GE Power Systems Oil & Gas B SERIES OPERATING INSTRUCTIONS Gas Compressors 2000TO OUR CUSTOMER: In preparing the contents of this Instruction Manual, we have endeavored to provide you the necessary information to understand, install and maintain your compressor. Our intention is to support you in every phase of preparation and operation with respect to simplification, ease and safety. However, with the rapid growth of technology, the range of compressor applications are ever increasing. In any area of question, your GEMINI representative or distributor is always there to assist and advise you in any way possible. Also, your inquiries and suggestions are encouraged as they serve greatly to improve communication through your GEMINI representative or distributor. Gemini Gas Compressors reserves the right to alter or improve the design or construction of its machinery as described herein and to furnish it, when so altered, without reference to the illustrations in this manual. INTRODUCTION TO MANUALS: WARNING: Every GEMINI compressor is provided with Instruction and Parts Manuals. The Instruction Manual contains vital information for the safe use and efficient operation of the compressor. READ THE INSTRUCTION MANUAL CAREFULLY BEFORE STARTING ‘THE UNIT. Failure to adhere to the instructions could result in serious bodily injury or property damage Manuals are forwarded to the distributor as soon as possible so that the information in the Instruction Manual can be thoroughly reviewed before installation is started. In addition, all necessary drawings and illustrations are included at the same time. In forwarding manuals and drawings, much consideration is given to their destination. It is important that this material be delivered to the responsible personnel. Unless otherwise specified, the standard procedure is to provide the manuals to the distributor for personal transmittal to the ‘owner. In this way, the material can be directed to a specific person and the transmittal letter will provide a detailed record for the file Keep all manuals and drawings in a readily available location, near the actual unit if possible, As soon as the machine arrives, check the nameplates and FILL IN THE INFORMATION IN THE SPACES PROVIDED ON THE ATTACHED COMPRESSOR INFORMATION SHEET. It is very important that this information be referred to when discussing the compressor, and it MUST be included when ordering parts or making warranty claims, All parts orders and claims should be made through your local GEMINI distributor. They can also supply you with replacement copies of your manuals, if required.COMPRESSOR INFORMATION FRAME: MODEL. SER. NO. CYLINDERS: BORE. SER. NO. BORE SER. NO. NOTES: START-UP DATE: COMPANY:.Stroke lin] (Mina) (Min/Max) Cylinder Bas Soarts00 | —S0571080 | 600 Bas 306/1300_| 67571125 00 | 25,000_[ 25,000 [45-190 B50 30 9071200 | 75071000 300 | 30,000[_ 30,000 | 45-190 Notes: Tenath Wax Approx 1. Multiply clearances by 1.11 for BAS and 1.43 Width Gin) | Weight in) for BSS. Bo 739.1 | 6,000-7,500 2, Length measured from drive end of crankshaft to pump 3. Width measured between outer edges of extended variable clearance heads 4, All compressors include two double acting cylinders to be used in | or 2 stages of compression Cylinder Data B50 Clearance (See Nowe) Gi Boe | MAWP | Valves Flange Minimum VC Head Voriead Gn) | sic) | @y) Conn. Inherent Per Turn Max Oy (Coot HE) | Coof Hie) 430 2000 7 315008 224 3a 26.67 3.00 1600 4 39007 BGS 1.80 21.60 350 1600 4 39008 20.00 335 40.17 575 1600 4 35008 17.76 3.06 3675 6.00 1315 a F-65008 20.30 281 33.75 630 1315 4 F-65007 14.44 2.40 28.76 [70 i315 4 73.29 2.07 2480 7.50 1315 4 19.62 320 38.40 8.00 1315 a C6008 1620 281 BATS 830 1315 4 ‘66008 15.12 2.49 29.90 9.00 1250 4 56008 16.75 2a 26.67 9:50 1100 4 o°-6008 15.78 3.53 35 10.00 1100 a F-600H 15.17 3:20 38.40 10:50, 600 8 F408 18.12 2.30 25.02 11.00 350) & e408 16.46 264 26.45 1130 330) 5 o-a004 15.16 2.42 2420 12.00 500 = C=O 13.53 222 22.22 12.50 500 € C=4008 12.27 2.05 20.48 13.50 350 = 3007 1287 3.63 130.62 14.00 350) 5 37-3007 i199 337 121.45 14.50 350 s 373007 i129 3.15 T1322 18.00 150 2 T2150 18.95 3.95 OT16 18.50 150) 12 TP=IS0F 1794 3.74 G58 13.00) 150) 2 12150 17.02 335 | 6028INTRODUCTION GEMINI B-SERIES BALANCED OPPOSED RECIPROCATING COMPRESSORS GENERAL This instruction book is intended to assist those responsible for the proper installation, operation and maintenance of the unit. It is absolutely essential that the unit and its driving equipment be properly installed, aligned and operated Practical considerations require that some variation from the average design and data given in this book may be expected in any one unit, However, in all cases, limits, specifications, and recommendations are to be per information contained in SECTION 5. The responsibility for the correct installation and alignment of the unit and its elements, lies in the hands of the persons making the installation. It is the responsibility of the owner to insure that qualified personnel are used to carry out the initial start-up of the unit. The following page is a list and description of the standard features and components that make up the complete compressor assembly:GEM STANDARD EQUIPMENT ~G40 Cast Iron Enclosed, Oil and Dust Tight Compressor Frame. -One Piece 4140 Forged Steel Crankshaft -Precision Insert Type, Steel Backed Tri-Metal Main Bearings. Precision Insert Type, Steel Backed Tri-Metal Rod Bearings. -Ductile Iron Connecting Rods. Floating Type 4140 Hardened Steel Crosshead Pin, -Box Type, Ductile Iron, Babbitt Faced Crossheads. -C95400 Aluminum Bronze Crosshead and Con Rod Bushings. -One Piece Ductile Iron Crosshead Guide. -Full Flow Spin-On Type Oil Filter. -Gear Type Oil Pump for Full Pressure Lubrication to Running Gear and Crosshead Guides, -Mechanical Force Feed Lubricator with Filter, No-Flow Shutdown, Distribution Block, Pin Type Indicators, Check Valves and Stainless Stee! Tubing for Packing and Upper & ‘Lower Cylinder Lubrication. Bulls Eye Type Oil Level Gauge on Frame Rear Cover. - 4140 Alloy Steel Piston Rods. -Teflon Pa ig and Piston Rings. ~Cast Iron and/or hardcoated Aluminum Pistons. High Efficiency, Concentric Ring (Peek) Valves. -Ductile Iron Non-Cooled Cylinders. Optional — Auxiliary API distance pieces. GEMINI also offers a wide range of optional equipment, designed to meet the many varied needs of the industry. To check which of these options has been supplied with your unit, please contact your GEMINI distributor. We at GEMINI would like to take this opportunity to thank you for choosing our compressor for your needs. We trust that it will give you many years of satisfactory service.SECTION 1 OPERATING INSTRUCTIONS Before Starting Filling Sump... Priming Lube Oil System, Force Feed Lubrication Systems Starting . Running... Stopping. SECTION 2 FRAME AND PARTS General nn Connecting Rods... Removal. Crank Pin Bearing Crosshead Pin Bushing Installation Crosshead, Removal. Installation a Crankshaft and Bearings. Crankshaft Removal Bearings... Crankshaft Installation. Chain Driven Oil System Chain Adjustment noo. Replacing Chain Tensioner . Replacing Oil Pump and Lubricator Sprocket Replacing the Lubricator Pump Assembly. SECTION 3 ‘CYLINDERS Piston and Rod Removal... Disassembly... Reassembly. Installation Piston Rod Packing. Removal/Disassembly..... Reassembly/Installation . Identifying Packing Rings and a at 13 13 3B 13 4 16 18 19 19 2 2 22 22 a 25 25 26 26 26 “27 27 28 sn 28 30 130 ‘ABLE OF CONTENTS SECTION 3 (cont.) Valves. so 13 Removal... se B2 Valve Maintenance....nsernenee 34 Installation 34 Single Acting Hand Operated Variable Clearance Head.35 SECTION 4 FRAME LUBRICATION SYSTEM Description. Oil Changes Low Oil Pressure Shutdown ... General... FORCE FEED LUBRICATING SYSTEM... Lubricator Feed Adjustment 41 41 SECTIONS GENERAL DATA - B452 Serial No.’s C5895 & Lower Recommended Torque... 3 Operating Setting and Limits ........43 GENERAL DATA - All B Models Except Serial No.’s C5895 & Lower Recommended Torques... As Operating Settings and Limits......44 Clearances ~ All Models....ou45 oS 46 46 46 Ru Cylinder Clearance Lubrication Feed Rates. Sump Capacity....... Compressor Rotation SECTION 6 ‘Troubleshooting .. 2 ATFigure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 FIGURES LIST Typical Compressor Assembly Connecting Rod Crosshead.. Crankshaft Chain Driven Oil System Typical Piston Rod and Packing Assembly Packing Ring Identification Valve Chair and Valve Assembly. Hand Operated Variable Clearance Head Assembly Crankcase Oil System Cylinder and Rod Packing Lubrication System Page 12 14 W 19 23 28 31 33 36 42,SECTION 1 OPERATING INSTRUCTIONS, BEFORE STARTING Filling the Sump 1. Insure the drain valve is closed and that all crankcase openings are plugged or in use. Remove the filler cap in the top cover and pour oil into the compressor. 2. As you pour oil into the compressor, check the oil level gauge in the lower right side of the pump end cover. The oil level at start up should be near the top of the glass. DO NOT OVERFILL THE SUMP. After the machine is running, it may be necessary to add oil to bring the level to one-half the height of the leve! gauge, but it must never exceed, while running, two-thirds the height of the gauge. Do not add oil through the top fill connection while the unit is running 3. When the sump is filled to the proper level, replace the filler cap Priming the Lube Oil System ‘The GEMINI compressor MUST be equipped with an auxiliary oil pump which is to be used to prelubricate the running gear, prior to ALL starts. The pump may be manual, air/gas or electric driven. If the pump is air/gas or electric driven it may operate either manually or automatically, GEMINI recommends that some means be provided that will make prelubrication compulsory. ‘The main oil pump is mounted above the normal running oil level in the sump. Prime may be lost in the pump when the unit has not been operated for an extended period of time, It is recommended that, in this instance, you prime the system as though it were the initial startup to avoid damage to the pump gears and the rest of the running gear. Force Feed Lubrication System 1 Check the sight glass on the lubricator reservoir to insure that the reservoir is filled with oil. A suitable means of automatic oil level control must be installed in order to maintain the oil at the correct level. 2. For initial start-up, adjust the lubricator pump for maximum output by screwing the feed regulator sleeve, on the pump manual plunger, to the fully extended position. This will be reset to the normal position after the unit is running.3. The lubricator system was fully purged with oil at the factory and therefore should not require any further attention. For initial start-up, we do, however, recommend that the pump be operated manually and that while doing so each tubing connection at the check valves be ‘cracked ', and oil be allowed to flow out, then retighten the connection. This will insure that no air has entered the system after the unit was shipped from the factory. Air in the system can cause false shutdown indications and will interfere with the normal flow of oil. Ifthe system has been ‘opened up’ after it left the factory, then a full re-priming will be necessary. Remove the rupture disk plug and hook-up a hand priming pump. Pump oil through the system, bleed air from the high point between the No-Flow switch and the divider block, then, while loosening each tubing connection at the check valves, in turn, allow all air bubbles to escape and observe for a flow of oil with NO bubbles in it. Re-install the indicator and operate the lubricator pump manually for a few strokes, to insure that it is functioning normally. STARTING Consult the packager’s instructions for starting procedures SPECIAL NOTE OF CAUTIO ALL GEMINI COMPRESSOR CYLINDERS have a "Maximum Allowable Working Pressure (MAWP).” This MAWP and the hydrostatic test pressure is stamped on the nameplate of every GEMINI cylinder. It is the packager's responsibility to provide safety relief valves for every stage of compression in compliance with API 618 & LIP. BE SURE YOU HAVE CHECKED THE CYLINDER DESIGN LIMITATIONS AND COMPARED THEM WITH THE OPERATING CONDITIONS. RUNNING After running for about one hour, adjust the force feed lubricator rate to the ‘break-in’ rate shown on the cylinder lubrication sheet - SECTION 5, The lubricator pumping unit has a sight glass provided so that the lube rate may be observed by ‘drops per minute’. To adjust, screw the adjusting sleeve on the manual plunger - up to increase flow or down to decrease flow. When the proper rate is achieved tighten the locking nut. The rate may be left this way for approximately one week, then it should be reduced to the normal operating rate. When the machine is running be sure the oil level in the lubrication reservoir is maintaining minimum half way up the sight glass, You should always check the packager's specific data to determine the normal operating conditions for the unit. NO unit should be operated without having, on site, packager's operating curves and/or performance data sheets,STOPPING Consult packager's instructions for stopping procedures. “AUTION BEFORE STARTING A NEW COMPRESSOR, BE SURE YOU HAVE A "GEMINI" COMPRESSOR START-UP CHECK LIST.” FAILURE TO COMPLY WITH THE ITEMS ON THIS LIST MAY RESULT IN TERMINATION OF THE WARRANTY. 10SECTION 2 FRAME AND PARTS GENERAL (See Figure 1) The major components of the frame assembly are the crankcase, crankshaft and bearings, connecting rods, chain drive system, distance pieces/crosshead guides, crossheads, and crosshead wrist pins, A ‘rifle-drilled’ oil header runs the length of the crankcase. Drilled oil passages feed oil to the various components of the running gear. Removable end covers, top cover, crosshead guide covers, and distance piece covers provide generous access for inspecting and removal of internal components. The end and top covers are made of aluminum for easy handling, All covers are oil and dust sealed, When access covers are removed, care should be taken to insure that no foreign objects or dirt are allowed to enter the crankcase. As the machine is dismantled, gaskets and seals should be carefully examined before reuse. If in doubt, replace them. WE DO NOT RECOMMEND THE USE OF SILICONE SEALANTS. During major overhauls, fully drain and flush the crankcase. WARNING!!! BEFORE DOING INTERNAL MAINTENANCE ON ENGINE DRIVEN COMPRESSORS, REMOVE THE CENTER SECTION OF THE DRIVE COUPLING AND BE SURE THE STARTER AND FUEL GAS SUPPLIES ARE OFF AND LOCKED. ON ELECTRIC MOTOR DRIVEN COMPRESSORS, REMOVE THE CENTER SECTION OF THE DRIVE COUPLING AND INSURE THAT THE MANUAL SWITCH IS OFF. WARNINGU BEFORE STARTING ANY MAINTENANCE RELIEVE ALL PRESSURE FROM THE COMPRESSOR CYLINDERS AND PACKAGE PIPING. SHUT IN THE SYSTEM WITH POSITIVE SHUT-OFF VALVES, BOTH SUCTION AND DISCHARGE. REFER TO PACKAGER'S INSTRUCTIONS FOR COMPLETE VENTING PROCEDURES. 12Fro aews roise owove onan avon oaSl® ovassno’ awn 1S | a Or age ——— — 7 “\ T , © (©) somal olSeees ee ans sera FIGURE 1; TYPICAL COMPRESSOR ASSEMBLY 12FAILURE TO COMPLY WITH EITHER OF THE ABOVE WARNINGS MAY RESULT IN SERIOUS BODILY INJURY OR DEATH. SERIOUS DAMAGE MAY ALSO OCCUR TO THE MACHINE OR ITS COMPONENTS. CONNECTING RODS (See Figure 2) See General Instructions and appropriate warnings. 1, Remove the top cover from the crankcase and the side covers from the crosshead guides, 2. Remove the center crankcase cross-tie. 3. Rotate the crankshaft, moving the subject throw to the outer dead center position. Remove the large outer snap-ring from one end of the crosshead pin. Remove the crosshead pin, being careful not to let the con rod drop as the pin comes clear of the bushing in the con rod. 4. Rotate the crankshaft until the throw is at its highest point, being careful not to let the con rod drop onto the crosshead guide. Place a cloth under the rod to prevent it from rubbing on the guide. Remove the connecting rod cap retaining bolts and the cap, be careful that the rod does not drop off the crankshaft. 5. Rotate the crankshaft away from the rod as you hold the rod to prevent it from falling ‘When the crankshaft throw is as far from the rod as possible the rod may be withdrawn through the top of the crankcase. On 3.5" stroke models, the rod must be removed through the crosshead guide. This will require the complete removal of the crosshead, see "Crosshead Removal.” Crank Pin (Con Rod) Bearing This bearing is a TRI-METAL (steel, bronze and babbitt) precision insert type. A visual inspection should be sufficient to determine if the bearing is serviceable, ANY appreciable wear of the babbitt would expose the bronze beneath. Such exposure is cause for rejection of the entire bearing. Care should be taken when cleaning this bearing, as the babbitt is quite soft and subject to damage. NEVER HANDLE THE BABBITT SURFACE WITH BARE HANDS OR FINGERS. Residue from the oils on your skin can attack and corrode the babbitt. Always oil or grease the babbitt prior to handling, There are notches in the rod cap and the rod, These are intended to align with the tabs on each of the bearing halves and thus align the shells in place. Crosshead (Con Rod) Pin Bushing Check the bushing for general condition. Using micrometers, measure for correct pin to bushing clearance. This should be done in 3 positions around the circumference in order to determine if the pin or bushing is out of round. Replace the pin and/or bushing if necessary. If. replacement bushing is needed, the existing one should be filed or hacksawed to within 1/32" of its thickness then drifted out. This procedure insures that no material is removed from the inside of the con rod due to pressing out of the old bushing. 13