GE 1333 West Loop North, Suite 800

Houston, Texas 77027 U.S.A.

compressor
OIL & GAS

________
Subject: Trouble Shooting Group: All
Number: 04-007 Sub Group: All
Date: 17 Sept 04 Series: All______
Minor situations can occur during the operation of a GE Gemini compressor that require trouble shooting. Often
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.

It is 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 • Cylinders gas pressure loaded
Will Not • Piston end clearance improper, piston hitting 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 balance 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

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GE 1333 West Loop North, Suite 800
Houston, Texas 77027 U.S.A.

compressor
OIL & GAS

Situation Potential Common Causes

Frame Noise • Loose crosshead pin or pin caps
Or Knock • Loose or worn main, crankpin or crosshead bearings
• Knock coming from cylinder end
• Loose crosshead balance weight
• Damaged crosshead
• Loose crosshead pin or pin caps
• Improper lube oil selection

Cylinder or • Compressor frame or crosshead guide mounting bolts loose

Frame Vibration • Discharge bottle wedges loose or improperly adjusted
• Drive train misalignment
• Bottle/piping acoustical pulsations
• Excessive crosshead guide clearance (crosshead slap)

Low Oil • Low oil level

Supply • Oil pump failure
Pressure • Oil pump cavitation from excessively cold oil
• Oil pressure regulating valve improperly adjusted
• Oil filter element – dirty, restricted or collapsed
• Low oil pressure switch setting too low
• Defective pressure gauge
• Oil foaming - high oil level being struck by counterweights
• Internal running gear leakage - excessive bearing clearance

High Oil • Cold oil

Supply • Oil pressure regulating valve improperly 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 valve closed 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

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GE 1333 West Loop North, Suite 800
Houston, Texas 77027 U.S.A.

compressor
OIL & GAS

Situation Potential Common Causes

“No-flow” • Lube line blockage or 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 fitting 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 carryover

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
• Piston rod wear – scored, tapered or out of round
• Excessive piston rod run out

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GE 1333 West Loop North, Suite 800
Houston, Texas 77027 U.S.A.

compressor
OIL & GAS

Situation Potential Common Causes______________

Excessive • Worn packing rings
Packing • Packing case bolts loose
Leakage • Packing rings incorrectly assembled/installed
• Improper lube oil selection and associated lube rate
• Contaminants (liquid or solid) affecting packing rings
• Packing not seated or properly 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 worn or scored

Packing Wear • Oil dilution from liquid carryover
Excessive • Improper oil 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 • Worn 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

Situation Potential Common Causes________________

High Discharge • Excessive compression ratio across cylinder – back pressure from
Gas Temperature leaking suction valves or piston rings of next higher stage cylinder
• 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

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GE 1333 West Loop North, Suite 800
Houston, Texas 77027 U.S.A.

compressor
OIL & GAS

• Change in cylinder mode of operation, from single acting (SA) to double

acting (DA)
High Discharge • Excessive compression ratio across cylinder – back pressure from
Gas Pressure leaking suction valves or piston rings of next higher stage cylinder
• Downstream line obstruction or isolation valve closed
Inadequate • Unit recycle, vent or scrubber dump valve open or leaking
Compressor • Compressor speed lower than rating
Output Flow • 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 valve 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 start/fuel gas, dehydration unit and other auxiliary
equipment
Crankshaft • Clogged top cover breather
Drive End • Back pressure from excessive cylinder packing leak
Seal Oil Leak • Excessive seal wear due to drive coupling misalignment
• Excessive seal wear due to incorrectly adjusted front cover
Situation Potential Common Causes_ _______________
Gas Safety • Faulty or improperly adjusted pressure safety valve (PSV)
Relief Valve • Back pressure from leaking suction valves or piston rings of
Popping higher stage cylinder downstream
• Downstream line obstruction or isolation valve closed
• Discharge line check valve restriction – sticking or damaged
• Gas cooler tubing restriction – fouled or exceeds flow capacity

If you 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

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