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ABB PT003901 manual available for free PDF download: Operation Manual
ABB PT003901 Operation Manual (116 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 13.29 MB
Table of Contents
Power2 340-H / 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
Table 4: Transient Pressure Increase in the Event of Deflagration
18
Deflagration on Gas Engines
19
Warning Plates on the High-Pressure Stage
20
Fig. 6 High-Pressure Stage
20
Rating Plate of the High-Pressure Stage
21
Fig. 7: Rating Plate
21
Table 5: Operating Limits
21
Table 6: Recommended Inspection and Replacement Intervals
21
Table 7: Further Data
21
Periodic Check of the Pressure Vessels
22
Fig. 8: Location of Power2 HP Rating Plate
22
Fig. 10: Attachment Angle
23
Fig. 9: Attachment of Loads on the Crane Hook
23
Lifting of Loads
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 8: Swivel Lifting Eyes
32
Table 9: Weight of Complete High-Pressure Stage
32
Fig. 13: Removing the High-Pressure Stage
33
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 10: 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 11: Tightening Torque (01, 61003)
40
Fig. 21: Preparing the Clamping Nut for the Tightening Procedure
41
Fig. 22: Tightening Pressure Screws
42
Table 12
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 13: Lubricating Oil Pressure at Oil Inlet Upstream of the Turbocharger
47
Lubricating Oil Temperature
48
Table 14
48
Table 15
48
Speeds
49
Fig. 24: Overview: Speed Measurement on High-Pressure Stage
49
Operation and Service
52
Noise Emission
52
Fig. 25: Noise Insulation, Bellows
53
Service Work
54
Expected Replacement Intervals
56
Table 16: Expected Replacement Intervals [H]
56
Stopping the Engine
58
Table 17
58
Periodic Maintenance
59
Foreword to Maintenance
59
Table 18
59
Cleaning the Compressor During Operation
60
Table 19: Parameters for Wet Cleaning of Compressor
61
Cleaning the High-Pressure Stage Bellows (if Present)
62
Cleaning Turbine and Nozzle Ring During Operation
62
Fig. 26: Bellows
62
Troubleshooting
63
Malfunctions When Starting
63
Table 20: Malfunctions When Starting - Delayed Start-Up
63
Table 21: Malfunctions When Starting - Vibrations
63
Table 22: Malfunctions When Starting - Rubbing of Rotating Parts
63
Table 26: Malfunctions During Operation - Power2 LP Speed Increases
64
Table 25: Malfunctions During Operation - Power2 HP Speed Reductions
64
Table 23: Malfunctions During Operation - Lubricating Oil Pressure too Low
64
Table 24: Malfunctions During Operation - Power2 LP Speed Reductions
64
Malfunctions During Operation
64
Table 27: Malfunctions During Operation - Power2 HP Speed Increases
65
Table 28: Malfunctions During Operation - Exhaust Gas Temperature too High
65
Table 29: Malfunctions During Operation - Charge Air Pressure too Low
66
Table 30: Malfunctions During Operation - Charge Air Pressure too High
66
Table 31: Malfunctions During Operation - Compressor 1 Contamination
67
Table 32: Malfunctions During Operation - Compressor 2 Contamination
67
Table 33: Malfunctions During Operation - Blow-By too High
67
Surging of the Low-Pressure or High-Pressure Stage
68
Table 34: Surging of the Low-Pressure or High-Pressure Stage
68
Table 36: Malfunctions When Stopping - Runout Time too Short
69
Table 35: Malfunctions When Stopping - Runout Noises
69
Malfunctions When Stopping
69
Speed Measurement System
70
Table 37: Speed Measurement - Poor Signal Amplitude
70
Table 38: Speed Measurement - Speed too High
70
Table 39: Speed Measurement - Speed too Low
70
Disassembly and Assembly
71
Introduction
71
Material Required
72
Fig. 27: Swivel Lifting Eye (Example)
73
Table 40: Swivel Lifting Eyes
73
Table 41: Weights of the Assemblies
74
Fig. 28: Weights of the Assemblies
74
Weights of Assemblies
74
Removing the Gas Outlet Casing
75
Fig. 29: Removing the Gas Outlet Casing
75
Removing Air Inlets
76
Fig. 30: Removing the Air Inlets
76
Removing the Compressor Casing
77
Fig. 31: Removing the Compressor Casing
77
Removing the Cartridge Group
78
Fig. 32: Removing the Cartridge Group
79
Fig. 33: Removing the Gas Outlet Flange / Nozzle Ring
80
Table 42: Nozzle Ring Compression PD
81
Fig. 34: Nozzle Ring Compression PD
81
Installing the Cartridge Group
81
Fig. 35: Installing the Gas Outlet Flange / Nozzle Ring
82
Table 43: Tightening Torque (51005)
82
Fig. 36: Installing the Cartridge Group
83
Table 44: Tightening Torque (51007)
83
Installing the Compressor Casing
84
Fig. 37: Installing the Compressor Casing
84
Table 45: Tightening Torques (42007, 72011, 77022)
84
Installing the Air Inlets
85
Fig. 38: Installing the Air Inlet
85
Table 46: Tightening Torque (72013)
85
Table 47: Tightening Torques (51009, 61003)
86
Installing the Gas Outlet Casing
86
Fig. 39: Installing the Gas Outlet Casing
86
Measuring Radial Clearances N and R
87
Fig. 40: Measuring Clearances N and R
87
Table 48: Permissible Clearances N and R
87
Measuring Clearance a and B
88
Fig. 41: Measuring Clearance a and B
88
Table 49: Permissible Clearances a and B
88
Table of Tightening Torques
89
Fig. 42: Overview of Tightening Torques
89
Table 50: Tightening Torques [Nm]
89
Possible Emergency Repairs
90
Taking out of Operation at Short Notice
90
Installing a Replacement Cartridge Group
91
Fitting the Cover Plate
92
Fig. 43: Attaching a Cover Plate
92
Table 51: Tightening Torque (51007)
92
Cover Plate Drawing
93
Fig. 44: Cover Plate Drawing
93
Table 52: Cover Plate Dimensions [MM]
93
Fig. 45: Figure for Cover Plate, Slots for O-Rings
94
Table 53: Dimensions of Cover Plate, Slots for O-Rings [MM]
94
Mothballing the High-Pressure Stage
95
Taking the Engine out of Operation for up to 12 Months
95
Taking the Engine out of Operation for more than 12 Months
96
Material and Disposal
97
REACH and Rohs Compliance Declaration for Products
97
Disposing of Low-Pressure and High-Pressure Stage Components
98
Spare Parts
99
Ordering Spare Parts
99
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
Tools
112
Table 66: Customer Tool Set 90000
112
Gas Piping (Option)
113
Figures
114
Tables
115
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