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ABB PT003988 manual available for free PDF download: Operation Manual
ABB PT003988 Operation Manual (122 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 13.42 MB
Table of Contents
Power2 550-M / High-Pressure Stage
3
Table of Contents
3
Contact Information
6
Introduction
6
Purpose of the Manual
6
Essential Information
7
Power2 Layout and Function
9
Fig. 1: Layout and Function
9
Layout and Function of the High-Pressure Stage
10
Fig. 2: Layout of the High-Pressure Stage
10
Fig. 3: Function of the High-Pressure Stage
11
Symbols, Definitions
12
Registered Trademarks
13
Table 1: Definition of Pictograms
13
Fig. 4: Volatile Corrosion Inhibitor (VCI)
14
Storage of New Low-Pressure and High-Pressure Stages
14
Fig. 5: Package with Hygrometer
15
Safety
16
Introduction
16
CE Conformity
16
Definition of Mandatory Signs
17
Definition of Safety Instructions
17
Table 2: Personal Protective Equipment to be Worn at All Times
17
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
17
Intended Use
18
Deflagration on Gas Engines
19
Fig. 6 High-Pressure Stage
20
Warning Plates on the High-Pressure Stage
20
Rating Plate of the High-Pressure Stage
21
Fig. 7: Rating Plate
21
Table 4: Operating Limits
21
Table 5: Recommended Inspection and Replacement Intervals
21
Table 6: Further Data
21
Periodic Check of the Pressure Vessels
22
Fig. 8: Location of Power2 HP Rating Plate
22
Lifting of Loads
23
Fig. 9: Attachment of Loads on the Crane Hook
23
Fig. 10: Attachment Angle
23
Prerequisites for Operation and Maintenance
24
Hazards During Operation and Maintenance
25
Safe Operation
27
Safe Maintenance
28
Removal and Installation
32
Transport / Weight
32
Fig. 11: Swivel Lifting Eye (Example)
32
Fig. 12: Transport
32
Table 7: Swivel Lifting Eyes
32
Table 8: Weight of Complete High-Pressure Stage
32
Removing the High-Pressure Stage
33
Fig. 13: Removing the High-Pressure Stage
33
Fig. 14: Loosening the Clamping Nut
34
Fig. 15: Removing the High-Pressure Stage
35
Installing the High-Pressure Stage
36
Fig. 16: Gaskets in the Slots of the Bearing Casing
36
Fig. 17: Preparing the Fastening Elements of the High-Pressure Stage
37
Fig. 18: Placing the High-Pressure Stage on the Bracket
38
Table 9: Values X and L
38
Fig. 19: Steps for Fastening the High-Pressure Stage
39
Fig. 20: Steps for Fastening the High-Pressure Stage
40
Table 10: Tightening Torque (01, 61003)
40
Fig. 21: Preparing the Clamping Nut for the Tightening Procedure
41
Table 11
42
Fig. 22: Tightening Pressure Screws
42
Commissioning
43
Oil Supply
43
Inspection Procedures
44
Commissioning after Taking out of Operation
46
Monitoring During Operation
47
Lubricating Oil Pressure
47
Fig. 23: Oil Monitoring
47
Table 12: Oil Pressure Range
47
Lubricating Oil Temperature
48
Table 13: Oil Temperature at the Inlet
48
Table 14: Oil Temperature at the Outlet
48
Fig. 24: Overview: Speed Measurement on High-Pressure Stage
49
Speeds
49
Operation and Service
52
Noise Emission
52
Fig. 25: Noise Insulation, Bellows
53
Service Work
54
Expected Replacement Intervals
56
Table 15: Expected Replacement Intervals [H]
56
Stopping the Engine
58
Table 16: Post-Lubrication Time
58
Periodic Maintenance
59
Foreword to Maintenance
59
Table 17: Maintenance Intervals
59
Cleaning the Compressor During Operation
60
Table 18: Cleaning Parameters
61
Table 19: Cleaning Parameters
61
Cleaning the High-Pressure Stage Bellows (if Present)
62
Cleaning Turbines and Nozzle Rings During Operation
62
Fig. 26: Bellows
62
Fig. 27: Load/Time Chart
65
Fig. 28: Wet Cleaning Operation
66
Table 20: Cleaning Parameters
68
Table 21: Cleaning Parameters
68
Table 22: Water Volumes
68
Table 24: Malfunctions When Starting - Vibrations
69
Table 25: Malfunctions When Starting - Rubbing of Rotating Parts
69
Table 23: Malfunctions When Starting - Delayed Start-Up
69
Malfunctions When Starting
69
Troubleshooting
69
Malfunctions During Operation
70
Table 26: Malfunctions During Operation - Lubricating Oil Pressure too Low
70
Table 27: Malfunctions During Operation - Power2 LP Speed Reductions
70
Table 28: Malfunctions During Operation - Power2 HP Speed Reductions
70
Table 29: Malfunctions During Operation - Power2 LP Speed Increases
70
Table 30: Malfunctions During Operation - Power2 HP Speed Increases
71
Table 31: Malfunctions During Operation - Exhaust Gas Temperature too High
71
Table 32: Malfunctions During Operation - Charge Air Pressure too Low
72
Table 33: Malfunctions During Operation - Charge Air Pressure too High
72
Table 34: Malfunctions During Operation - Compressor 1 Contamination
73
Table 35: Malfunctions During Operation - Compressor 2 Contamination
73
Surging of the Low-Pressure or High-Pressure Stage
74
Table 36: Surging of the Low-Pressure or High-Pressure Stage
74
Malfunctions When Stopping
75
Table 37: Malfunctions When Stopping - Runout Noises
75
Table 38: Malfunctions When Stopping - Runout Time too Short
75
Speed Measurement System
76
Table 39: Speed Measurement - Poor Signal Amplitude
76
Table 40: Speed Measurement - Speed too High
76
Table 41: Speed Measurement - Speed too Low
76
Disassembly and Assembly
77
Introduction
77
Material Required
78
Fig. 29: Swivel Lifting Eye (Example)
79
Table 42: Swivel Lifting Eyes
79
Weights of Assemblies
80
Fig. 30: Weights of the Assemblies
80
Table 43: Weights of the Assemblies
80
Removing the Gas Outlet Casing
81
Fig. 31: Removing the Gas Outlet Casing
81
Removing Air Inlets
82
Fig. 32: Removing the Air Inlets
82
Removing the Compressor Casing
83
Fig. 33: Removing the Compressor Casing
83
Removing the Cartridge Group
84
Fig. 34: Removing the Cartridge Group
85
Fig. 35: Removing the Gas Outlet Flange / Nozzle Ring
86
Installing the Cartridge Group
87
Fig. 36: Nozzle Ring Compression PD
87
Table 44: Nozzle Ring Compression PD
87
Fig. 37: Installing the Gas Outlet Flange / Nozzle Ring
88
Table 45: Tightening Torque (51005)
88
Fig. 38: Installing the Cartridge Group
89
Table 46: Tightening Torque (51007)
89
Installing the Compressor Casing
90
Fig. 39: Installing the Compressor Casing
90
Table 47: Tightening Torques (42007, 72011, 77022)
90
Table 48: Tightening Torque (72013)
91
Fig. 40: Installing the Air Inlet
91
Installing the Air Inlets
91
Installing the Gas Outlet Casing
92
Fig. 41: Installing the Gas Outlet Casing
92
Table 49: Tightening Torques (51009, 61003)
92
Measuring Radial Clearances N and R
93
Fig. 42: Measuring Clearances N and R
93
Table 50: Permissible Clearances N and R
93
Measuring Clearance a and B
94
Fig. 43: Measuring Clearance a and B
94
Table 51: Permissible Clearances a and B
94
Table 52: Tightening Torques [Nm]
95
Fig. 44: Overview of Tightening Torques
95
Table of Tightening Torques
95
Taking out of Operation at Short Notice
96
Possible Emergency Repairs
96
Installing a Replacement Cartridge Group
97
Fitting the Cover Plate
98
Fig. 45: Attaching a Cover Plate
98
Table 53: Tightening Torque (51007)
98
Cover Plate Drawing
99
Fig. 46: Cover Plate Drawing
99
Table 54: Cover Plate Dimensions [MM]
99
Fig. 47: Figure for Cover Plate, Slots for O-Rings
100
Table 55: Dimensions of Cover Plate, Slots for O-Rings [MM]
100
Process for Taking out of Operation
101
General
101
Lubricating Oil
101
Taking out of Operation for a Long Period
101
Material and Disposal
102
REACH and Rohs Compliance Declaration for Products
102
Disposing of Low-Pressure and High-Pressure Stage Components
103
Spare Parts
104
Ordering Spare Parts
104
Table 56: Customer Spare Part Set (97070)
105
Spare Part - Illustrations
106
Table 57
106
Table 58
107
Table 59
108
Table 60
109
Table 61
110
Table 62
111
Table 63
112
Table 64
113
Table 65
114
Table 66
115
Table 67
116
Tools
117
Table 68: Customer Tool Set 90000
117
Gas Piping (Option)
118
Figures
119
Tables
120
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