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ABB Power2 340-H manual available for free PDF download: Operation Manual
ABB Power2 340-H Operation Manual (122 pages)
Low-pressure stage
Brand:
ABB
| Category:
Industrial Equipment
| Size: 12.97 MB
Table of Contents
Table of Contents
1
Contact Information
4
Introduction
4
Purpose of the Manual
4
Essential Information
5
Power2 Layout and Function
7
Fig. 1: Layout and Function
7
Layout and Function of the Low-Pressure Stage
8
Fig. 2
8
Fig. 3
9
Symbols, Definitions
10
Registered Trademarks
11
Table 1: Definition of Pictograms
11
Storage of New Low-Pressure and High-Pressure Stages
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Safety
14
Introduction
14
CE Conformity
14
Definition of Mandatory Signs
15
Definition of Safety Instructions
15
Table 2: Personal Protective Equipment to be Worn at All Times
15
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
15
Intended Use
16
Table 4: Transient Pressure Increase in the Event of Deflagration
16
Deflagration on Gas Engines
17
Fig. 6 Low-Pressure Stage
18
Warning Plates on the Low-Pressure Stage
18
Rating Plate of the Low-Pressure Stage
19
Fig. 7: Rating Plate
19
Table 5: Operating Limits
19
Table 6: Recommended Inspection and Replacement Intervals
19
Table 7: Further Data
19
Fig. 8: Locations of the Rating Plates
20
Periodic Check of the Pressure Vessels
21
Lifting of Loads
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Fig. 10: Attachment Angle
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
Removal and Installation
31
Transport / Weight
31
Removing the Low-Pressure Stage
31
Fig. 11: Transport
31
Table 8: Weight of the Low-Pressure Stage Complete
31
Fig. 12: Removing the Low-Pressure Stage
32
Installing the Low-Pressure Stage
33
Fig. 13: Inserting Gaskets into the Bracket
33
Fig. 14: Placing the Low-Pressure Stage on the Bracket
34
Table 11: Tightening Torque (61003)
35
Table 10: Fixing Screw Tightening Torque (05)
35
Table 9: Fixing Screw Tightening Torque (01)
35
Fig. 15: Low-Pressure Stage, Tightening the Fixing Screws
35
Commissioning
36
Oil Supply
36
Inspection Procedures
37
Commissioning after Taking out of Operation
39
Monitoring During Operation
40
Lubricating Oil Pressure
40
Fig. 16: Oil Monitoring
40
Table 12: Lubricating Oil Pressure at Oil Inlet Upstream of the Turbocharger
40
Lubricating Oil Temperature
41
Table 13
41
Table 14
41
Speeds
42
Fig. 17: Low-Pressure Stage Speed Measurement System
42
Operation and Service
45
Noise Emission
45
Fig. 18: Noise Insulation, Bellows
46
Service Work
47
Expected Replacement Intervals
49
Table 15: Expected Replacement Intervals [H]
49
Stopping the Engine
51
Table 16
51
Periodic Maintenance
52
Foreword to Maintenance
52
Table 17
52
Cleaning the Compressor During Operation
53
Table 18: Parameters for Wet Cleaning of Compressor
55
Cleaning the Filter Silencer
56
Fig. 19: Cleaning the Filter Silencer
56
Cleaning Turbine and Nozzle Ring During Operation
57
Troubleshooting
58
Malfunctions When Starting
58
Table 19: Malfunctions When Starting - Delayed Start-Up
58
Table 20: Malfunctions When Starting - Vibrations
58
Table 21: Malfunctions When Starting - Rubbing of Rotating Parts
58
Malfunctions During Operation
59
Table 22: Malfunctions During Operation - Lubricating Oil Pressure too Low
59
Table 23: Malfunctions During Operation - Power2 LP Speed Reductions
59
Table 24: Malfunctions During Operation - Power2 HP Speed Reductions
59
Table 25: Malfunctions During Operation - Power2 LP Speed Increases
59
Table 26: Malfunctions During Operation - Power2 HP Speed Increases
60
Table 27: Malfunctions During Operation - Exhaust Gas Temperature too High
60
Table 28: Malfunctions During Operation - Charge Air Pressure too Low
61
Table 29: Malfunctions During Operation - Charge Air Pressure too High
61
Table 30: Malfunctions During Operation - Compressor 1 Contamination
62
Table 31: Malfunctions During Operation - Compressor 2 Contamination
62
Table 32: Malfunctions During Operation - Blow-By too High
62
Surging of the Low-Pressure or High-Pressure Stage
63
Table 33: Surging of the Low-Pressure or High-Pressure Stage
63
Malfunctions When Stopping
64
Table 34: Malfunctions When Stopping - Runout Noises
64
Table 35: Malfunctions When Stopping - Runout Time too Short
64
Table 37: Speed Measurement - Speed too High
65
Table 38: Speed Measurement - Speed too Low
65
Table 36: Speed Measurement - Poor Signal Amplitude
65
Speed Measurement System
65
Disassembly and Assembly
66
Introduction
66
Material Required
67
Fig. 20: Swivel Lifting Eye (Example)
68
Table 39: Swivel Lifting Eyes
68
Weights of Assemblies
69
Fig. 21: Weights of the Assemblies
69
Table 40: Weights of the Assemblies
69
Removing the Gas Outlet Casing and Gas Outlet Flange
70
Fig. 22: Removing the Gas Outlet Casing and Gas Outlet Flange
70
Table 41: Press-Off Screws to be Used
70
Removing the Air Inlets
71
Fig. 23: Removing the Air Inlets
71
Measuring Radial Clearances N and R
72
Fig. 24: Measuring Clearances N and R
72
Table 42: Permissible Clearances N and R
72
Removing the Compressor Casing
73
Fig. 25: Removing the Compressor Casing
73
Fig. 26: Dismantling the Wall Insert
74
Pressing off the Casing
75
Fig. 27: Press off the Casing
75
Removing the Cartridge Group
76
Fig. 28: Oil Orifice
76
Fig. 29: Removing Cartridge Group 1
77
Fig. 30: Removing Cartridge Group 2
77
Removing the Nozzle Ring
78
Fig. 31: Removing the Nozzle Ring
78
Installing the Cartridge Group on the Service Support
79
Fig. 32: Installing the Cartridge Group on the Service Support
79
Measuring Clearance a and B
80
Fig. 33: Measuring Clearance a and B
80
Table 43: Permissible Clearances a and B
80
Nozzle Ring Compression PD
81
Fig. 34: Nozzle Ring Compression PD
81
Table 44: Nozzle Ring Compression PD
81
Installing the Nozzle Ring
82
Fig. 35: Installing the Nozzle Ring
82
Installing the Cartridge Group
83
Fig. 36: Lifting the Cartridge Group and Rotating It
83
Fig. 37: Installing the Cartridge Group
84
Table 45: Tightening Torque (51007)
84
Installing the Compressor Casing
85
Fig. 38: Fitting the Wall Insert and the Diffuser
85
Table 46: Tightening Torque (79041)
85
Fig. 39: Installing the Compressor Casing
86
Table 47: Tightening Torque (72011)
86
Measuring Radial Clearances N and R
87
Fig. 40: Measuring Clearances N and R
87
Table 48: Permissible Clearances N and R
87
Installing the Air Inlets
88
Fig. 41: Installing the Air Inlets
88
Table 49: Tightening Torque (72020)
88
Fig. 42: Installing the Gas Outlet Flange
89
Installing the Gas Outlet Flange
89
Fig. 43: Installing the Gas Outlet Casing
90
Table 50: Tightening Torques (51009, 61003)
90
Installing the Gas Outlet Casing
90
Table of Tightening Torques
91
Fig. 44: Tightening Torque Overview
91
Table 51: Tightening Torques [Nm]
91
Taking out of Operation at Short Notice
92
Possible Emergency Repairs
92
Installing a Replacement Cartridge Group
93
Fitting the Cover Plate
94
Fig. 45: Fitting the Cover Plate
94
Table 52: Tightening Torques (51007)
94
Table 53: Cover Plate Dimensions [MM]
95
Cover Plate Drawing
95
Fig. 46: Cover Plate Drawing
95
Mothballing the Low-Pressure Stage
96
Taking the Engine out of Operation for up to 12 Months
96
Taking the Engine out of Operation for more than 12 Months
97
Material and Disposal
98
REACH and Rohs Compliance Declaration for Products
98
Disposing of Low-Pressure and High-Pressure Stage Components
99
Spare Parts
100
Ordering Spare Parts
100
Table 54: Customer Spare Part Set (97070)
100
Spare Part - Illustrations
101
Table 55
101
Table 56
102
Table 57
103
Table 58
104
Table 59
105
Table 60
106
Table 61
107
Table 62
108
Table 63
109
Table 64
110
Table 65
111
Table 66
112
Tools
113
Table 67: Customer Tool Set 90000
113
Table 68: Expected Replacement Interval
114
Commissioning and Operating
114
Gas Piping (Option)
114
Periodic Maintenance
115
Table 69: Maintenance Interval
115
Removal and Installation
116
Fig. 47: Removing the Bellows
116
Table 70: Weight
116
Fig. 48: Installing the Bellows
117
Table 71: Tightening Torque (85003 / 85004)
117
Storage and Disposal
118
Spare Parts
118
Fig. 49: Gas Piping with Part Numbers (Power2 340-H)
119
Figures
120
Tables
121
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