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ABB Power2 850-M16 manuals available for free PDF download: Operation Manual, Operation Instructions Manual
ABB Power2 850-M16 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
Advertisement
ABB Power2 850-M16 Operation Manual (106 pages)
High-pressure stage PT004087
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
ABB Power2 850-M16 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
Advertisement
ABB Power2 850-M16 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
ABB Power2 850-M16 Operation Manual (178 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 25.67 MB
Table of Contents
Safety
11
Table of Contents
11
Introduction
12
Definition of Mandatory Signs
13
Intended Use
14
Deflagration on Gas Engines
15
Warning Plates on the Low-Pressure and High-Pressure Stage
16
Rating Plate of the High-Pressure and Low-Pressure Stage
17
Periodic Check of the Pressure Vessels
18
Lifting of Loads
19
Prerequisites for Operation and Maintenance
20
Hazards During Operation and Maintenance
21
Safe Operation
23
Safe Maintenance
24
Copyright 2018 ABB. All Rights Reserved. HZTL4025_EN Revision a March
25
Power2 Layout and Function
33
Table of Contents
34
Disassembly and Assembly
79
Taking out of Operation at Short Notice
81
Mothballing the Low-Pressure and High-Pressure Stage
83
Taking the Engine out of Operation for up to 12 Months
83
Taking the Engine out of Operation for more than 12 Months
84
Disposing of Low-Pressure and High-Pressure Stage Components
85
Spare Parts
87
Figures
89
Tables
91
Low-Pressure Stage
93
1 Further Applicable Documents
95
2 Removal and Installation
97
Transport / Weight
97
Removing the Low-Pressure Stage
98
Installing the Low-Pressure Stage
99
3 Expected Replacement Intervals
101
4 Disassembly and Assembly
103
Introduction
103
Weights of Assemblies
105
Removing the Air Suction Branch
106
Removing the Filter Silencer
107
Axial Clearance a Prior to Disassembly
108
Removing Wall Insert
109
Removing the Compressor Casing
111
Removing the Cartridge Group
112
Removing Turbine Diffuser and Nozzle Ring
114
Installing the Nozzle Ring and Turbine Diffuser
116
Installing the Cartridge Group
118
Installing the Compressor Casing
121
Installing the Wall Insert
122
Axial Clearance a after Assembly
124
Installing the Filter Silencer
125
Installing the Air Suction Branch
126
Table of Tightening Torques
128
5 Taking out of Operation at Short Notice
131
Possible Emergency Repairs
131
6 Spare Parts
135
Ordering Spare Parts
135
View of Low-Pressure Stage with Part Numbers
136
Figures
139
Tables
141
High-Pressure Stage
143
1 Further Applicable Documents
144
2 Removal and Installation
145
Transport / Weight
145
Removing the High-Pressure Stage
146
Installing the High-Pressure Stage
147
3 Expected Replacement Intervals
148
4 Disassembly and Assembly
150
Introduction
150
Weights of Assemblies
152
Removing the Air Suction Branch Together with Bellows
153
Removing Wall Insert
154
Removing the Compressor Casing
156
Removing the Cartridge Group
157
Removing the Nozzle Ring
159
Measuring Axial Clearance a
160
Installing the Nozzle Ring
161
Installing the Cartridge Group
162
Installing the Compressor Casing
165
Installing the Wall Insert
166
Installing the Air Suction Branch Together with Bellows
168
Table of Tightening Torques
169
5 Taking out of Operation at Short Notice
170
Possible Emergency Repairs
170
6 Spare Parts
173
Ordering Spare Parts
173
View of High-Pressure Stage with Part Numbers
174
Figures
176
Tables
177
ABB Power2 850-M16 Operation Instructions Manual (172 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 34.99 MB
Table of Contents
Table of Contents
34
Taking out of Operation for a Long Period
86
General
86
Lubricating Oil
86
Process for Taking out of Operation
86
Disposing of Low-Pressure and High-Pressure Stage Components
87
Spare Parts
88
Figures
89
Low-Pressure Stage
91
Further Applicable Documents
92
Removal and Installation
93
Transport / Weight
93
Removing the Low-Pressure Stage
94
Installing the Low-Pressure Stage
95
Expected Replacement Intervals
96
Disassembly and Assembly
98
Introduction
98
Material Required
99
Weights of Assemblies
100
Removing the Filter Silencer
101
Removing the Air Suction Branch
102
Axial Clearance a Prior to Disassembly
103
Removing the Wall Insert
104
Removing the Compressor Casing
105
Removing the Cartridge Group
106
Removing Turbine Diffuser and Nozzle Ring
108
Installing Turbine Diffuser and Nozzle Ring
110
Installing the Cartridge Group
112
Installing the Compressor Casing
114
Installing the Wall Insert
115
Axial Clearance a after Assembly
118
Installing the Air Suction Branch
119
Installing the Filter Silencer
120
Table of Tightening Torques
121
Possible Emergency Repairs
123
Taking out of Operation at Short Notice
123
Ordering Spare Parts
126
Spare Parts
126
View of Low-Pressure Stage with Part Numbers
129
Tools
131
Figures
132
Tables
133
High-Pressure Stage
135
Further Applicable Documents
136
Removal and Installation
137
Transport / Weight
137
Removing the High-Pressure Stage
138
Installing the High-Pressure Stage
139
Expected Replacement Intervals
140
Disassembly and Assembly
142
Introduction
142
Material Required
143
Weights of Assemblies
144
Removing the Air Suction Branch Together with Bellows
145
Removing the Wall Insert
146
Removing the Compressor Casing
148
Removing the Cartridge Group
149
Removing the Nozzle Ring
151
Measuring Axial Clearance a
152
Installing the Nozzle Ring
153
Installing the Cartridge Group
154
Installing the Compressor Casing
157
Installing the Wall Insert
158
Installing the Air Suction Branch Together with Bellows
160
Table of Tightening Torques
161
Possible Emergency Repairs
162
Taking out of Operation at Short Notice
162
Ordering Spare Parts
165
Spare Parts
165
View of High-Pressure Stage with Part Numbers
167
Tools
169
Figures
170
Tables
171
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