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ABB Power2 850LP manual available for free PDF download: Operation Manual
ABB Power2 850LP Operation Manual (119 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 17.39 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: Power2 Layout and Function
7
Layout and Function of the Low-Pressure Stage
8
Fig. 2: Layout and Function of the Low-Pressure Stage
8
Fig. 3: Power2 LP Diagram
9
Symbols, Definitions
10
Registered Trademarks
11
Table 1: Definition of Pictograms
11
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Storage of New Low-Pressure and High-Pressure Stages
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
Deflagration on Gas Engines
17
Fig. 6: Locations of Power2 LP Warning Plates
18
Warning Plates on the Low-Pressure Stage
18
Rating Plate of the Low-Pressure Stage
19
Fig. 7: Rating Plate
19
Table 4: Operating Limits
19
Table 5: Recommended Replacement Intervals
19
Table 6: Further Data
19
Periodic Check of the Pressure Vessels
20
Fig. 8: Location of Power2 LP Rating Plate
20
Lifting of Loads
21
Fig. 9: Attachment of Loads on the Crane Hook
21
Fig. 10: Attachment Angle
21
Prerequisites for Operation and Maintenance
22
Hazards During Operation and Maintenance
23
Safe Operation
25
Safe Maintenance
26
Removal and Installation
30
Transport / Weight
30
Table 7: Swivel Lifting Eyes to be Used
30
Table 8: Transporting the Low-Pressure Stage
30
Removing the Low-Pressure Stage
31
Fig. 11: Suspension of Complete Low-Pressure Stage
31
Installing the Low-Pressure Stage
32
Fig. 12: Suspension of Complete Low-Pressure Stage
32
Table 9: Pre-Lubrication Time
33
Table 10: Post-Lubrication Time
33
Oil Supply
33
Commissioning
33
Table 11: Filter Mesh Width
34
Inspection Procedures
35
Commissioning after Taking out of Operation
37
Monitoring During Operation
38
Lubricating Oil Pressure
38
Fig. 13: Lubricating Oil Pressure Measuring Point
38
Table 12: Oil Pressure Range
38
Lubricating Oil Temperature
39
Table 13: Lubricating Oil Temperature
39
Speed Measurement
40
Fig. 14: Functional Principle
40
Fig. 15: Dimension X
42
Fig. 16: Removing the Speed Measurement System
42
Fig. 17: Setting Dimension X
43
Fig. 18: Control Dimension S
44
Operation and Service
45
Noise Emission
45
Service Work
46
Expected Replacement Intervals
48
Table 14: Expected Replacement Intervals [H]
48
Stopping the Engine
49
Periodic Maintenance
50
Foreword to Maintenance
50
Table 15: Maintenance Intervals
50
Cleaning the Compressor During Operation
51
Table 16: Cleaning Parameters Power2 LP
53
Table 17: Cleaning Parameters Power2 HP
53
Cleaning Turbine and Nozzle Ring During Operation
54
Fig. 19: Load/Time Chart
56
Table 18: Operating Point for Turbine Cleaning
56
Table 19: Cleaning Parameters HP
57
Table 20: Cleaning Parameters LP
57
Table 21: Holding Time
57
Table 22: Surface of the Flow Channel
58
Cleaning the Filter Silencer
59
Fig. 20: Cleaning the Filter Silencer
59
Fig. 21: Cleaning the Filter Silencer (2)
61
Table 23: Tightening Torque (81272)
61
Table 24: Tightening Torque (81273)
61
Fig. 22: Cleaning the Filter Silencer
62
Troubleshooting
64
Malfunctions When Starting
64
Table 25: Malfunctions When Starting - Delayed Start-Up
64
Table 26: Malfunctions When Starting - Vibrations
64
Table 27: Malfunctions When Starting - Rubbing of Rotating Parts
64
Malfunctions During Operation
65
Table 28: Malfunctions During Operation - Lubricating Oil Pressure too Low
65
Table 29: Malfunctions During Operation - Power2 LP Speed Reductions
65
Table 30: Malfunctions During Operation - Power2 HP Speed Reductions
65
Table 31: Malfunctions During Operation - Power2 LP Speed Increases
65
Table 32: Malfunctions During Operation - Power2 HP Speed Increases
66
Table 33: Malfunctions During Operation - Exhaust Gas Temperature too High
66
Table 34: Malfunctions During Operation - Charge Air Pressure too Low
67
Table 35: Malfunctions During Operation - Charge Air Pressure too High
67
Table 36: Malfunctions During Operation - Compressor 1 Contamination
68
Table 37: Malfunctions During Operation - Compressor 2 Contamination
68
Surging of the Low-Pressure or High-Pressure Stage
69
Table 38: Surging of the Low-Pressure or High-Pressure Stage
69
Malfunctions When Stopping
70
Speed Measurement System
70
Table 39: Malfunctions When Stopping - Runout Noises
70
Table 40: Malfunctions When Stopping - Runout Time too Short
70
Table 41: Measured Speed Incorrect
70
Disassembly and Assembly
71
Introduction
71
Material Required
72
Weights of Assemblies
73
Fig. 23: Overview of Assemblies
73
Table 42: Weights of the Assemblies
73
Removing the Filter Silencer
74
Fig. 24: Removing the Filter Silencer
74
Removing the Air Suction Branch
75
Fig. 25: Removing the Air Suction Branch
75
Axial Clearance a Prior to Disassembly
76
Fig. 26: Measuring Axial Clearance a
76
Table 43: Axial Clearance a
76
Removing the Wall Insert
77
Fig. 27: Removing Wall Insert 1
77
Fig. 29: Removing Wall Insert 3
78
Fig. 28: Removing Wall Insert 2
78
Fig. 30: Removing the Compressor Casing 1
79
Fig. 31: Removing the Compressor Casing 2
79
Removing the Compressor Casing
79
Removing the Cartridge Group
80
Fig. 32: Moving out Cartridge Group 1
80
Fig. 33: Moving out Cartridge Group 2
81
Fig. 34: Putting down Cartridge Group Onto Cover
81
Removing Turbine Diffuser and Nozzle Ring
82
Fig. 35: Removing Turbine Diffuser and Nozzle Ring 1
82
Fig. 36: Removing Turbine Diffuser and Nozzle Ring 2
82
Fig. 37: Removing Turbine Diffuser and Nozzle Ring 3
83
Fig. 38: Removing Turbine Diffuser and Nozzle Ring 4
83
Table 44: Tightening Torque (56017)
84
Installing Turbine Diffuser and Nozzle Ring
84
Fig. 39: Installing the Nozzle Ring and Turbine Dif
84
Fig. 40: Installing the Nozzle Ring and Turbine Dif
85
Table 45: Tightening Torque (61056)
85
Installing the Cartridge Group
86
Fig. 41: Installing O-Rings
86
Fig. 42: Installing the Cartridge Group 1
86
Fig. 43: Inserting the Cartridge Group
87
Table 46: Tightening Torque (42087)
87
Fig. 44: Measuring Control Dimension X
88
Table 47: Control Dimension X
88
Table 48: Tightening Torque (61037 / 72021)
89
Fig. 45: Installing the Compressor Casing
89
Installing the Compressor Casing
89
Table 49: Tightening Torque (77016)
90
Installing the Wall Insert
90
Fig. 46: Installing the Wall Insert 1
90
Fig. 47: Installing the Wall Insert 2
91
Table 50: Tightening Torque (72002)
91
Axial Clearance a after Assembly
92
Fig. 48: Measuring Axial Clearance a
92
Table 51: Axial Clearance a
92
Installing the Air Suction Branch
93
Fig. 49: Installing the Air Suction Branch
93
Table 52: Tightening Torque (72004)
93
Table 53: Tightening Torque (72004 / 77022)
94
Fig. 50: Installing the Filter Silencer
94
Installing the Filter Silencer
94
Table of Tightening Torques
96
Fig. 51: Overview of Tightening Torques
96
Table 54: Tightening Torques
96
Taking out of Operation at Short Notice
97
Possible Emergency Repairs
97
Fig. 52: Cover Plate / Gasket, Sleeves and Screws
98
Table 55: Cover Plate / Gasket
98
Fig. 53: Fitting the Cover Plate
99
Fig. 54: Installing the Casing
99
Table 56: Tightening Torque (42087)
99
Process for Taking out of Operation
100
Taking out of Operation for a Long Period
100
Lubricating Oil
100
General
100
Material and Disposal
101
REACH and Rohs Compliance Declaration for Products
101
Disposing of Low-Pressure and High-Pressure Stage Components
102
Spare Parts
103
Ordering Spare Parts
103
Table 57: Customer Spare Part Set (97070)
104
Spare Part - Illustrations
105
Table 58
105
Table 59
106
Table 60
107
Table 61
108
Table 62
109
Table 63
110
Table 64
111
Table 65
112
Table 66
113
Table 67
114
Table 68
115
Tools
116
Table 69: Customer Tool Set 90000
116
Figures
117
Tables
118
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