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PT003915
ABB PT003915 User Manual
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Operation Manual / Power2 340-H / Low-pressure stage
15 Gas piping (option) / 15.5 Spare parts
© Copyright 2022 ABB. All rights reserved.
HZTL4053_EN
Rev.F
March 2022
15.5.2
View of gas piping with part numbers
Fig.49: Gas piping with part numbers (Power2 340-H)
Page 119 / 122
120
122
Table of Contents
Power2 340-H / Low-Pressure Stage
3
Table of Contents
3
Introduction
6
Purpose of the Manual
6
Contact Information
6
Essential Information
7
Power2 Layout and Function
9
Fig. 1: Layout and Function
9
Layout and Function of the Low-Pressure Stage
10
Fig. 2
10
Fig. 3
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
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
Fig. 6 Low-Pressure Stage
20
Warning Plates on the Low-Pressure Stage
20
Rating Plate of the Low-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
Fig. 8: Locations of the Rating Plates
22
Periodic Check of the Pressure Vessels
23
Lifting of Loads
24
Fig. 9: Attachment of Loads on the Crane Hook
24
Fig. 10: Attachment Angle
24
Prerequisites for Operation and Maintenance
25
Hazards During Operation and Maintenance
26
Safe Operation
28
Safe Maintenance
29
Removal and Installation
33
Transport / Weight
33
Removing the Low-Pressure Stage
33
Fig. 11: Transport
33
Table 8: Weight of the Low-Pressure Stage Complete
33
Fig. 12: Removing the Low-Pressure Stage
34
Installing the Low-Pressure Stage
35
Fig. 13: Inserting Gaskets into the Bracket
35
Fig. 14: Placing the Low-Pressure Stage on the Bracket
36
Fig. 15: Low-Pressure Stage, Tightening the Fixing Screws
37
Table 9: Fixing Screw Tightening Torque (01)
37
Table 10: Fixing Screw Tightening Torque (05)
37
Table 11: Tightening Torque (61003)
37
Oil Supply
38
Commissioning
38
Inspection Procedures
39
Commissioning after Taking out of Operation
41
Monitoring During Operation
42
Lubricating Oil Pressure
42
Fig. 16: Oil Monitoring
42
Table 12: Lubricating Oil Pressure at Oil Inlet Upstream of the Turbocharger
42
Lubricating Oil Temperature
43
Table 13
43
Table 14
43
Speeds
44
Fig. 17: Low-Pressure Stage Speed Measurement System
44
Operation and Service
47
Noise Emission
47
Fig. 18: Noise Insulation, Bellows
48
Service Work
49
Expected Replacement Intervals
51
Table 15: Expected Replacement Intervals [H]
51
Stopping the Engine
53
Table 16
53
Periodic Maintenance
54
Foreword to Maintenance
54
Table 17
54
Cleaning the Compressor During Operation
55
Table 18: Parameters for Wet Cleaning of Compressor
57
Cleaning the Filter Silencer
58
Fig. 19: Cleaning the Filter Silencer
58
Cleaning Turbine and Nozzle Ring During Operation
59
Table 20: Malfunctions When Starting - Vibrations
60
Table 21: Malfunctions When Starting - Rubbing of Rotating Parts
60
Troubleshooting
60
Table 19: Malfunctions When Starting - Delayed Start-Up
60
Malfunctions When Starting
60
Malfunctions During Operation
61
Table 22: Malfunctions During Operation - Lubricating Oil Pressure too Low
61
Table 23: Malfunctions During Operation - Power2 LP Speed Reductions
61
Table 24: Malfunctions During Operation - Power2 HP Speed Reductions
61
Table 25: Malfunctions During Operation - Power2 LP Speed Increases
61
Table 26: Malfunctions During Operation - Power2 HP Speed Increases
62
Table 27: Malfunctions During Operation - Exhaust Gas Temperature too High
62
Table 28: Malfunctions During Operation - Charge Air Pressure too Low
63
Table 29: Malfunctions During Operation - Charge Air Pressure too High
63
Table 32: Malfunctions During Operation - Blow-By too High
64
Table 31: Malfunctions During Operation - Compressor 2 Contamination
64
Table 30: Malfunctions During Operation - Compressor 1 Contamination
64
Surging of the Low-Pressure or High-Pressure Stage
65
Table 33: Surging of the Low-Pressure or High-Pressure Stage
65
Malfunctions When Stopping
66
Table 34: Malfunctions When Stopping - Runout Noises
66
Table 35: Malfunctions When Stopping - Runout Time too Short
66
Speed Measurement System
67
Table 36: Speed Measurement - Poor Signal Amplitude
67
Table 37: Speed Measurement - Speed too High
67
Table 38: Speed Measurement - Speed too Low
67
Disassembly and Assembly
68
Introduction
68
Material Required
69
Fig. 20: Swivel Lifting Eye (Example)
70
Table 39: Swivel Lifting Eyes
70
Weights of Assemblies
71
Fig. 21: Weights of the Assemblies
71
Table 40: Weights of the Assemblies
71
Fig. 22: Removing the Gas Outlet Casing and Gas Outlet Flange
72
Removing the Gas Outlet Casing and Gas Outlet Flange
72
Table 41: Press-Off Screws to be Used
72
Fig. 23: Removing the Air Inlets
73
Removing the Air Inlets
73
Fig. 24: Measuring Clearances N and R
74
Measuring Radial Clearances N and R
74
Table 42: Permissible Clearances N and R
74
Compressor Casing
75
Fig. 25: Removing the Compressor Casing
75
Removing the Compressor Casing
75
Fig. 26: Dismantling the Wall Insert
76
Wall Insert
76
Fig. 27: Press off the Casing
77
Pressing off the Casing
77
Fig. 28: Oil Orifice
78
Removing the Cartridge Group
78
Fig. 29: Removing Cartridge Group 1
79
Fig. 30: Removing Cartridge Group 2
79
Fig. 31: Removing the Nozzle Ring
80
Removing the Nozzle Ring
80
Fig. 32: Installing the Cartridge Group on the Service Support
81
Installing the Cartridge Group on the Service Support
81
Fig. 33: Measuring Clearance a and B
82
Measuring Clearance a and B
82
Table 43: Permissible Clearances a and B
82
Fig. 34: Nozzle Ring Compression PD
83
Nozzle Ring Compression PD
83
Table 44: Nozzle Ring Compression PD
83
Fig. 35: Installing the Nozzle Ring
84
Installing the Nozzle Ring
84
Fig. 36: Lifting the Cartridge Group and Rotating It
85
Installing the Cartridge Group
85
Fig. 37: Installing the Cartridge Group
86
Table 45: Tightening Torque (51007)
86
Diffuser
87
Fig. 38: Fitting the Wall Insert and the Diffuser
87
Installing the Compressor Casing
87
Table 46: Tightening Torque (79041)
87
Fig. 39: Installing the Compressor Casing
88
Table 47: Tightening Torque (72011)
88
Fig. 40: Measuring Clearances N and R
89
Measuring Radial Clearances N and R
89
Table 48: Permissible Clearances N and R
89
Fig. 41: Installing the Air Inlets
90
Installing the Air Inlets
90
Table 49: Tightening Torque (72020)
90
Fig. 42: Installing the Gas Outlet Flange
91
Installing the Gas Outlet Flange
91
Fig. 43: Installing the Gas Outlet Casing
92
Installing the Gas Outlet Casing
92
Table 50: Tightening Torques (51009, 61003)
92
Fig. 44: Tightening Torque Overview
93
Table 51: Tightening Torques [Nm]
93
Table of Tightening Torques
93
Possible Emergency Repairs
94
Taking out of Operation at Short Notice
94
Cartridge Group
95
Installing a Replacement Cartridge Group
95
Fig. 45: Fitting the Cover Plate
96
Fitting the Cover Plate
96
Table 52: Tightening Torques (51007)
96
Cover Plate Drawing
97
Fig. 46: Cover Plate Drawing
97
Table 53: Cover Plate Dimensions [MM]
97
Mothballing the Low-Pressure Stage
98
Taking the Engine out of Operation for up to 12 Months
98
Taking the Engine out of Operation for more than 12 Months
99
Material and Disposal
100
REACH and Rohs Compliance Declaration for Products
100
Disposing of Low-Pressure and High-Pressure Stage Components
101
Ordering Spare Parts
102
Spare Parts
102
Table 54: Customer Spare Part Set (97070)
102
Spare Part - Illustrations
103
Table 55
103
Table 56
104
Table 57
105
Table 58
106
Table 59
107
Burst Ring
108
Gas Outlet Flange
108
Nozzle Ring
108
Table 60
108
Turbine Casing * (1 Inlet)
108
Gas Outlet Casing
109
Table 61
109
Table 62
110
Table 63
111
Table 64
112
Table 65
113
Table 66
114
Table 67: Customer Tool Set 90000
115
Tools
115
Commissioning and Operating
116
Gas Piping (Option)
116
Table 68: Expected Replacement Interval
116
Periodic Maintenance
117
Table 69: Maintenance Interval
117
Fig. 47: Removing the Bellows
118
Removal and Installation
118
Table 70: Weight
118
Fig. 48: Installing the Bellows
119
Table 71: Tightening Torque (85003 / 85004)
119
Spare Parts
120
Storage and Disposal
120
Fig. 49: Gas Piping with Part Numbers (Power2 340-H)
121
Figures
122
Tables
123
4
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ABB PT003915 Specifications
General
Brand
ABB
Model
PT003915
Category
Industrial Equipment
Language
English
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