The vales dushrge e's seed oss ike cnereoes Foe su bets @© ihrer asian seston Toa hep omnes ceanvoren omens tave oon ‘SETTING VALVES GE initially sets the unit's PRV vaive during its factory test run. The PRV utilizes a manual adjusted, spring- loaded piston to control cil pressure between throughout the unit's operating speed range, Since higher oll pressures occur during cold startups when the cil is cold and viscous, itis common that the oil supply pressure must be adjusted during normal (hot) operation. An adjustment to the PRV's spring-loaded piston regulates cil flow to the frame sump by means of observed oll pressure at the #1 main bearing, ‘The compressor “Startup Checklist” recommends field adjustment, during startup and normal compressor ‘operations, to maintain the unit's cil supply pressure within GE specifications. PRVs are not designed to be ‘a positive shut-off, and will bypass a minimal amount of oil in operation even with the spring is fully tightened, Turning the adjustment screw clockwise (into the valve body) increases spring tension, which also increases system pressure. Turning the adjustment screw counter-clockwise (out of the valve body) {decreases spring tension, which also decreases system pressure. The adjustment screw has a locknut to hhold the spring tension setting. MAINTENANCE PRV valves provide reliable ‘chatter-ree" operation when the system is free of abrasives and foreign materials. Since the piston fits loosely inthe valve body, small debris can become trapped between the piston and valve body. if you suspect the piston is stuck, shutdown the compressor and disassemble the PRV. Inspection of the piston and cylinder body will show whether trapped debris or scoring has caused the piston to *hang up”. The loose fiting piston should move freely within the valve body. Minor scratches ‘or scoring can be polished out. Major intemal component damage requires replacement of the entire valve. ‘The valve should be disassembled and inspected annually as part of the compressor’s scheduled e maintenance program. aon Compressor NewsiCN 06-009GE 1535 West Loop Nort, Suite €00 Oil & Gas Houston, Texas 77027 USA Ware SVWNTS) compressor 1: 1d Parts lustration TYPICAL DISASSEMBLY OF STANDARD PRESSURE REGULATING VALVE Caution: Shutdown compressor before disassembling this valve. Failure to relieve oil pressure prior to disassembly can result in personal injury. Disassembly Procedure Refer to Figure #2 for exploded pars illustration Remove cap "B” Remove O-Ring “E” Remove lock nut "F* Remove adjusting screw *C* Remove retainer ‘D" Remove spring "G* Remove piston "I" Remove stop ring "H" (Not Recommended - Special tooling is required to install new stop ring.) eNopren= Inspection Inspect valve bore and piston for wear and scoring. Replace broken or damaged parts as required. Clean all parts thoroughly and re-assemble by reversing the above procedure. Re-assembly Procedure 1. Reassemble valve by reversing the above disassembly procedure Please call GE Oil & Gas with any questions you may have. 24 Hour Technical Assistance: 832-978-9760 24 Hour OEM Replacement Parts: 1-800-727-8443 (Phone) 1-513-774-2925 (Fax) Parts Web Page: woww partsdirect.ge.com 30F3 Compressor NewsiCn 06.008GE 1333 West Loop North, Suite 800 ro Houston, Texas 77027 USA. oi eee compressor [ews Subject: Balance Weight Configurator Group: Frame Number: 06-011 ‘Sub Group: Maintenance Date: 06 ‘ies: D: Proper balancing of opposing compressor throws is essential for safe and reliable operation, When compressors are reconfigured, there will often be a change in the weight of the running gear components (Giston, piston rod, crosshead). In these instances, the opposing compressor throws must be re-balanced, To assist with proper balance weight selection, the GE High Speed reciprocating compressor Technical Data CD includes an Excel too! designed to assist with proper balance weight selection (bill of material or SOM). This tool is titled “DS ES FS balance weight configurator Version C.xls”. This tool includes. instructions on its use. Attached is an example the balance input and output worksheets. Items of Importance: ‘+ To avoid confusion conceming what constitutes individual items or pairs/sets, please note that ‘when ordering a quantity of (1) each of crosshead pin weights, you will receive two (2) pieces (1 pair). When installing crosshead pin weights, the weighted caps should be installed on each side. of the crosshead pin. Ref PIN 1-026511 for the DS frame, and 2.027073 for ESIFS series frame. + Weight rings and weight ring adapters, are designed to form a complete citcle, and are sold as a ring set consisting of two pieces. Order quantity of one each consists of these two “half circle steel pieces.) Ref PIN _X_-026510 for weight rings, and 1-102903 for weight ring adapters. I'you have any questions regarding this tool, or balancing your compressor, refer the operations and ‘maintenance manual, o* contact the Technical Assistance hallin listed below 24 Hour Technical Assistance: 832-978-9780 | 24 Hour OEM Replacement Parts; 1-800-727-8443 (Phone) 1-513-774-2925 (Fax) worw partscirect ge. Parts Web Page: TOF 2 compressor NewsiCN 06-011GE 11535 West Loop North, Suite 600 Houston, Texas 77027 USA. Oil & Gas compressor (awe Throw Location - DS, ES, FS Compressor Frames Le Lele ema me a Cl os.esrs A,DS, £5, FS Models ES & FS Models, freon Balance Weight Configurator Input Sheet GE HIGH SPEED RECIPROCATING GAS COMPRESSORS, Buses vRrons ea Balance Weight Configurator Ouput Sheet @ 20F2 Ny (Compressor NowsiCN 06-011GE 1833 West Loop North, Suite 800 Houston, Texas 77027 USA. Oil & Gas eed compressor [)@./s Subject: 3-Piece Piston Design Upgrade Group: 06 Cylinders Number: 06-012, revi Sub Group: “03 Pistons” May 200: ies: Di 'S),F(S) Seri 'n 2006 GE Oil and Gas upgraded its 10° to 16.5" piston design ('03 series), which is used in the 98 series cylinders installed on the D(S), €(S), F(S) and SHMB frames. Effective June '08, the 6.75" to 9.75" piston Fange will be upgraded to the new '03 series design, see Table 1. This piston upgrade affects the compressor's operational envelope, interchangeability, maintenance procedures (piston rut torque), and compressor throw balancing. The cylinder nameplate tag (size line) will identify these '06 cylinders, which Row come with the upgraded '03 series pistons, see Figure 4 Piston Upgrade Summary: Figure 1: “89/95 Series” Piston Figure 2: ‘The upgraded three-piece piston combinations ('03 series) are listed in Table #1. The *03 Series” piston ‘esign can be used with the legacy (D, €, F) running gear or the uprated (DS, ES, FS) running gear “03 Series” Piston Upgrade [if Operation: Cylintler Bors Ranged (iniches) Sama] MAWAIOSII) | Double Acting 6.76, 7.00, 7.25, 7.50, 7.75, 8.25 1800 Double Acting 8.00, 8.50, 8.00, 8.50, 9.75, "1800 Double Acting 10.0, 10.26, 10.5, 10.75, 110, 1725, 1175 1250 Double Acting 41.50. 11.75, 12.0, 125.12 76, 13.0 13.5, 1375, 1426] 800 Double Acting 14.0, 14.25, 145. 15.0 635 Double Acting 15.5, 16.0, 165 635 Pipeline Applications AHR SOK Bre (a) RE MAW Ipal 9.76, 10.0, 10.25, 10.6, 10.75, 11.0. 14.25, 1250 Doubie Acting 11.00, 11.26, 11.60, 11.75, 12.00, 1680 Ductile iron ‘Table #1: '06 Series Cylinder Bores and MAWP 10F9 Compressor NeweICK 06-012, eviG E 1333 West Loop North, Suite 800 Houston, Texas 77027 USA. Oil & Gas compressor (ows ITEMS OF IMPORTANCE: Intorchangeability The “03 Series’ piston assembly can be retrofit to existing “95 Series” cylinders, Both ‘95 and 03 pistons ‘can be mounting on the same piston rod with the same piston nut. However, the individual components of the 03 and '95 pistons are NOT interchangeable Piston Rod NutTorque and piston rod torque stamping ‘The new piston assemblies require a higher torque value than the 95 series pistons, see Table 2 below. When retrofitting “03 Series” pistons, remove the old torque value stamped on the piston rod end, ‘The “03 Series” piston rods will not have this torque value. The “03 Series" piston rod assembles will have the torque values stamped on the piston face. Torque values can also be obtained from the operator's, ‘manual. Below is a table of torque values for the D(S)/E(S)F(S) frames. k =! hes) i Dy) [2.00 | 1400-1500 | 2450-2600 E(S) 2.25 | 2600-2700 | 3250-3300 FS) 2.50 _- | 2600-2700 | 3250-3300 Table 2: “03 Series” Piston Nut - torque valu: Note: Ensure that Molykote P-37® (or equivalent anti-seize lubricant) is used ‘on the piston rod threads, piston rod pilots, and piston nut face when assembling the components, Refer to Figure #3 for locations. Apply Molycoat P-37@ on piston rod pilot diameters and piston rod threads, nut & bushing faces igure #3: Assembly Instructions 20F9 ‘Compressor Nows\CN 06-012, revGE 11333 West Loop North, Suite 800 Houston, Texas 77027 USA Oil & Gas compressor [ows ITEMS OF IMPORTANCE CONT'D: Reciprocating Weights ‘The increased reciprocating weights associated withthe '03 Series pistons may exceed current guidelines for rod load. crank pin load, and cross head reversals. In these sitvalions, the operating erwvelope must be revalidated, Extra consideration should be given to any cylinder running in a partly loaded o° “blow through’ cylinder configuration. Refer to CN 08-014 (Operational speed tits) for addtional details on speed imitations of unloaded cylinders. There's no change in frame rod load ratings associated with this Piston upgrade. Proper Balancing Proper balancing of the opposing compressor throws is critical for safe and smooth operation. The upgraded piston assembly is slightly heavier. Any change in reciprocating weight must be accounted for when balancing the frame. The rec/procating balancing procedure is in the DS, ES, FS Frame operator's ‘manual. Norrnally, the reciprocating components (piston rod assembly, crosshead, balancing weights and hardware) are weighed to calculate any required balance hardware adjustments. Conversely, rotating ‘components (connecting rod assembly and crosshead pin) are normally not included in this reciprocating balance calculation. To facilitate proper reciprocating weight adjustment, refer to Compressor News CN 06-011 (Balance weight calculator and balance tool). The “03 Series” components and their estimated weights can be found on table #5. The ESTIMATED weight cifference between the "95 Series” to "03 Series" pistons can be found in table #6, Identification of Cylinders with ‘03 Series Pistons ‘The upgraded cylinders will have a name plate to identify the new piston design as shown in Figure #4. In addition, cylinders with SIN 95622854, 9562286, and 9562675 will have the 03 series pistons but will NOT have the new cylinder tag format, Piston Identification New Pistons will have the words "03 Series" stamped on the face of the piston halves for easy identification. Part numbers are described in Table #3 and Table #4. iston Bushings For '03 piston sizes 6.75"to 7.75” & 8.25” Existing crank-end and head-end bushings are used with the new piston halves. For '03 piston sizes 8.00” & 8.50"to 16.50” Ensure that the new crank-end and head-end bushings are used with the new piston halves. Do NOT use the old bushing part number with the "03 Series" pistons. New bushings must, be used 24 Hour Technical Assistance: 832-978-9780 24 Hour OEM Replacement Parts: 1-866-565-2903 (Phone) 1-513-774-4018 (Fax) Parts Web Page wait partssupercenter com | eee Seer tvee ttaeeccs| 30F9 Compressor NewsiCN 06-012, re71GE Oil & Gas 11333 West Loop North, Suite 800 Houston, Texas 77027 USA. compressor [))20s Tables and Figure: “03 Series” Piston, Ring Carrier & Piston Ring Part Numbers [ERDSOESOR SO] OTre0 a te ETOIETO MSR Sm PIStOR SPiston eiCarrieg. iis ¥ CaiFiek | aPistOn3]| :Carrier!/ st Rings (aRPIN EH PEPIN SPINS: SPIN SAN SS] See PIN [6-104631 [6- 104625) '6-104632 6.104629) [6-104633 [6-104629)2044-100067| 7104631 | 1-104629} 1.104632] 1-104629] 4104633] 1-104629|2045-100067] '5-104631 [5-104829) 5-104632|5-104629) '5-104633 [5-104629| 2046-100067| 2-104631]2-104629 2-104632 |2-104629| 2-104633 [2-104629|2047-100067| 3104631 |3-104629) '3-104632 [3-104629) '3-104633 /3-104629]2048-100067| -4-104631 [4-104629) 4104632 |4-104629) [4-104633 4-104629] 2050-1 00067] 7-104638 | 7-104630) 7-404638]|7-104630} /7-104640 |7-104630]|2049-100057| 7.104638 | 1-104830, 1.104639] 1-104630 4104640] 1-104630]2051-100067| [5-104638/5-104830) 5-104639]/5-104630| '5-104640 [5-104630]2052-700067| 2-104636 |2-104639) 2-104639 |2-104630) 2-104540 |2-104630]2053-100067| |4-104636 4.104630) 4-104639 | 4-104630) 4104640 |4-104830|2054-100067| 3-104638/3-104630) 3104639] 3-104630} [3-104840|3-104830|2056- 100067, [6.104638 |6-104630 6-104639/6-104630) [6-104640 |6-104630|2056-100067, 4-103548 | 1-103551 4103549] 1103561 1-103560]|1-103551}2057-100067] 5.103548 |5-103551 '5-103549 |5-103551 '5-103550|5-103551|2058-100067| '2-103548 |2-103551 [2-103549|2-103551 2-103550|2-103551]2059-100067| [6-103648 [6.103551 (6-103549/6-103551 16-103650 6-103551|2060-100067; 103548] 3-103651 3-103549| 3-103551 3.403550 [3-103551]20611-100067| 4-103548|4-103551 4103549] 4-103551 4-103550|4-103551]2082-100067| '5-103430] 5-103408| 5-103476|5-103408 '5-103407 [5-103408)2063-100067| 7-103430 |7-103408| 7103416 |7-103408 7-103407 |7-103408)2064-100067| 1-103430| #103408 1-103416 | 1-103408 1-103407 |1-103406]2065-100067| [2-103430]2-103408) 2-103416|2-103408; [2-103407 |2-103408]2067-100067| [6-103430]6-103408| [6-103416[6-103408| [5-103407 [6-103408| 2068-100067| 3-103430|3-103408, '3-103416/3-103408] [3-103407 |3-103408|2069-100067| 4-103430|4-103408, /4-103416] 4.103408; '4-103407 [4-103408|207 1-100067| -103430| 8-103408) 6-103416|8-103408} /8-103407 [8-103408|2072-100067| 4-103531[1-103534] 1103532] 1-103534| 4-103533] 1-103534]2073-100067| 7.103531 |7-103534 7-403532|7-103534 '7-103535 |7-103534)2074-100067| 14.50_|2-103531|2-103534 2-103532|2-103534) [2-103533 2-103534]2078-100067| 15.00 |3-103631] 3.103534) 3-103592| 3-103534| 3-103533 |3-103634|2077-100067| 15.80 _[4-103531]4-103534 [4-103532|4-103534| 4-103533 [4-103534|2079-100087| 16.00 |5-103531|6-103534 '5-103532|5-103534 '5-103533|5-103534)2081-100067| 16.50_[6-103631]6-103534 [6.103532 ]6-103534 6-103533/6-193534)2083-100067| 40F9 Compressor NowsiGN 06-012, rev!@ cE 1533 vest cop ort sue eto Houston Texos 77027 USA. Oil & Gas compressor (ews Ne #4: 6.75"-7.75", 8.25” “03 Series” Bushing Part Number BUSHING, PISTON. CE D50/60 4-011386 BUSHING, PISTON, HE E/F 50/60/70. 4011387 BUSHING, PISTON, CE E/F 50/60/70 ¥ 13sSeri A INTE 3-011388 4.103521 3.011389 4.103522 4-011385 4-103417___ BUSHING, 4.011387 4103418 BUSHING, PISTON, CE E/F 50/60/70 SOF Compressor New\CN 06-012, 071@ ce iss west Loop Nort, sue 200 Gino tear merase Oil & Gas compressor (ows. Table #6: “03 Series” Pistons - DS Component Estimated Weights, Ibs [CE HEY 7: Stroke. | sBushings Piston Ecombiied 7170 170 1170 77 1.70 1.70 1738 788 i738 788 a7 88 376 788 386 788 aad 7788 e puss aisarcie Peay aoa | 908 1012 312 78.1 ea 788 10 227 305 a4 1788 1" 342 2 “34 788 wi 357 335 445 178 [es [aT 34 an 456 17.88 134 38) 326 066 788 2 363 34 a6 i788 22 0 a6 | Es 768 1234 208 a7. wu 17.68 2 “7 393 522 1788 ne 438 41 544 1768 1334 “4s 2 552 17.00 rr 156 rn 56.1 17.88 a a 456 aa 62 1788 1412 a7 45 581 17.98 16 49.8 ara eo 1788 Te12 24 482 626 1788 6 sad S15. 647 1788 16.12 567, 537 669) sz08 | sors Compressor NewsiCN 06-012, rov1GE Oil & Gas compressor (\ “03 Se 11333 West Loop North, Suite 800 Houston, Texas 77027 USA. aNVVIC SWS i do Tica ESS O38 ESS 7, ESS Ti ESS Tie ESS [Tae ESS ei ESS 3 ESS oie ESS Baia ESS 3 ESS Sim ESS 312, 785, 245 21s 38. 188. ESS aaa 302 259. 26. 286, 168 ESFS “2 2B 23 zap see 88 ESS Toa 297 277 256 404 165 ESS 1012. 312 234 259) a1 185 ESES 109 327 305) 28.4 224 186. ESS 1" 342 32 208 4 185. ESES TET 357 335 313 45 186 ESES 112 34 312 239) 458 7166 ESS a3 ue 26 203) 485 165, ESS 12 363 34 37) ara 166 ESFS 1242 40 378 352 60 166. ESFS 12314 409) 315; 6 om 166 ESES 8 417 309) 365 522 166 ESS B12 436 ‘41 385 sa 768. ESS 1904 Prey 42 394 552 165 ESS 4 | 456. 2 404 on 168. ESS 1a va 456 a4 a1 572. 168 ESS 112 ary 45 223 68.4 166 ESS 5 298 a4 443 eo 165 ESS ee 224 402 464 026 166 ESS 16 e44 51s 486 ea. 165 ses [tev | eer [sar | so | eso ss ToF9 ‘Compressor NewetON 06-012, v1GE 4533 West Loop North, Suite €00 Houston, Texas 77027 USA. Oil & Gas compressor (ews Table #8: Estimated Weight Difference - 95 Series to 03 Series Pistons Note: Weights are estimates only. Exact weights should be determined by weighing individual components. -'03'Seriés y-"95 Series’ Estiriatod Total prston Weight Oitstence Iba: Pistoralves? Ring Cather, abd Bushings) # esc s meme ESAS: fs wg a] se Sea 7080 | 1040 | 10.80 i140 [i120 | 11-40 1220 | 1200 | 1970 137 | 180] 990 Estimated wight diferences are se [uo | et es 2270] 23.80] 2270] 79.00 jonas 23.00} 2450 | 2250} 2180 Delta 220 go. 23.10| 2480 | 23.60 | 21-70 2330_| 25.20] 22.80 | 21-60 Therefore a posive 73.40 25.80 —| 22.90 | 160 value shows e weight 2360_| 26.20 | 93.10 p80 increase ftom the "85 23.40 [26.80 —| 2830] >t 8 series" 1658 [1140 | 1600 | 19.30 1763 [12.30 | 17.10 | 20 50 1848 [13.10 | 17.90 | 21.30 1958_| 1410 | 1800 | 20.80 20.78 [1520 | 2020] 23.90. z203 | 16.30 | 2150 | 25.40 16.98_| 900 | 14011670 17.08 | 890_| 1680 | 16.90 2038 | 1230 | 18.80] 20.10 2as8_| 1620 | 2400 | 2430] 23.08 | 1740 | 2340 | 2.60 2528 | 1640 | 2470] 2500 2548 | 1670 | 24.90} 25.20 2598 | i660 | 25.40] 2870 703 | 020] 650 13.40 Z| 0.30 | ~660 13:50 718 | 030 | e690] 13,70 a6 | 050 720 | 75.10 1512 | 128 | a8 | 070 800 | 15.76 E 16__| 097 [678 | 180 | 620 14-10 a612 | 108 [e989 | 050 | 8.40 1670 sore Compressor NewetiCN 06-012, 1| 1555 West Lop North it o0 7 GE Towson Tous Moar Use Oil & Gas compressor (2. Cylinder Tag 06 Designates. the 08 series cylinder with the new '03 series piston design. 90F9 @ ‘Compressor NoweiCN 06-012, covt002851 GE oe Oil & Gas ~ : compressor [aw Subject: Operating Limits ‘Group: All Number: 06-014 Sub Group: All ite: 6-May-21 ‘ies: In recent years, GE Oil & Gas has introduced a variety of compressor upgrades. These changes may affect the speed, pressure, and temperature limitations of the compressors. Always make certain that you are using the most recent version of our performance software. Also, due to the variely of components now available for GE frames (including legacy Chicago Pneumatic, Energy Industries, and Gemini frames), itis important to verity the compressor model, as well as the piston and rod weights. Upgraded ‘components can have significantly different weights when compared to legacy parts, which can change ‘compressor performance limitations, lems of importance: * Always use the most current version of the performance software. If you are not sure you have the latest version of the software. contact the GE technical services hotline fora copy of the latest, Tech CD. * The default data within the compressor performance program will nt reflect changes to meet specific performance requirements. It is the users’ responsibility to adjust the peormance rogram to reflect the specific configuration. The accuracy of the performance program depends ‘upon the input of data for: © Allperformance points, including start up. Piston rod assembly and crosshead weights Low it valve areas. Valve Spacers Variable Volume Clearance Pocket Setting Clearance Rings (90 series cylinders) Cylinder action (HE unloaded, CE unloaded, Blow Through, and Double Acting) © Cylinder locations ‘* The Technical Data CD includes instructions on how to input of these variables into the performance software. For assistance or questions related to this task, contact the GE technical services hatin, ‘+ The weights of the compressor running gear components have a direct relationship upon the inertial loads within the compressor. During start up, no load, and partial load operation, a thorough understand of the inertial loads is important (refer to CN 06-007). GE has introduced a variety of upgraded components that are interchangeable with existing frames and cylinders, for safe and reliable operation, it's important to setthe operating limits using the actual weights of the Compressor and piston rods. The performance software begins with “nominal weights, actual weights can found on the GE shop documentation shipped with the compressor, as well as, ‘stamped’ on the piston rod, or piston half, or assembled weights as measured in the field, o00000 | 24 Hour Technical Assistance "632.878.9780 24 Hour OEM Replacement Parts: 1-800-727-8443 (Phone) 1-513-774-2925 (Fax) Parts Web Page: new partsdirect.ge.com i Hora Compressor NewatCn 06-014002851 GE 1533 West Loop North, Suite 800 Houston, Texos 77027 USA. OIL & GAS NAIVE compressor (jaws Subject: Spacer, Valve Group: Cylinder Number: 07-001, rev 2 ‘Sub Group: Cover & Holder Date: _4Jan, 2008 __—__—Series: __89, 95, 06, 07, PL ‘As part of our process to improve operational fexibiliy, GE Oil and Gas provides valve spocers for its product line, This updoted Compressor News lsts currently available spocers for the 83, 95,06. 07 and PL (pipeline) cinder bodies, in the 4.5" through 21” cylinder range, These are cylinders, barrel & conical type, used on DS/D, SIE, FS/F and SHMB compressor frames. Use of these spacers will chonge the eylinder' internal fixed leorance volume. Any clecrance change will affect the unit's horsepower, flow, and inter-stage pressures. itis ‘mportont that all clearance changes and corresponding compression affects ore accounted for using GE's most cutrent compressor performance prediction program. Failure to do so may resul in compressor overload. Compressor valves ore normally designed to be close to the cylinder bore, thus minimizing « cyiinder's inherent fixed clearonce volume, (see attoched IL 1394 & IL2001, A valve spacer is an optional clearance device used to physically relocate the vaive in its port further away from the cylinder bore which wil increase a cylinders fixed Clearance volume. As shown in Figures #1 & #2, the valve spacer and valve holder set ore used to replace the standard valve and holder set. Tables #1 6 #2 list the additional fixed clearance available by use of these. devices. Another common method to odd a small amount of fixed cylinder clearance volume is to use the {HE] head end ‘ond ICE! crank end indictor ports, Fo minimize fixed clearance, a long indicator plug is normally provided in these cylinder ports. An indicator valve {Keinexr), when installed, is used to access the cylinder for performonce evaluation. The indicator port plug can be replaced wath a short pipe plug. The attached list provides the volume ‘added for each indicator plug replaced. There ore.a maximum of four lé} indicator plugs per cylinder, two HE and two CE. The port number for a standord NPT steel plug is 1019. ITEMS OF IMPORTANCE When valve spacers are used. two vaive seat gaskets are required for each spacer (see Figures #1 & #2). Aseat {gasket is placed on each side of the valve spacer for proper sealing. 'tis recommended thot cylinders with additional fixed clearance devices installed be identified by on external means, Compressor performance cannot be accurately predicted unless all addtional clearance volume is token into eccount including the quantity and type of spacer or plug, In cases where voive spacers are no longer needed itis highly recommended that you do NOT place both the valve spacer and holder above the valve. In these situations GE recommends the re-installation of the valve's ‘stondard holder. Stacking the valve spacer & its holder obiove the valve con cause gas flow restriction & and ‘component damage. you have any questions in regords to this topic, or need assistance checking the performance of your ‘compressor please contact the GE High Speed Reciprocating Compressor technical assistance phone number listed below. 24 Hour Technical Assistance. 832-978-9780 (Phone) _ 24 Hour Parts: 1-866-565-2303 (Phone) 1-513-774-4018 (Fax) Parts Webpage: www partsdirect. ge.com Emoil address for replacement parts inquiries: olgasteambox@ge,com TOFS compeessoe Newson 07-001 rev2GE 1333 West Loop North, Suite 800 Houston, Texas 77027 USA. OIL & GAS compressor (0 ‘ 95 & 06 Series Cylinders 89 SERIES CYLINDER WITH VALVE COVER WITH VALVE Cover O-RING SEAL CRUSH GASKET SEAL VALVE WITHOUT SPACER : VALVE WITHOUT SPACER STANDARD) i ¢ STANDARD) A VALE COVER Wa z “y LOTMA cove cover osteve corte Gagne st ¥6 Hove R— aL noveer Pe aL eres! «Shangasor om caser VALVE WITH SPACER : VALVE WITH SPACER caTOR rv OPTIONAL FOR ADDED CLEARANCE? * {OPTIONAL FOR ADDED CLEARANCE) NOTE: VALUE SPACER SHOWN WH TH SEALING BASKETS PROPERLY INSTALLED 11394 GENERAL ARRANGEMENT tv. awe TYPICAL CYLINDER WITH AND WITHOUT VALVE SPACERS Figured {394 Typical “Barrel cylin 20F5 Compressor NewsiCN 07-001 va @GE 11833 West Loop North, Suite 800 Houston, Texos 7027 USA OIL & GAS compressor (awe 89 8 07 TYPICAL CONICAL CYLINDER WITH VALVE COVER CRUSH GASKET SEAL cau ca |p ci meH0 Exo VALVES WITH SPACER (OPTIONAL FOR ADDED CLEARANCE) NOTE: VALVE SPACER SHONT HLTH SEALING ASHES PROPERLY THSTALLED sontd Genie NOTE: 141 - 1" MPT INDICATOR PLUGS (2 HE & 2 CED ER CHLINOEE, ORLY OnE SET OF HHDICATOR PLUG. SHON 2001 89 AND 07 SERIES meet TYPICAL CONICAL CYLINDER WITH AND WITHOUT VALVE SPACERS Fis 2 ical “Conical” Type Cylinders SOF S Compressor News\CN 07-001 rev2GE OIL & GAS ‘Suction Valve Spacer/Halder Cvlinder Shor Bodys | vane | spacer added vane | Number | valve | indicator Bore Sze, | Depth, | Spacer | clearance | Holder | Holder | Suction | Seat | plug added Range mam | Inches | Port Number | Volume | Depth port | valves’ | Gosket | Volume ‘ond Winch | inches | Number | cylinder | Port # | —tineh!) Type wear 0 Wi 7 330 | Sor aae Sse 7 ora9 | 179 | o3re | ro

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