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Operation Manual / Power2 850-M / 4.1 Low-pressure stage

5 Taking out of operation at short notice / 5.1 Possible emergency re-
pairs

HZTL4062_EN

Rev.C

July 2020

5.1.1

Manufacturing the cover plate

The cover plate and the other parts that are required are not part of the scope of delivery of
ABB and must be manufactured by the operator on the basis of the drawing

(see Fig. 32:

Cover plate / gasket, sleeves and screws

→

34)

Parts required

1 cover plate (01) (recommended material: 1.4541 / 1.4571)

1 gasket (02) (temperature resistant up to 550 °C)

8 additional screws (03) to the screws (42087) from the scope of delivery

15 sleeves (04)

Fig. 32: Cover plate / gasket, sleeves and screws

Cover plate (gasket), sleeves and screws, dimensions [mm]

Ø1

Ø2

Ø3

Ø4

Ø5

655

600

M12

Table 18: Cover plate / gasket

Page

Summary of Contents for HT608780

Page 1: ...80_A English Original Operation Manual Chapter Document ID 1 Introduction HZTL4004_EN_D 2 Safety HZTL4025_EN_B 3 Safety data sheets HT608780_A 4 Product description HZTL4061_EN_D 4 1 Low pressure stag...

Page 2: ...ls and the corresponding operating limits in chapter 3 are jointly defined with the enginebuilder This information is specific to the product Non observance of the recommended replacement intervals an...

Page 3: ...rights reserved HZTL4004_EN Revision D June 2017 Introduction 1 Introduction 2 1 1 Purpose of the manual 2 1 2 Symbols definitions 2 1 3 Registered trademarks 4 1 4 Power2 layout and function 5 1 5 S...

Page 4: ...r the proper operation of the engine and for the Power2 connected to it Availability of the Operation Manual The Operation Manual must be available where the Power2 is used All persons operating or wo...

Page 5: ...s document Two stage turbocharging Power2 Low pressure stage Power2 LP High pressure stage Power2 HP Low pressure and high pressure stage ABB Turbo Systems ABB Turbo Systems Ltd is identified as ABB T...

Page 6: ...Affix Tighten over specified tighten ing angle Measure Hand tight tighten without tools Note Oil Visually inspect Apply screw locking paste e g Loctite Please note text for numbered work step Apply hi...

Page 7: ...re Power2 LP and high pressure stage Power2 HP within two stage turbocharging Power2 The low pressure stage is always op erated in combination with a high pressure stage connected in series The two st...

Page 8: ...ge groups for more than 6 months VCI WARNING Health protection when handling VCI VCI products are not hazardous in terms of the Ordinance on Hazardous Substances Nevertheless the following points must...

Page 9: ...changed colour the maximum admissible atmospheric humidity has been exceeded In this case the low pressure or high pressure stage or the cartridge group must be checked and repackaged by an ABB Turbo...

Page 10: ...rights reserved HZTL4004_EN Revision D June 2017 1 6 Contact information Contact information for the ABB Turbocharging Service Stations is available online u Scan the QR code to access our website AB...

Page 11: ...ition of safety instructions 3 1 5 Intended use 4 1 6 Deflagration on gas engines 5 1 7 Warning plates on the low pressure and high pressure stage 6 1 8 Rating plate of the high pressure and low press...

Page 12: ...supplies and materials Are a consequence of insufficient compliance with safety instructions Are a consequence of insufficient or inappropriate performance of maintenance and in spection work The ope...

Page 13: ...spiratory mask to protect against Dusts Gases Safety helmet Ear protection Table 2 Personal protective equipment to be worn specific to the respective task 1 4 Definition of safety instructions WARNIN...

Page 14: ...s 1 Euromot The European Association of Internal Combustion Engine Manufacturers 2 Directive 94 9 EC concerning equipment and protective systems intended for use in po tentially explosive atmospheres...

Page 15: ...15 bar guideline value After a deflagration event ABB Turbo Systems recommends verifying the following points on the low pressure and high pressure stages Position of the turbine and compressor casing...

Page 16: ...The warning plates must always be present in the intended locations and must be legible Fig 1 Warning plate If warning plates are not present in the intended locations or are not legible they must be...

Page 17: ...greed with the enginebuilder 2 Operating limits during operation Table 3 Recommended replacement intervals 3 Replacement interval of plain bearings in 1000 h 4 Replacement interval of compressor in 10...

Page 18: ...ring operation for special applications Operation above nMmax and tMmax is not permitted Non observance of the recommended replacement intervals increases the risk of unpredict able component failures...

Page 19: ...helmet Fig 3 Attachment of loads on the crane hook Fig 4 Attachment angle If there are two or more suspension points the attachment angle of 45 must not be ex ceeded This prevents excessive loading du...

Page 20: ...d periodically Suitable working materials and personal protective equipment must be kept in a perfect condition Only authorised personnel may remain in the vicinity of the Power2 when the engine is ru...

Page 21: ...ar protection if the sound pressure level exceeds 85 dB A Wear ear protection Hazards due to hot surfaces Surfaces of the low pressure and high pressure stage attached parts and operating fluids lubri...

Page 22: ...lation and for providing protection against contact with hot sur faces u Compliance with the instructions and specifications given by the en ginebuilder to protect against contact with hot surfaces on...

Page 23: ...eration Safety during commissioning and operation u Visually inspect your working environment before starting work u Remove any obstacles and objects littering the workplace u Check all pipes to and f...

Page 24: ...r train ing Wear safety footwear to protect against mechanical hazard and risk of fall ing Wear protective clothing WARNING Risk of falling When work is performed on the low pressure or high pressure...

Page 25: ...lectric cables for abrasion and damage before and after your cleaning work Safety during disassembly assembly maintenance and repair u Observe the procedures for set up service and inspection work and...

Page 26: ...ation of the tur bocharger or for the performance of maintenance work Oils greases coolants detergents and solvents acids and similar substances can be classified as hazardous substances WARNING Handl...

Page 27: ...in the material safety data sheet for the operat ing materials and supplies u Comply with local legislation Hazards due to the handling of insulation materials WARNING Danger from insulation material...

Page 28: ......

Page 29: ...16 Safety data sheets Contents Page 1 3 Safety data sheets Copyright 2022 ABB All rights reserved HT608780_A January 2022 Power2 850 M16 HT608780 Name Hardware ID Page Low pressure stage PT003824 2 Hi...

Page 30: ...16 HT608780 Low pressure stage PT003824 Power2 850 M16 HT608780 Low pressure stage PT003824 32 420 412 80 2022 1900 80 HZTL52274D Additional Safety Data Maximum permissible temperatures Exhaust gas in...

Page 31: ...23 Power2 850 M16 HT608780 High pressure stage PT003823 32 612 580 80 2022 700 80 HZTL53374D Additional Safety Data Maximum permissible temperatures Exhaust gas inlet temperature At engine overload 11...

Page 32: ......

Page 33: ...out of operation 17 4 Monitoring during operation 18 4 1 Lubricating oil pressure 18 4 2 Lubricating oil temperature 19 4 3 Speed measurement 20 5 Operation and service 28 5 1 Noise emission 28 5 2 Se...

Page 34: ...All rights reserved HZTL4061_EN Rev D March 2020 10 Taking out of operation for a long period 54 10 1 General 54 10 2 Lubricating oil 54 10 3 Process for taking out of operation 54 11 Disposing of lo...

Page 35: ...d HZTL4061_EN Rev D March 2020 1 Introduction 1 1 Related documents Chapter Document number Operation Manual 1 Introduction HZTL4004 Operation Manual 2 Safety HZTL4025 Operation Manual 3 Safety data s...

Page 37: ...Power2 LP and high pressure stage Power2 HP within two stage turbocharging Power2 The low pressure stage is always op erated in combination with a high pressure stage connected in series The two stage...

Page 38: ...ed HZTL4061_EN Rev D March 2020 1 3 Layout and function of the low pressure stage Fig 2 Layout and function of the low pressure stage 01 Filter silencer air suction branch 06 Gas inlet casing 02 Compr...

Page 39: ...ure stage 6 the exhaust gas coming from the high pressure stage Power2 HP flows through the gas inlet casing 06 and the nozzle ring 07 and reaches the turbine 08 The LP turbine uses the energy contain...

Page 40: ...reserved HZTL4061_EN Rev D March 2020 1 4 Layout and function of the high pressure stage Fig 4 Layout and function of the high pressure stage 01 Air suction branch 06 Gas inlet casing 02 Compressor w...

Page 41: ...ut and function of the high pressure stage 8 the exhaust gas flows through the gas inlet cas ing 06 and the nozzle ring 07 and reaches the turbine 08 The HP turbine uses the en ergy contained in the e...

Page 42: ...er2 HP warning plates If warning plates are not present in the designated locations or not readable proceed as fol lows u Order new warning plates from ABB Turbocharging Service Stations u Remove any...

Page 43: ...8 Location of Power2 LP rating plate One rating plate each is attached on the left and the right side of the foot bearing casing and to the filter silencer and air suction branch of the low pressure...

Page 44: ...Rev D March 2020 2 Removal and installation u For more information on how to remove and install the low pressure stage see document Operation Manual Power2 4 1 Low pressure stage u For more informati...

Page 45: ...essure and high pressure stage must be pre lubricated in order to avoid bearing damage caused by dry running u Adhere to the admissible oil pressure range see Table 5 Oil pressure range 18 An electric...

Page 46: ...isk of oil leakage during standstill The following measures are recommended for reducing the risk of oil leakage during stand still Reduction of the pressure in the bearing space by a means of an appr...

Page 47: ...ine or property can be caused by dirt and solid ma terial particles in the oil u For the initial commissioning phase and after all service work flush the complete lubricating system with warm oil u Us...

Page 48: ...e speed oil pressure and charging pressure at various engine performances u Measure the exhaust gas temperature before and after the turbine u Measure the air temperature before and after the compress...

Page 49: ...after the turbine for combustion residues or wa ter residues and clean it Remove any foreign objects that may be present u Check and clean filter silencer or air supply line and remove any foreign obj...

Page 50: ...measuring point The measuring point M is at the oil supply channel of the high and low pressure stage that is not used for the oil supply Power2 Status Engine Status Low pressure and high pressure st...

Page 51: ...temperature at the outlet Toil inlet C 850 Admissible 90 150 Temporarily admissible 1 h Alarm 90 95 150 155 Not admissible stop engine 95 155 Not admissible preheat oil prior before start 30 Table 6...

Page 52: ...ent system consists of a sensor 01 with integrated cables 02 05 an electronic unit 04 and a plug 06 The sensor operates according to the eddy current prin ciple and is installed in a radial direction...

Page 53: ...engine performance until the maximum speed of all low and high pressure stages does not exceed 70 of nBmax u If the engine cannot be stopped it can continue to be driven with this reduced engine perfo...

Page 54: ...urement Copyright 2020 ABB All rights reserved HZTL4061_EN Rev D March 2020 4 3 5 Replacing the speed measurement system 4 3 5 1 Low pressure stage Removing the speed measurement system Fig 12 Dimensi...

Page 55: ...Copyright 2020 ABB All rights reserved HZTL4061_EN Rev D March 2020 Installing the speed measurement system Fig 14 Setting dimension X 1 Set speed sensor 86505 in the plate 86507 to dimension X 2 Secu...

Page 56: ...HZTL4061_EN Rev D March 2020 Fig 15 Control dimension S 3 Secure plate with wedge lock washer 86508 and socket screw 86510 Observe tighten ing torque 4 Adjust dimension X until S 0 mm is reached 5 Pos...

Page 57: ...eration 4 3 Speed measurement Copyright 2020 ABB All rights reserved HZTL4061_EN Rev D March 2020 4 3 5 2 High pressure stage Removing the speed measurement system Fig 16 Dimension X u Measure and not...

Page 58: ...Copyright 2020 ABB All rights reserved HZTL4061_EN Rev D March 2020 Installing the speed measurement system Fig 18 Setting dimension X 1 Set speed sensor 86505 in the plate 86507 to dimension X 2 Secu...

Page 59: ...HZTL4061_EN Rev D March 2020 Fig 19 Control dimension S 3 Secure plate with wedge lock washer 86508 and socket screw 86510 Observe tighten ing torque 4 Adjust dimension X until S 0 mm is reached 5 Pos...

Page 60: ...tance of 1 metre from the low pressure and high pressure stage The highest value of the emission sound pressure level1 reaches a maximum of 105 dB A near the compressor end compressor casing filter si...

Page 61: ...sh envir onmental conditions poor fuel quality or high system vibrations can lead to untimely machine damage even if the prescribed service intervals are ob served u Agree on a specific service interv...

Page 62: ...pecifications on the rating plate The following work must be carried out by an ABB Turbocharging Service Station Replacement of the bearing parts Replacement of the turbine and the compressor 5 2 6 En...

Page 63: ...For information on the expected replacement intervals of the components of the high pressure stage see document Operation Manual Power2 4 2 High pressure stage 5 4 Stopping the engine CAUTION Residua...

Page 64: ...ting state LP compressor 25 100 h Engine load 50 100 HP compressor HP turbine stage 80 200 h Engine load 25 LP turbine stage LP filter silencer2 500 h Engine stopped Table 7 Maintenance intervals 1 If...

Page 65: ...The contamination of the compressor stage compressor wheel and diffuser depends on the degree of purity of the sucked in air Deposits can form in the flow channels if salt oil mist or dust are sucked...

Page 66: ...water but only pure water for cleaning CAUTION Volume of water Uncontrolled volumes of water can damage the pressure stages and the en gine u Never connect the water line without the orifice specified...

Page 67: ...igger water injection according to the instructions of the enginebuilder u Observe water pressure before connection to pressure stage u Operate engine for at least five additional minutes after cleani...

Page 68: ...nders Incompletely burnt fuel Sodium vanadyl vanadate It is advantageous to use fuels with low ash sulphur sodium and vanadium contents The fuel must also be correctly stored prepared and handled ABB...

Page 69: ...impacting water droplets Solubility Water solubility of the contamination deposits in water Thermal shock Spalling of contamination due to the temperature differential CAUTION Corrosion and deposits w...

Page 70: ...inlet in the LP stage N m2 Engine load Max gas inlet temperature when starting cleaning C Holding time at reduced load min 850 9500 2500 3200 800 25 430 10 Table 10 Operating point for turbine cleani...

Page 71: ...ning connection of the tur bocharger is to be set as a rough approximation 3 Cleaning the low pressure turbine stage LP stage u If present open the drain pipe in the low pressure stage during cleaning...

Page 72: ...utes or not at all If the drainage of the gas outlet casing is omitted the low pressure stage speed and or the gas inlet temperature must be monitored during the cleaning process If the load is too lo...

Page 73: ...er ring if present 81273 Lock nut E Insert unit absorption segment sheet metal covering Cleaning the filter ring if present u Remove filter ring 81265 u Clean filter ring 81265 as required or every 50...

Page 74: ...ny heavily contaminated absorption segments and filter rings as well as damaged connecting rods replaced by an ABB Turbocharging Service Station Fitting the filter silencer u Assemble the insert units...

Page 75: ...necting rods 81269 with the screws 81272 While tightening the screws 81272 make sure that the connecting rods 81269 lie correctly in the slots on the filter silencer body 81135 Now alternately tighten...

Page 76: ...compliance with locally applicable regulations Cleaning the absorption segments see Fig 23 Cleaning the filter silencer 43 u Loosen the tension bands 81270 u Remove the cover grid 81266 u Pull out an...

Page 77: ...7 Malfunctions when starting Vibrations Rubbing of rotating parts Normal behaviour not a malfunction Low pressure or high pressure stage A minimal and uniform wear at the circumference of the rotor co...

Page 78: ...high pressure stage speed Possible causes Remedy Engine Defects on the connected cylinders Contact enginebuilder High pressure stage Heavy contamination of the turbine Clean Damaged rotor components o...

Page 79: ...ssure stage Insufficient air for example because filter silencer is blocked by contam ination Clean Compressor turbine contaminated Exhaust gas back pressure too high Clean or repair boiler or exhaust...

Page 80: ...ter silencer contaminated there fore pressure drop too high Clean Compressor turbine contaminated Compressor turbine damaged Contact ABB Turbocharging Service Station Exhaust gas back pressure too hig...

Page 81: ...tion gases Correct the influx of ventilation gases in accordance with the enginebuilder s in structions Table 27 Malfunctions during operation Compressor 1 contamination Reduced fatigue strength of th...

Page 82: ...uously or periodic ally their components may be damaged u Gradually reduce the engine load u Have the cause clarified and remedied immediately by an ABB Turbochar ging Service Station u Have parts ass...

Page 83: ...ing Foreign object in the pressure stage Table 30 Malfunctions when stopping Runout noises Runout time too short Possible causes Remedy Low pressure or high pressure stage Pressure stage contaminated...

Page 84: ...D March 2020 8 Disassembly and assembly u For more information on the disassembly and assembly of the low pressure stage see document Operation Manual Power2 4 1 Low pressure stage u For more informat...

Page 85: ...March 2020 9 Taking out of operation at short notice u For more information on briefly taking the low pressure stage out of operation see docu ment Operation Manual Power2 4 1 Low pressure stage u Fo...

Page 86: ...udes cleaning and applying preservative oil to the relevant compon ents 10 3 Process for taking out of operation Different measures are required depending on the process used to take the low pressure...

Page 87: ...bearing brass Further components are Non metallic materials filter components of felt and polyethylene lubricants engine oil electronic parts speed sensor and associated components u Dispose of metal...

Page 88: ...HZTL4061_EN Rev D March 2020 12 Spare parts u For more information on spare parts for the low pressure stage see document Operation Manual Power2 4 1 Low pressure stage u For more information on spare...

Page 89: ...warning plates 10 Fig 8 Location of Power2 LP rating plate 11 Fig 9 Location of Power2 HP rating plate 11 Fig 10 Lubricating oil pressure measuring point 18 Fig 11 Functional principle 20 Fig 12 Dime...

Page 90: ...ctions when starting Rubbing of rotating parts 45 Table 19 Malfunctions during operation Lubricat ing oil pressure too low 46 Table 20 Malfunctions during operation Power2 LP speed reductions 46 Table...

Page 91: ...6 Axial clearance A prior to disassembly 13 4 7 Removing the wall insert 14 4 8 Removing the compressor casing 15 4 9 Removing the cartridge group 16 4 10 Removing turbine diffuser and nozzle ring 18...

Page 92: ...applicable documents Chapter Document number Operation Manual Power2 1 Introduction HZTL4004 Operation Manual Power2 2 Safety HZTL4025 Operation Manual Power2 3 Safety data sheet Power2 serial number...

Page 93: ...e ABB scope of delivery Swivel lifting eye S Power2 Thread Length Minimum load limit Lmin Lmax 850 LP M24 30 mm 40 mm 1900 kg Table 2 Swivel lifting eyes to be used Lifting gear with a sufficient load...

Page 94: ...suitable location u Secure with lifting gear wherever possible Fig 1 Suspension of complete low pressure stage u Remove insulation according to the instructions of the enginebuilder u Disconnect all g...

Page 95: ...he orifices specified for the low pressure stage have been installed in both oil supply lines u Check that the gaskets have been correctly fitted at the oil inlet and the oil outlet in the bracket u A...

Page 96: ...acing the non rotating components exposed to hot gas A decisive role is played by various influencing parameters which in extreme cases can drastically reduce the replacement interval of these parts D...

Page 97: ...uel treatment Load profile thermal cycling also number of starts stops emergency shutdowns Gas inlet temperature Frequency and execution of turbine and compressor cleaning Specification of the low pre...

Page 98: ...are described in this document u Only perform operations for which you have previously received instruc tion or training u Have further operations carried out only by trained personnel from an ABB Tur...

Page 99: ...ks deformation and wear u Damaged tools must no longer be used and must be replaced WARNING Servicing the assembly devices Assembly devices must be checked for damage before and after use u Visually i...

Page 100: ...eights of assemblies The specified weights of the individual parts or assemblies are rounded up standard values Fig 3 Overview of assemblies Designation Weight kg 01 Air suction branch 80 02 Filter si...

Page 101: ...y u If present Disconnect supply line for compressor cleaning from filter silencer Fig 4 Removing the filter silencer 1 Fit the swivel lifting eye 90231 to the silencer 81000 Attach the lifting gear t...

Page 102: ...branch u Disconnect air line according to the instructions of the enginebuilder u Dismantle insulation as far as necessary u If present Disconnect supply line for compressor cleaning from air suction...

Page 103: ...tolerance Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts u Have the components assessed and if necessary replaced by an ABB Tur boch...

Page 104: ...wheel does not rub against the wall insert during disassembly assembly by rotating the rotor Fig 7 Removing wall insert 1 1 Screw nut 72004 onto end of bolt thread as protection 2 Use three press off...

Page 105: ...9 Removing wall insert 3 9 Fit support angle 90480 with screws 90955 and nut 90415 10 Put down the wall insert 77000 11 Remove plate 90032 screw 90656 nut 90432 and plates 90031 Remove lifting gear a...

Page 106: ...vel lifting eye 90231 and secure compressor casing 72000 to crane 5 Loosen and remove nuts 61037 6 Press off compressor casing 72000 with three press off screws 90924 7 Move out compressor casing 7200...

Page 107: ...two screws 90955 4 Fit five plates 90031 and secure with plate 90032 screw 90656 and nut 90432 5 Secure lifting gear to swivel lifting eye 90231 and secure cartridge group to crane 6 Evenly press off...

Page 108: ...storage of the cartridge group u The cover must be on a level surface u The cover may not be used to transport the cartridge group Fig 14 Putting down cartridge group onto cover 4 10 Removing turbine...

Page 109: ...f screws 90902 5 Secure guide tube 90422 to bracket 90030 with screws 90955 and nuts 90415 6 Do not fit front bolt 90033 yet Fig 17 Removing turbine diffuser and nozzle ring 3 7 Insert bracket with gu...

Page 110: ...late 90032 screw 90656 nut 90432 and plates 90031 Remove the press off screws 90902 14 Loosen screws 56017 with box spanner insert 90770 and remove together with clamps 56018 15 Remove nozzle ring 560...

Page 111: ...Installation of bracket and plate see Removing turbine diffuser and nozzle ring 18 6 Insert turbine diffuser 63000 via the guide studs 7 Coat a screw 61056 with high temperature grease and screw in to...

Page 112: ...rubbing or jamming of the blade tips on the casing u Check that the blades do not rub on the turbine diffuser during disas sembly assembly by rotating the rotor Fig 21 Installing O rings u Fit new O...

Page 113: ...the cartridge group 4 Remove plates 90031 and bracket 90030 5 Remove the guide stud 90321 6 Coat thread of remaining screws 42087 with high temperature grease and fit screws Observe tightening torque...

Page 114: ...alling the cartridge group the control dimension X must be measured Control dimension X mm 63 0 0 1 Table 10 Control dimension X 4 13 Installing the compressor casing Fig 25 Installing the compressor...

Page 115: ...w 72021 Observe tightening torque Application of special key for nuts that are difficult to access u Attach the special key 90250 91250 90251 91251 to the torque spanner by using the adapter 90249 912...

Page 116: ...1 Coat the threads of screws 77016 with Loctite 243 and secure diffuser 79000 with screws 77016 Observe tightening torque 2 Install new O rings 77040 79020 79021 3 Secure lifting gear to swivel liftin...

Page 117: ..._EN Rev C July 2020 Part number Tightening torque 72002 M16x104 50 Nm Table 13 Tightening torque 72002 1 Remove plate 90032 screw 90656 nut 90432 and plates 90031 2 Remove the bracket 90030 3 Detach s...

Page 118: ...nce Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts u Have the components assessed and if necessary replaced by an ABB Tur bocharging...

Page 119: ...nch Part number Thread and tightening torque 72004 M16 200 Nm Table 15 Tightening torque 72004 1 Remove the two opposing nuts 72004 and washers 72003 that were used to secure the wall insert 2 Loop ar...

Page 120: ...22 1 Application with adapter 90249 and special key 90250 90251 see below 1 Fit sleeves 77023 and nuts 77022 in accordance with position of filter silencer and tighten nuts 77022 2 Remove the two oppo...

Page 121: ...91251 to the torque spanner by using the adapter 90249 91249 u Use the special key in an angle range between 30 and 90 u Use the special key only for nuts that are difficult to access and observe the...

Page 122: ...torque 61037 nuts that are difficult to access Pre tightening torque 60 Nm Tightening angle 90 5 190 Nm 1 61056 M10x90 50 Nm 72002 M16x104 50 Nm 72004 M16 200 Nm 72004 nuts that are difficult to acces...

Page 123: ...the alarm and depending on the situation stop the engine u Seal the oil leak u Soak up oil and dispose of in an environmentally compatible manner Wear safety gloves to protect against thermal hazards...

Page 124: ...very of ABB and must be manufactured by the operator on the basis of the drawing see Fig 32 Cover plate gasket sleeves and screws 34 Parts required 1 cover plate 01 recommended material 1 4541 1 4571...

Page 125: ...torque 42087 1 Remove alternative air inlet wall insert compressor casing and cartridge group 2 Close opening in bearing casing with gasket 02 and cover plate 01 3 Secure cover plate 01 with spacer sl...

Page 126: ...ing data when making queries and ordering spare parts Serial number of Power2 HT Serial number of the low or high pressure stage PT Designation and part number Spare parts can be ordered from an ABB T...

Page 127: ...Operation Manual the customer spare part set 97070 is required These parts are only available in the complete set Part number Designation Quantity 42012 79020 O ring 2 42017 O ring 1 42018 O ring 2 4...

Page 129: ...6 2 View of low pressure stage with part numbers Copyright 2020 ABB All rights reserved HZTL4062_EN Rev C July 2020 6 2 View of low pressure stage with part numbers Fig 35 Low pressure stage with part...

Page 130: ...Clamp 61001 Gas outlet casing 61009 Hexagon head screw 61037 in customer spare part set Hexagon nut 61050 Spiral wound gasket 61056 in customer spare part set Hexagon head screw 63000 Turbine diffuser...

Page 131: ...e 1 90920 Press off screw 3 90924 Press off screw 3 90902 Press off screw 3 90320 Guide stud 2 90321 Guide stud 2 90316 Guide stud 2 90955 Hexagon head screw 6 90959 Hexagon head screw 4 90950 Hexagon...

Page 132: ...ser and nozzle ring 1 18 Fig 16 Removing turbine diffuser and nozzle ring 2 19 Fig 17 Removing turbine diffuser and nozzle ring 3 19 Fig 18 Removing turbine diffuser and nozzle ring 4 20 Fig 19 Instal...

Page 133: ...torque 56017 20 Table 8 Tightening torque 61056 21 Table 9 Tightening torque 42087 23 Table 10 Control dimension X 24 Table 11 Tightening torque 61037 72021 24 Table 12 Tightening torque 77016 26 Tabl...

Page 134: ......

Page 135: ...air suction branch together with bellows 11 4 5 Removing the wall insert 12 4 6 Removing the compressor casing 14 4 7 Removing the cartridge group 15 4 8 Removing the nozzle ring 17 4 9 Measuring axi...

Page 136: ...applicable documents Chapter Document number Operation Manual Power2 1 Introduction HZTL4004 Operation Manual Power2 2 Safety HZTL4025 Operation Manual Power2 3 Safety data sheet Power2 serial number...

Page 137: ...Fig 1 Swivel lifting eyes Thread M Length L Minimum load limit Quantity 12 min 15mm max 20mm 700kg 2 Table 2 Swivel lifting eyes Lifting gear with a sufficient load limit must be used for removing and...

Page 138: ...n must be transported and fitted separately Fig 2 Suspension of complete high pressure stage u Remove insulation u Disconnect all gas air water and oil pipes in accordance with the enginebuilder s ins...

Page 139: ...ints of the bearing casing and one lifting gear to the support u Check that the orifices specified for the high pressure stage are installed in the two oil supply pipes u Check that the gaskets have b...

Page 140: ...lacing the non rotating components exposed to hot gas A decisive role is played by various influencing parameters which in extreme cases can drastically reduce the replacement interval of these parts...

Page 141: ...file thermal cycling also number of starts stops emergency shutdowns Gas inlet temperature Frequency and execution of turbine and compressor cleaning Specification of the high pressure stage System sp...

Page 142: ...are described in this document u Only perform operations for which you have previously received instruc tion or training u Have further operations carried out only by trained personnel from an ABB Tur...

Page 143: ...ING Servicing the tools The tools must be checked for damage before and after use u Visually inspect for corrosion cracks deformation and wear u Damaged tools must no longer be used and must be replac...

Page 144: ...July 2020 4 3 Weights of assemblies The specified weights of the individual parts or assemblies are rounded up standard values Fig 4 Overview of assemblies Designation Weight kg 01 Air suction branch...

Page 145: ...ith bellows u Disconnect the air line in accordance with the enginebuilder s instructions u Dismantle insulation as far as necessary u If present Disconnect supply line for compressor cleaning from ai...

Page 146: ...upper area 2 Unplug cable connector 86515 and fix speed measurement cable in wall insert 3 Use three press off screws 90900 to press off the wall insert 77000 until the lifting device can be fitted F...

Page 147: ...embly 4 5 Removing the wall insert Copyright 2020 ABB All rights reserved HZTL4063_EN Rev D July 2020 Fig 8 Removing wall insert 3 8 Fit support angle 90450 with screws 90658 washers 72003 and nuts 72...

Page 148: ...0030 to compressor casing 72000 with screws 90658 2 Fit two plates 90031 and secure with plate 90032 screw 90656 and nut 90432 3 Secure lifting gear to swivel lifting eye 90657 and attach compressor c...

Page 149: ...ring 42010 2 Loosen and remove the screws 42099 3 Fit bracket 90030 and fit swivel lifting eye 90657 to cartridge group with screws 90900 4 Move in three plates 90031 5 To secure fit plate 90032 with...

Page 150: ...y be used for intermediate storage of the cartridge group u The cover must be on a level surface u The cover may not be used to transport the cartridge group Fig 12 Moving out cartridge group 3 9 Lowe...

Page 151: ...le ring Copyright 2020 ABB All rights reserved HZTL4063_EN Rev D July 2020 Fig 13 Moving out cartridge group 4 12 Remove O rings 42017 42018 4 8 Removing the nozzle ring Fig 14 Removing the nozzle rin...

Page 152: ...Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts u Have the components assessed and if necessary replaced by an ABB Tur bocharging Ser...

Page 153: ...served HZTL4063_EN Rev D July 2020 4 10 Installing the nozzle ring Fig 16 Installing the nozzle ring Part number Thread and tightening torque 56017 M8 Tx40 25 Nm Table 7 Tightening torque 56017 1 Fit...

Page 154: ...4 11 Installing the cartridge group Fig 17 Installing O rings u Fit new O rings 42017 42018 Fig 18 Installing the cartridge group 1 1 Clean slots for lamellar rings 64001 and fit new lamellar rings Ar...

Page 155: ...4063_EN Rev D July 2020 Fig 19 Installing the cartridge group 2 Part number Thread and tightening torque 42099 M12x80 80 Nm Table 8 Tightening torque 42099 5 Fit a screw 42099 as a safeguard 6 Remove...

Page 156: ...on is out of tolerance the cartridge group has not been correctly installed and can be the cause of serious damage to the ma chine or property u Remove and reinstall the cartridge group u Always repla...

Page 157: ...ication with adapter 90249 and special key 90250 see below 1 Fit a new O ring 42012 2 Secure lifting gear to swivel lifting eye 90657 and insert compressor casing Installation of bracket and plates se...

Page 158: ...Rev D July 2020 4 13 Installing the wall insert Fig 22 Installing the wall insert 1 1 Fit bracket 90030 Installation of bracket see Fig 7 Removing wall insert 2 12 2 Secure lifting gear to swivel lif...

Page 159: ...Installing the wall insert 2 Part number Thread and tightening torque 72002 M12x95 50 Nm Table 11 Tightening torque 72002 6 Fit a nut 72004 as a safeguard 7 Remove bracket 90030 8 Slide in wall inser...

Page 160: ...Part number Thread and tightening torque 72004 M12 120 Nm Table 12 Tightening torque 72004 1 Remove lock nut 72004 2 Loop around air suction branch and secure to air line in such a way that the bellow...

Page 161: ...s The following tightening torques Nm must be observed for the designated bolted connec tions Part number Thread and tightening torque 42099 M12x80 80 Nm 56017 M8 Tx40 25 Nm 61090 M12 120 Nm 61090 nut...

Page 162: ...the alarm and depending on the situation stop the engine u Seal the oil leak u Soak up oil and dispose of in an environmentally compatible manner Wear safety gloves to protect against thermal hazards...

Page 163: ...s that are required are not part of the scope of delivery of ABB and must be manufactured by the operator on the basis of the drawing see Fig 26 Cover plate gasket and sleeves 29 Parts required 1 cove...

Page 164: ...2099 1 Remove air suction branch with bellows wall insert compressor casing and cartridge group 2 Close opening in bearing casing with gasket 02 and cover plate 01 3 Secure cover plate 01 with spacer...

Page 165: ...ing data when making queries and ordering spare parts Serial number of Power2 HT Serial number of the low or high pressure stage PT Designation and part number Spare parts can be ordered from an ABB T...

Page 166: ...e stage For the operations described in the Operation Manual the customer spare part set 97070 is required These parts are only available in the complete set Part number Designation Quantity 42010 O r...

Page 167: ...2 View of high pressure stage with part numbers Copyright 2020 ABB All rights reserved HZTL4063_EN Rev D July 2020 6 2 View of high pressure stage with part numbers Fig 29 High pressure stage with pa...

Page 168: ...radial 56001 Nozzle ring 56017 in customer spare part set Hexalobular head screw 61001 Gas outlet casing 61003 Hexagon head screw 61004 Verbus Ripp locking washer 61009 Hexagon head screw 61036 Stud...

Page 169: ...0450 Support 2 90426 Ring spanner 1 90657 Swivel lifting eyes 2 90900 Press off screw 3 90901 Press off screw 3 90913 Press off screw 4 90658 Hexagon head screw 4 90656 Hexagon head screw 1 90662 Hexa...

Page 170: ...ng out cartridge group 2 15 Fig 12 Moving out cartridge group 3 16 Fig 13 Moving out cartridge group 4 17 Fig 14 Removing the nozzle ring 17 Fig 15 Measuring axial clearance A 18 Fig 16 Installing the...

Page 171: ...of the assemblies 10 Table 6 Axial clearance A 18 Table 7 Tightening torque 56017 19 Table 8 Tightening torque 42099 21 Table 9 Control dimension X 22 Table 10 Tightening torque 61090 23 Table 11 Tig...

Page 172: ......

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ABB HT608780, Operation Instructions Manual

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