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ABB PT004149 manual available for free PDF download: Operation Manual
ABB PT004149 Operation Manual (106 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 14.05 MB
Table of Contents
Power2 850-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: Power2 Layout and Function
9
Layout and Function of the High-Pressure Stage
10
Fig. 2: Layout and Function of the High-Pressure Stage
10
Fig. 3: Power2 HP Diagram
11
Symbols, Definitions
12
Registered Trademarks
13
Table 1: Definition of Pictograms
13
Storage of New Low-Pressure and High-Pressure Stages
14
Fig. 4: Volatile Corrosion Inhibitor (VCI)
14
Fig. 5: Package with Hygrometer
15
Safety
16
Introduction
16
CE Conformity
16
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
17
Definition of Safety Instructions
17
Table 2: Personal Protective Equipment to be Worn at All Times
17
Definition of Mandatory Signs
17
Intended Use
18
Deflagration on Gas Engines
19
Warning Plates on the High-Pressure Stage
20
Fig. 6: Locations of Power2 HP Warning Plates
20
Table 5: Recommended Replacement Intervals
21
Table 6: Further Data
21
Table 4: Operating Limits
21
Fig. 7: Rating Plate
21
Rating Plate of the High-Pressure Stage
21
Fig. 8: Location of Power2 HP Rating Plate
22
Periodic Check of the Pressure Vessels
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
Table 7: Swivel Lifting Eyes
32
Table 8: Transporting the High-Pressure Stage
32
Fig. 11: Swivel Lifting Eye (Example)
32
Transport / Weight
32
Removal and Installation
32
Removing the High-Pressure Stage
33
Fig. 12: Suspension of Complete High-Pressure Stage
33
Installing the High-Pressure Stage
34
Fig. 13: Suspension of Complete High-Pressure Stage
34
Commissioning
35
Oil Supply
35
Table 9: Pre-Lubrication Time
35
Table 10: Post-Lubrication Time
35
Table 11: Filter Mesh Width
36
Inspection Procedures
37
Commissioning after Taking out of Operation
39
Monitoring During Operation
40
Lubricating Oil Pressure
40
Fig. 14: Lubricating Oil Pressure Measuring Point
40
Table 12: Oil Pressure Range
40
Lubricating Oil Temperature
41
Table 13: Lubricating Oil Temperature
41
Speed Measurement
42
Fig. 15: Functional Principle
42
Fig. 17: Removing the Speed Measurement System
44
Fig. 16: Dimension X
44
Fig. 18: Setting Dimension X
45
Fig. 19: Control Dimension S
46
Operation and Service
47
Noise Emission
47
Service Work
48
Expected Replacement Intervals
50
Table 14: Expected Replacement Intervals [H]
50
Stopping the Engine
51
Periodic Maintenance
52
Foreword to Maintenance
52
Table 15: Maintenance Intervals
52
Cleaning the Compressor During Operation
53
Table 16: Cleaning Parameters Power2 LP
55
Table 17: Cleaning Parameters Power2 HP
55
Cleaning Turbine and Nozzle Ring During Operation
56
Fig. 20: Load/Time Chart
58
Table 18: Operating Point for Turbine Cleaning
58
Table 19: Cleaning Parameters HP
59
Table 20: Cleaning Parameters LP
59
Table 21: Holding Time
59
Table 22: Surface of the Flow Channel
60
Table 25: Malfunctions When Starting - Rubbing of Rotating Parts
61
Table 24: Malfunctions When Starting - Vibrations
61
Table 23: Malfunctions When Starting - Delayed Start-Up
61
Malfunctions When Starting
61
Troubleshooting
61
Malfunctions During Operation
62
Table 26: Malfunctions During Operation - Lubricating Oil Pressure too Low
62
Table 27: Malfunctions During Operation - Power2 LP Speed Reductions
62
Table 28: Malfunctions During Operation - Power2 HP Speed Reductions
62
Table 29: Malfunctions During Operation - Power2 LP Speed Increases
62
Table 30: Malfunctions During Operation - Power2 HP Speed Increases
63
Table 31: Malfunctions During Operation - Exhaust Gas Temperature too High
63
Table 32: Malfunctions During Operation - Charge Air Pressure too Low
64
Table 33: Malfunctions During Operation - Charge Air Pressure too High
64
Table 34: Malfunctions During Operation - Compressor 1 Contamination
65
Table 35: Malfunctions During Operation - Compressor 2 Contamination
65
Surging of the Low-Pressure or High-Pressure Stage
66
Table 36: Surging of the Low-Pressure or High-Pressure Stage
66
Malfunctions When Stopping
67
Speed Measurement System
67
Table 37: Malfunctions When Stopping - Runout Noises
67
Table 38: Malfunctions When Stopping - Runout Time too Short
67
Table 39: Measured Speed Incorrect
67
Disassembly and Assembly
68
Introduction
68
Material Required
69
Weights of Assemblies
70
Table 40: Weights of the Assemblies
70
Fig. 21: Overview of Assemblies
70
Removing the Air Suction Branch Together with Bellows
71
Fig. 22: Removing the Air Suction Branch
71
Removing the Wall Insert
72
Fig. 23: Removing Wall Insert 1
72
Fig. 24: Removing Wall Insert 2
72
Fig. 25: Removing Wall Insert 3
73
Removing the Compressor Casing
74
Fig. 26: Removing the Compressor Casing
74
Fig. 28: Moving out Cartridge Group 2
75
Removing the Cartridge Group
75
Fig. 27: Moving out Cartridge Group 1
75
Fig. 29: Moving out Cartridge Group 3
76
Fig. 30: Moving out Cartridge Group 4
76
Removing the Nozzle Ring
77
Fig. 31: Removing the Nozzle Ring
77
Measuring Axial Clearance a
78
Fig. 32: Measuring Axial Clearance a
78
Table 41: Axial Clearance a
78
Table 42: Tightening Torque (56017)
79
Fig. 33: Installing the Nozzle Ring
79
Installing the Nozzle Ring
79
Installing the Cartridge Group
80
Fig. 34: Installing O-Rings
80
Fig. 35: Installing the Cartridge Group 1
80
Fig. 36: Installing the Cartridge Group 2
81
Table 43: Tightening Torque (42099)
81
Fig. 37: Control Dimension X
82
Table 44: Control Dimension X
82
Table 45: Tightening Torque (61090)
83
Fig. 38: Installing the Compressor Casing
83
Installing the Compressor Casing
83
Installing the Wall Insert
84
Fig. 39: Installing the Wall Insert 1
84
Fig. 40: Installing the Wall Insert 2
85
Table 46: Tightening Torque (72002)
85
Installing the Air Suction Branch Together with Bellows
86
Fig. 41: Installing the Air Suction Branch
86
Table 47: Tightening Torque (72004)
86
Table of Tightening Torques
87
Fig. 42: Tightening Torques
87
Table 48: Tightening Torques
87
Possible Emergency Repairs
88
Taking out of Operation at Short Notice
88
Fig. 43: Cover Plate / Gasket and Sleeves
89
Table 49: Cover Plate / Gasket
89
Fig. 44: Fitting the Cover Plate
90
Fig. 45: Installing the Casing
90
Table 50: Tightening Torque (42099)
90
Taking out of Operation for a Long Period
91
General
91
Lubricating Oil
91
Process for Taking out of Operation
91
REACH and Rohs Compliance Declaration for Products
92
Material and Disposal
92
Disposing of Low-Pressure and High-Pressure Stage Components
93
Spare Parts
94
Ordering Spare Parts
94
Table 51: Customer Spare Part Set (97070)
94
Spare Part - Illustrations
95
Table 52
95
Table 53
96
Table 54
97
Table 55
98
Table 56
99
Figures
104
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