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

1 Introduction / 1.5 Layout and function of the low-pressure stage

© Copyright 2022 ABB. All rights reserved.

HZTL4062_EN

Rev.E

March 2022

Mode of operation of the low-pressure stage (Power2 LP)

Fig. 3: Power2 LP diagram

Power2

Two-stage turbocharging

21

HP compressor

Power2 LP

Low-pressure stage

22

HP turbine

Power2 HP High-pressure stage

24

LP turbine

A

Exhaust gas inlet from internal combus-
tion engine

25

LP compressor

B

Exhaust gas outlet

26

Intercooler

C

Air or air/gas mixture inlet

D

Air or air/gas mixture outlet and supply
to the charge air cooler

- - -

Not included in the Turbo Systems
scope of delivery

The low-pressure stage (Power2 LP) is a turbomachine and its main components are a tur-
bine and a compressor. These components are installed on a common shaft and form the ro-
tor.

In the low-pressure stage (Power2 LP) shown in the illustration 

 (see Fig. 2: Layout and func-

tion of the low-pressure stage 

→

8)

, the exhaust gas coming from the high-pressure stage

(Power2 HP) flows through the gas inlet casing (07) and the nozzle ring (08) and reaches the
turbine (09). The LP turbine uses the energy contained in the exhaust gas to drive the rotor.
The exhaust gases then reach the atmosphere through the gas outlet casing (06) and the ex-
haust gas pipe connected to it.

The rotor runs in two radial plain bearings (02/05). These are located between the com-
pressor and turbine and are guided in the bearing bush (04) and axial bearing (03). The plain
bearings are connected to a central lubricating oil duct which is normally supplied by the lub-
ricating oil circuit of the engine. The oil outlet lies at the deepest point of the bearing casing
(10).

The LP compressor wheel (12) connected to the shaft sucks in fresh air or an air/gas mixture
through the filter silencer (01) or the air suction branch. The air is compressed in the LP com-
pressor (12) and the downstream diffuser (11). The compressed air is passed on to the inter-
cooler (26) via the compressor casing (13). The air is cooled in the intercooler (26) and sub-
sequently supplied to the HP compressor (21).

Page 

9

 / 

119

Summary of Contents for Power2 850-M

Page 1: ...15 2 5 Intended use 16 2 6 Deflagration on gas engines 17 2 7 Warning plates on the low pressure stage 18 2 8 Rating plate of the low pressure stage 19 2 9 Periodic check of the pressure vessels 20 2 10 Lifting of loads 21 2 11 Prerequisites for operation and maintenance 22 2 12 Hazards during operation and maintenance 23 2 13 Safe operation 25 2 14 Safe maintenance 26 3 Removal and installation 3...

Page 2: ...lter silencer 74 9 5 Removing the air suction branch 75 9 6 Axial clearance A prior to disassembly 76 9 7 Removing the wall insert 77 9 8 Removing the compressor casing 79 9 9 Removing the cartridge group 80 9 10 Removing turbine diffuser and nozzle ring 82 9 11 Installing turbine diffuser and nozzle ring 84 9 12 Installing the cartridge group 86 9 13 Installing the compressor casing 89 9 14 Insta...

Page 3: ...0 M Low pressure stage Table of contents Copyright 2022 ABB All rights reserved HZTL4062_EN Rev E March 2022 13 Spare parts 103 13 1 Ordering spare parts 103 13 2 Spare part Illustrations 105 14 Tools 116 Figures 117 Tables 118 ...

Page 4: ... prevention and environmental protection Target group The Operation Manual is aimed at engineers and trained mechanics responsible for 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 working on the Power2 must have read and fully understood the Operati...

Page 5: ...pressure stages This may result in sections and descriptions of components that are not relevant for a specific Power2 high pressure stage Please contact a Turbo Systems service station if you have any questions regarding a design variant see Contact information at www abb com turbocharging Accuracy of illustrations The illustrations in this document are general in nature and intended for ease of ...

Page 6: ...Operation Manual Power2 850 M Low pressure stage 1 Introduction 1 3 Essential information Copyright 2022 ABB All rights reserved HZTL4062_EN Rev E March 2022 Page 6 119 ...

Page 7: ...ure 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 tur bocharging Power2 supplies the engine with the air volume and associated charging pres sure required for operation Here the exhaust gases of the internal combustion engine flow through the tu...

Page 8: ... 5 Layout and function of the low pressure stage Fig 2 Layout and function of the low pressure stage 01 Filter silencer air suction branch 08 Nozzle ring 02 Radial plain bearing 09 Turbine 03 Axial bearing 10 Bearing casing 04 Bearing bush with heat shield 11 Diffuser 05 Radial plain bearing 12 Compressor wheel 06 Gas outlet casing 13 Compressor casing 07 Gas inlet casing Page 8 119 ...

Page 9: ...re stage 8 the exhaust gas coming from the high pressure stage Power2 HP flows through the gas inlet casing 07 and the nozzle ring 08 and reaches the turbine 09 The LP turbine uses the energy contained in the exhaust gas to drive the rotor The exhaust gases then reach the atmosphere through the gas outlet casing 06 and the ex haust gas pipe connected to it The rotor runs in two radial plain bearin...

Page 10: ...must be complied with Definition of Caution Warning Caution and warning signs are described in chapter Safety Terms used The following terms are used in this document Two stage turbocharging Power2 Low pressure stage Power2 LP High pressure stage Power2 HP Low pressure and high pressure stage Turbo Systems Turbo Systems Switzerland Ltd is referred to in this document as Turbo Systems Official serv...

Page 11: ...en over specified tightening angle Hand tight tighten without tools Oil Apply screw locking paste e g Loctite Apply high temperature grease Apply other paste in accordance with specifications Oil free grease free and dry Affix Measure Note Visually inspect Please note text for numbered work step See document Dispose of in an environmentally compatible professional way and in compliance with locall...

Page 12: ...ctions must be observed Fig 4 Volatile Corrosion Inhibitor 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 be observed when handling VCI u Observe information in material safety data sheet u Ensure proper space ventilation u Do not eat drink or store food at the workplace while w...

Page 13: ...e or the cartridge group must be checked and repack aged by a Turbo Systems service station u Inspect the package for damage If the package is damaged the low or high pressure stage or the cartridge group must be checked and repackaged by a Turbo Systems ser vice station After every 3 years the following work steps must be performed by a Turbo Systems service station Inspect the component Replace ...

Page 14: ... or 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 operating company is responsible for defining measures that regulate safe access to and safe handling of the Power2 All instructions contained in this chapter must be observed for safe and trouble fre...

Page 15: ...d Respiratory mask to protect against Dusts Gases Safety helmet Ear protection Table 3 Personal protective equipment to be worn specific to the respective task 2 4 Definition of safety instructions WARNING Definition of Warning Non compliance or inaccurate compliance with working or operating in structions indicated by this symbol and the word WARNING can lead to seri ous injuries to personnel and...

Page 16: ...ects all warranty claims for any non intended ap plications 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 ATEX The Euromot Position as of November 2003 ATEX Euromot Position 191103 WARNING Unapproved operation Operation of the Power2 outside of the...

Page 17: ...e of 15 bar guideline value After a deflagration event Turbo Systems recommends verifying the following points on the low pressure and high pressure stages Position of the turbine and compressor casings to the bearing casing Shifting of the bearing casing in relation to the bracket Cracks in casings If during external inspection anomalies are found or if a particularly strong deflagration event ha...

Page 18: ...he designated locations or not readable proceed as fol lows u Order new warning plates from Turbo Systems service stations u Remove any warning plates that have become unreadable u Clean and degrease the areas designated for the warning plates u Fit new warning plates and remove protective sheets Non insulated high and low pressure stages High and low pressure stages supplied to the enginebuilder ...

Page 19: ...Further data 6 Power2 designation 7 Power2 serial number 8 Power2 stage 9 Serial number of the low or high pressure stage 10 Year of construction of the low or high pressure stage 11 Weight of the low or high pressure stage 12 Part number of the customer of the low or high pressure stage Table 6 Further data Explanations of the rating plate The recommended replacement intervals and the correspondi...

Page 20: ... 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 stage 2 9 Periodic check of the pressure vessels The pressure vessels used by Turbo Systems such as those for wet or dry cleaning are so called simple pressure vessels The locally applicable legal regulations regarding periodic checks of the pressure vessels ...

Page 21: ...ty helmet Fig 9 Attachment of loads on the crane hook Fig 10 Attachment angle If there are two or more suspension points the attachment angle of 45 must not be ex ceeded This prevents excessive loading due to diagonal pull u Before looping around the components of the low pressure and high pressure stage al low them to cool down maximum 80 C u Attach components of the low pressure and high pressur...

Page 22: ...ust be checked 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 run ning Competence of personnel The Power2 may only be operated and serviced by trained and authorised personnel Basic mechanical training is a prerequisite Modifications to the Power2 Mod...

Page 23: ...ar ear 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 lubricating oil get hot during operation The surface temperature depends on the efficacy of the existing insulation The temperature may rise to a level that can cause burns WARNING Danger of burns Touc...

Page 24: ... sulation and for providing protection against contact with hot surfaces u Compliance with the instructions and specifications given by the en ginebuilder to protect against contact with hot surfaces on the low pres sure and high pressure stage is compulsory Wear safety gloves to protect against thermal hazards Hazards due to rotating parts WARNING Physical hazards due to rotating parts Contact wi...

Page 25: ...g 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 from the Power2 for damage and leaks before commissioning u Check Power2 for recognisable damage or defects every 12 hours of operation or at least once a day u Report any damage and any alterations of operational charact...

Page 26: ...ootwear 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 stage there is a risk of falling u Do not climb onto the low pressure or high pressure stage or onto at tached parts and do not use them as climbing aids u Use suitable climbing aids and working platforms for work above body ...

Page 27: ...g work Safety during disassembly assembly maintenance and repair u Observe the procedures for set up service and inspection work and the inspection inter vals u Inform the operating staff before starting any service or repair work Make sure the en gine is not started while work is being conducted on the Power2 u Before taking off any cover or removing any guard from the low pressure or high pres s...

Page 28: ...aling vapours of operating materials and supplies or con tact with them may be harmful to health u Do not breathe in these substances and avoid contact with the skin u Ensure proper ventilation u Observe the information in the material safety data sheet for the operat ing materials and supplies u Wear personal protective equipment PPE according to the material safety data sheet u Comply with local...

Page 29: ...ibres from insulation materials can have adverse effects on the health or cause irritations Unsuitable and combustible insulation materials are a fire hazard u Only use suitable and non combustible insulation materials u Ensure good ventilation at the workplace u Avoid whirling up dust u Use dust free tools and working methods u Remove package at the workplace only u Proceed with particular care w...

Page 30: ... Systems 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 7 Swivel lifting eyes to be used Lifting gear with a sufficient load limit must be used for removing and installing the low pressure stage The following weight specification is the heaviest variant possible This standard value may deviate from the data on the ratin...

Page 31: ...itable location u Secure with lifting gear wherever possible Fig 11 Suspension of complete low pressure stage u Remove insulation according to the instructions of the enginebuilder u Disconnect all gas air cleaning and oil pipes according to the instructions of the en ginebuilder u Disconnect the cable connector from the speed sensor u Attach one lifting gear to each of the two bearing casing susp...

Page 32: ...e 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 Align the low pressure stage on the engine u Tighten the fixing elements on the foot according to the instructions of the engineb uilder u Attach all gas air water and oil pipes in accordance with the i...

Page 33: ...sure 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 12 Oil pressure range 38 An electrically driven oil pump is recommended for pre lubrication Power2 Pre lubrication time 850 2 min Table 9 Pre lubrication time 4 1 3 Post lubrication Post lubrication is necessary after switching the engin...

Page 34: ...sk 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 appropriate crankcase vent design Reduction of the pressure decrease outside the shaft seal due to stack draft effect by taking measures at the system side Reduction of the pressure increase in the engine ...

Page 35: ...ne 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 Use special running in filters when running in the engine and after all ser vice work on the lubricating system u Check that the oil filter is clean before commissioning u Check the oil pressure in the o...

Page 36: ... 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 compressor The measured values must be compared with the values of the acceptance protocol differ ent operating conditions must be taken into account here Escape of oily fluids Lubricants and pastes used for t...

Page 37: ...fter 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 objects that may be present u With the high pressure stage check the bellows located between the radial air suction branch and the compressor casing for damage and replace if necessary u Put engine side o...

Page 38: ...easuring 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 stage Oil pressure at measuring point M poil in bar 850 Engine run ning Admissible 1 3 2 5 Temporarily admissible 15 min after engine start cold oil 1 3 5 0 Temporarily admissible 1 h Warning signal 1 0 1...

Page 39: ...Oil 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 13 Lubricating oil temperature The specified maximum oil outlet temperature is considered to be an alarm value for the op eration of the low pressure and high pressure stage and must be monitored acc...

Page 40: ...tem 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 in relation to the compressor wheel The electron ics must be provided with a power supply and deliver a square pulse signal The signal fre quency depends on the number of main blades on the compressor wheel ...

Page 41: ...formance immediately until the maximum speed of all low and high pressure stages no longer exceeds 70 of nBmax u If the engine cannot be stopped it can continue to be driven with this reduced engine performance or at this low pressure and high pressure stage speed u If a low pressure or high pressure stage surges continuously the engine performance must be reduced further u Measure the temperature...

Page 42: ...3 Speed measurement Copyright 2022 ABB All rights reserved HZTL4062_EN Rev E March 2022 5 3 5 Replacing the speed measurement system Removing the speed measurement system Fig 15 Dimension X u Measure and note down dimension X Fig 16 Removing the speed measurement system Page 42 119 ...

Page 43: ...opyright 2022 ABB All rights reserved HZTL4062_EN Rev E March 2022 Installing the speed measurement system Fig 17 Setting dimension X 1 Set speed sensor 86505 in the plate 86507 to dimension X 2 Secure speed sensor with wedge lock washer 86509 and clamping nut 86505 Observe tightening torque Page 43 119 ...

Page 44: ...ZTL4062_EN Rev E March 2022 Fig 18 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 Position cable and secure it with rubber grommet 86516 6 Screw in pressure nut 86505 secured with Loctite 243 Observe tightening torque Page 44 119 ...

Page 45: ...ance 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 silencer air suction branch The following prerequisites must be fulfilled with regard to the low pressure and high pres sure stage to observe this limit value Air inlet system and piping fitted All stand...

Page 46: ... harsh 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 interval with Turbo Systems To prevent machine damage caused by ageing and downtime we recommend having an in spection carried out by a Turbo Systems service station no later than 5 years after the last...

Page 47: ...ecifications on the rating plate The following work must be carried out by a Turbo Systems service station Replacement of the bearing parts Replacement of the turbine and the compressor 6 2 6 Entries in the engine logbook The monitoring of the engine enables conclusions to be drawn on the behaviour of the low pressure and high pressure stage The following operating data and measured values must be...

Page 48: ...rts and replacing 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 During the prescribed periodic service work the individual parts are examined for wear and replaced if necessary Expected replacement intervals h GAS MDO HFO Gas inlet casing 50000 100000 3...

Page 49: ...CAUTION Residual heat in the low pressure and high pressure stage If the residual heat in the low pressure and high pressure stage is not suffi ciently dissipated by the circulating lubricating oil machine damage could occur u Observe the post lubrication times and the oil pressure specified for post lubrication see chapter Monitoring during operation Lubricating oil pressure Page 49 119 ...

Page 50: ...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 15 Maintenance intervals 1 If the recommended cleaning intervals are incompatible with operation of the engine con tact Turbo Systems 2 If present Compressor cleaning We recommend cleaning the HP compressor after the LP compressor On...

Page 51: ...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 in with the air Consequences of contamination Impaired compressor efficiency Higher exhaust gas temperatures Increased fuel consumption Increased rotor unbalance Periodic cleaning of the compressor du...

Page 52: ...alt 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 for the low pressure and high pressure stages Compressor surging Should repeated surging of the compressor stage occur during compressor cleaning first the cleaning parameters water flow rate as ...

Page 53: ... u Trigger 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 cleaning The cleaning process can be repeated up to three times The success of the cleaning can be recognised based on the charging pressure or the ex haust gas temperature If the cleaning is still uns...

Page 54: ...uels with low ash sulphur sodium and vanadium contents The fuel must also be correctly stored prepared and handled Turbo Systems recommends using fuels with a mass ratio of vanadium to sodium of less than 3 1 so that the melting temperature of the sodium vanadyl vanadate is as high as pos sible Consequences of contamination Poor turbine efficiency Elevated exhaust gas temperatures Higher charging ...

Page 55: ...ater Thermal shock Spalling of contamination due to the temperature differential CAUTION Corrosion and deposits when cleaning Salt water and cooling water treatment substances damage and adversely affect parts of the low pressure and high pressure stage u Never use salt water but only pure water for cleaning The turbine end components are cleaned at reduced engine load The exhaust gas temperat ure...

Page 56: ...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 18 Operating point for turbine cleaning Algorithm for the gas pulse For an optimum cleaning result the gas pulse adopted when designing the cleaning process should be set via the control system on the engine side The algorithm for the gas...

Page 57: ...in the low pressure stage during cleaning u Switch the 3 way valve during cleaning from scavenging air to water supply u Carry out the cleaning process with cleaning parameters according to the specifications in the following table Power2 Water flow rate l min Water pressure guideline value bar Duration of water injection min 850 LP 20 0 1 0 1 5 10 Table 20 Cleaning parameters LP For an optimum cl...

Page 58: ...he cleaning process If the load is too low water can collect in the gas outlet casing Indications for this are a sudden severe drop in the low pressure stage speed or a very large increase in the gas inlet tem perature In such cases the cleaning operations must be stopped and the cleaning cycle restarted with reduced water pressure or higher engine load Calculation of the gas pulse The pulse IG fo...

Page 59: ...nt 81273 Lock nut If present Clean the filter ring 81265 u Remove the filter ring u Clean the filter ring as required or every 500 hours of operation and replace it after the fifth cleaning process at the latest Contamination of the filter ring depends on the degree of purity of the sucked in air u Rinse the filter ring with water and mild detergent or in the case of heavy contamination soak and c...

Page 60: ...segments 81136 u Pull out and bend up the sheet metal coverings 81137 and remove the absorption seg ments 81136 u Clean the absorption segments When cleaning note that the absorption segments may only be cleaned lightly with pres surized air a soft brush or a moist cleaning cloth u Have any heavily contaminated absorption segment replaced by a Turbo Systems service station Fitting the filter silen...

Page 61: ...Cleaning the filter silencer 2 u Place cover grids 81266 evenly and in the correct position u Push connecting rods 81269 through the lugs of the cover grids 81266 u Connect the connecting rods 81269 with the screws 81272 When tightening the screws 81272 make sure that the flattened ends of the connecting rods 81269 are cor rectly positioned on the edge of the filter silencer body 81135 u Tighten s...

Page 62: ...an the filter ring 81265 u Remove the filter ring u Clean the filter ring as required or every 500 hours of operation and replace it after the fifth cleaning process at the latest Contamination of the filter ring depends on the degree of purity of the sucked in air u Rinse the filter ring with water and mild detergent or in the case of heavy contamination soak and carefully push through Rinse in c...

Page 63: ...on segments When cleaning note that the absorption segments may only be cleaned lightly with pres surized air a soft brush or a moist cleaning cloth u Have any heavily contaminated absorption segment replaced by a Turbo Systems service station Fitting the filter silencer u Insert the absorption segments 81136 into the sheet metal coverings 81137 u Bend the sheet metal coverings 81137 back to their...

Page 64: ...essure stage Rotor unbalance Contact a Turbo Systems service sta tion Turbine or compressor damaged Bearing damaged Table 26 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 components caused by slight local rubbing against adjacent components is permit...

Page 65: ...a Turbo Systems service sta tion Change of operating state of high pressure stage Check the operating point of the high pressure stage Pipes Defects such as leaks in the ex haust gas pipes or charge air ducts Repair Table 29 Malfunctions during operation Power2 LP speed reductions Drop in high pressure stage speed Possible causes Remedy Engine Defects on the connected cylinders Contact enginebuild...

Page 66: ...ture too high Engine performance and engine speed unchanged Possible causes Remedy Engine Malfunction in the injection system Repair or contact manufacturer Low pressure or high pressure 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 gas si lencer Turb...

Page 67: ...ter silencer contaminated there fore pressure drop too high Clean Compressor turbine contaminated Compressor turbine damaged Contact a Turbo Systems service sta tion Exhaust gas back pressure too high Clean or repair boiler or exhaust gas si lencer Table 34 Malfunctions during operation Charge air pressure too low Charge air pressure too high Engine performance and engine speed unchanged suction c...

Page 68: ...ion gases Correct the influx of ventilation gases in accordance with the enginebuilder s in structions Table 36 Malfunctions during operation Compressor 1 contamination Reduced fatigue strength of the compressor wheel compressor blade breakage Possible causes Remedy Low pressure or high pressure stage Material of the compressor wheel corroded due to the influx of ventila tion gases containing corr...

Page 69: ...ontinuously or periodic ally their components may be damaged u Gradually reduce the engine load u Have the cause clarified and remedied immediately by a Turbo Systems service station u Have parts assessed for damage and if necessary replaced by a Turbo Systems service station Sporadic surge blows Surging of the low pressure stage can occur during certain operating states such as when reducing the ...

Page 70: ...ing Foreign object in the pressure stage Table 39 Malfunctions when stopping Runout noises Runout time too short Possible causes Remedy Low pressure or high pressure stage Pressure stage contaminated Clean Bearing damaged Contact a Turbo Systems service sta tion Rotor rubbing Foreign object in the pressure stage Table 40 Malfunctions when stopping Runout time too short 8 5 Speed measurement system...

Page 71: ...ark the casing position for assembly Tightening torques for components The specified tightening torques of the bolted connections must be observed Tightening torques for assembly devices Unless otherwise described the screws and nuts of the assembly devices supplied by Turbo Systems must be tightened in such a way that they are tight fitting WARNING Suspended loads Loads that are not attached acco...

Page 72: ...ion of the assembly devices Not all assembly devices are marked with a part number Identification is guaranteed by the tool list This list is enclosed with the toolbox WARNING Servicing the assembly devices Assembly devices must be checked for damage before and after use u Visually inspect for corrosion cracks deformation and wear u Damaged assembly devices must no longer be used and must be re pl...

Page 73: ...ghts of assemblies The specified weights of the individual parts or assemblies are rounded up standard values Fig 23 Overview of assemblies Designation Weight kg 01 Air suction branch 80 02 Filter silencer 190 03 Wall insert 190 04 Diffuser 25 05 Compressor casing 210 06 Cartridge group 330 07 Turbine diffuser 40 08 Nozzle ring 15 Table 42 Weights of the assemblies Page 73 119 ...

Page 74: ... u If present Disconnect supply line for compressor cleaning from filter silencer Fig 24 Removing the filter silencer 1 Fit the swivel lifting eye 90231 to the silencer 81000 Attach the lifting gear to the swivel lifting eye 90231 and loop through the eyelets at the rear of the filter silencer 81000 2 Loosen and remove nuts 72004 Remove washers 72003 3 Remove and put down filter silencer 4 Loosen ...

Page 75: ...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 branch Fig 25 Removing the air suction branch 1 Loop around air suction branch 82000 with lifting gear 2 Loosen and remove nuts 72004 Remove washers 72003 3 Remove and put down the air suction branch ...

Page 76: ... 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 a Turbo Systems service station Fig 26 Measuring axial clearance A The axial clearance A must be measured prior to removal and after installation of the cart ridge group u Measure and note axial clearance A Axial c...

Page 77: ...property can result from rubbing or jam ming of the compressor wheel at the wall insert u Check that the compressor wheel does not rub against the wall insert during disassembly assembly by rotating the rotor Fig 27 Removing wall insert 1 1 Screw nut 72004 onto end of bolt thread as protection 2 Use three press off screws 90920 to press off the wall insert 77000 until the lifting device can be fit...

Page 78: ...0955 and nuts 90415 Fit two plates 90031 and secure with plate 90032 screw 90656 and nut 90432 7 Secure lifting gear to swivel lifting eye 90231 8 Remove nut 72004 and carefully move out wall insert Fig 29 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 gea...

Page 79: ...two studs 72002 and screw 72021 in the upper area 2 Fit bracket 90030 with four screws 90959 3 Fit four plates 90031 and secure with plate 90032 screw 90656 and nut 90432 Fig 31 Removing the compressor casing 2 4 Secure lifting gear to swivel 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 ...

Page 80: ... the blades do not rub on the turbine diffuser during disas sembly assembly by rotating the rotor Fig 32 Moving out cartridge group 1 1 Remove the O ring 42012 2 Loosen and remove the screws 42087 3 Fit swivel lifting eye 90231 to bracket 90030 and screw bracket to cartridge group with two screws 90955 4 Fit five plates 90031 and secure with plate 90032 screw 90656 and nut 90432 5 Secure lifting g...

Page 81: ...turned over toolbox cover 9 Remove plate 90032 screw 90656 nut 90432 and plates 90031 10 Remove the press off screws 90920 11 Remove O rings 42017 42018 Putting down cartridge group onto cover CAUTION Damage to cartridge group and toolbox cover The turned over toolbox cover may only be used for intermediate storage of the cartridge group u The cover must be on a level surface u The cover may not b...

Page 82: ...ng 1 1 Loosen and remove the screws 61056 2 Secure connecting flange 90428 to star plate 90414 with screws 90950 and nuts 90431 3 Align arm of star plate 90414 marked FRONT in direction of gas outlet flange and screw star plate to turbine diffuser with screws 90961 Fig 36 Removing turbine diffuser and nozzle ring 2 4 Loosely screw in three press off screws 90902 5 Secure guide tube 90422 to bracke...

Page 83: ...ure lifting gear to swivel lifting eye 90231 10 Fit four plates 90031 and secure with plate 90032 screw 90656 and nut 90432 11 Press off turbine diffuser evenly using the press off screws 90902 Fig 38 Removing turbine diffuser and nozzle ring 4 12 Carefully move out turbine diffuser 63000 13 Put down turbine diffuser Remove plate 90032 screw 90656 nut 90432 and plates 90031 Remove the press off sc...

Page 84: ...ue 56017 1 Fit nozzle ring 56001 2 Coat thread of screws 56017 with high temperature grease Fit clamps 56018 and screws 56017 3 Tighten screws with torque spanner using the box spanner insert 90770 Observe tight ening torque 4 Screw in a guide stud 90316 in the upper area on the left and right 5 Secure lifting gear to swivel lifting eye 90231 Installation of bracket and plate see Removing turbine ...

Page 85: ...22 Fig 40 Installing the nozzle ring and turbine diffuser 2 Part number Thread and tightening torque 61056 M10x90 50 Nm Table 45 Tightening torque 61056 1 Remove plates and brackets 2 Loosen screws 90961 and remove together with star plate 90414 Remove guide stud 90316 3 Coat thread of remaining screws 61056 with high temperature grease and fit screws Observe tightening torque Page 85 119 ...

Page 86: ...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 41 Installing O rings u Fit new O rings 42017 42018 Fig 42 Installing the cartridge group 1 1 Screw bracket to cartridge group with two screws 90955 2 Fit swivel lifting eye 90231 to bracket 90030 and secure lifting gear to swivel lift...

Page 87: ...re 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 7 Fit a new O ring 42012 Control dimension after installing cartridge group CAUTION Control dimension outside the tolerance value If the control dimension is out of tolerance the cartridge group ha...

Page 88: ...stalling the cartridge group Copyright 2022 ABB All rights reserved HZTL4062_EN Rev E March 2022 Fig 44 Measuring control dimension X After installing the cartridge group the control dimension X must be measured Control dimension X mm 63 0 0 1 Table 47 Control dimension X Page 88 119 ...

Page 89: ...ication with adapter 90249 and special key 90250 90251 see below 1 Secure lifting gear to swivel lifting eye 90231 and insert compressor casing For installation of bracket and plates see Removing the compressor casing 79 2 Fit nuts 61037 Observe tightening torque 3 Remove plates 90031 and bracket 90030 4 Fit screw 72021 Observe tightening torque Application of special key for nuts that are difficu...

Page 90: ...sert during disassembly assembly by rotating the rotor Fig 46 Installing the wall insert 1 Part number Thread and tightening torque 77016 M5x35 5 Nm Table 49 Tightening torque 77016 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 lifting eye 90231 4 Fit ...

Page 91: ... Fig 47 Installing the wall insert 2 Part number Tightening torque 72002 M16x104 50 Nm Table 50 Tightening torque 72002 1 Remove plate 90032 screw 90656 nut 90432 and plates 90031 2 Remove the bracket 90030 3 Detach speed measurement cable from provisional holder and insert cable con nector 86515 4 Fit four studs 72002 in the upper area Observe tightening torque Page 91 119 ...

Page 92: ...rance 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 a Turbo Systems service station Fig 48 Measuring axial clearance A The axial clearance A must be measured prior to removal and after installation of the cart ridge group u Measure and note axial clearance A Axial cleara...

Page 93: ...ch Part number Thread and tightening torque 72004 M16 200 Nm Table 52 Tightening torque 72004 1 Remove the two opposing nuts 72004 and washers 72003 that were used to secure the wall insert 2 Loop around air suction branch 82000 with lifting gear 3 Position the air suction branch 4 Fit nuts 72004 with washers 72003 and tighten nuts 72004 u Reinstall dismantled insulation u Reinstall all air lines ...

Page 94: ...2 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 opposing nuts 72004 and washers 72003 that were used to secure the wall insert 3 Fit the swivel lifting eye 90231 to the filter silencer 81000 Attach the lifting gear to the swivel lifting eye 90231 and lo...

Page 95: ...062_EN Rev E March 2022 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 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 reduced torque Page 95 119 ...

Page 96: ...olted connec tions Part number Thread and tightening torque 42087 M12x60 80 Nm 56017 M8 Tx40 25 Nm 61037 M16 250 Nm 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 access Pre tightening torque 60 Nm Tightening angle 60 5 150 Nm 1 72021 M10x20 70 Nm 77016 M5x35...

Page 97: ...e 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 CAUTION Directives for taking out of operation Serious damage to engine or property can be caused by non compliance with the directives for blanking off the low pressure or high pressure stage on th...

Page 98: ... Turbo Systems and must be manufactured by the operator on the basis of the drawing see Fig 52 Cover plate gasket sleeves and screws 98 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 52 Cover plate gasket sleeves and screws Cover plate gasket sle...

Page 99: ... 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 sleeves 04 and screws 42087 03 Fig 54 Installing the casing 4 Reinstall compressor casing wall insert and alternative air inlet CAUTION Escaping lubricating oil If the cover plate is fitted complete se...

Page 100: ...udes cleaning and applying preservative oil to the relevant components 11 3 Process for taking out of operation Different measures are required depending on the process used to take the low pressure and high pressure stage out of operation The low pressure and high pressure stage remains on the engine Take countermeasures if there is a risk that the rotor will turn due to the stack draught One opt...

Page 101: ...rm the customer of the presence of such substance s with sufficient information available to the supplier RoHS2 Directive 2011 65 EC in English only The EU Directive 2011 65 EC recast restricts the use of certain hazardous substances in electrical and electronic equipment RoHS2 Products and related accessories manufac tured by Turbo Systems Switzerland Ltd do not fall within the Scope of RoHS2 due...

Page 102: ...aluminium and 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 metals as scrap metal for recycling u Dispose of non metallic materials as waste u Dispose of residues of lubricants as waste oil u Dispose of electronic components as electronic waste WARNING...

Page 103: ...llowing 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 Turbo Systems Service Station u If different model variants are not taken into account in this document contact an Turbo Systems Service Station u Dispose of placed and unusable parts in an environment...

Page 104: ... set 97070 is re quired These parts are only available in the complete set Customer spare part set 97070 Designation Quantity 42012 O ring 1 42017 O ring 1 42018 O ring 2 42087 Hexagon head screw 1 56017 Hexalobular head screw 3 56018 Clamp 1 61037 Hexagon nut 3 61056 Hexagon head screw 8 72003 Washer 3 72004 Hexagon nut 3 77016 Hexagon head screw 5 77022 Hexagon nut 1 77040 O ring 1 79020 O ring ...

Page 105: ... 32189 32102 32190 32001 32105 32003 32106 42057 32101 32118 42302 25000 Available within the spare part set HZTL443398 Mod A Part no Designation 21000 Turbine 21002 Piston ring 21011 Sealing bush for shaft 25000 Compressor wheel 32001 Thrust bearing 32003 O ring 32101 Radial bearing compressor end 32102 Radial bearing turbine end 32105 Floating disc 32106 Axial bearing 32118 Auxiliary bearing 321...

Page 106: ...Illustrations Copyright 2022 ABB All rights reserved HZTL4062_EN Rev E March 2022 Cartridge 42049 42043 10900 42099 42012 Available within the spare part set HZTL443549 Mod A Part no Designation 42012 O ring 42043 Orifice 42049 Locking ring 42099 Socket screw Table 59 Page 106 119 ...

Page 107: ...015 42011 42400 42700 42087 42405 42306 42305 42300 42008 Available within the spare part set HZTL443399 Mod A Part no Designation 42001 Bearing casing 42008 Socket screw 42011 O ring 42015 Sealing cover 42017 O ring 42018 O ring 42039 Hexagon head screw 42087 Hexagon head screw 42300 Partition wall 42305 O ring 42306 O ring 42400 Heat shield 42405 Hexagon screw 42700 Bearing bush Table 60 Page 10...

Page 108: ...256 51258 51229 52208 51169 51001 56017 56018 56001 51074 Available within the spare part set HZTL443405 Mod A Part no Designation 51001 Gas inlet casing 51074 Screw plug 51169 Screw plug 51229 Water supply pipe 51230 Angular screw coupling 51256 Union nut 51258 Pressure plate 51259 Hexalobular head screw 52208 Nozzle 56001 Nozzle ring 56017 Hexalobular head screw 56018 Clamp Table 61 Page 108 119...

Page 109: ...1259 51256 51258 52208 51074 51001 51169 56001 56017 56018 Available within the spare part set HZTL443400 Mod A Part no Designation 51001 Gas inlet casing 51074 Screw plug 51169 Screw plug 51229 Water supply pipe 51230 Angular screw coupling 51256 Union nut 51258 Pressure plate 51259 Hexalobular head screw 52208 Nozzle 56001 Nozzle ring 56017 Hexalobular head screw 56018 Clamp Table 62 Page 109 11...

Page 110: ... 61052 61035 61036 61011 61037 61038 61039 Available within the spare part set HZTL443401 Mod A Part no Designation 61001 Gas outlet casing 61009 Hexagon head screw 61011 Blind flange 61012 Gasket 61035 Socket screw 61036 Stud 61037 Hexagon nut 61038 Washer 61039 Screw 61042 Hexagon head screw 61050 Gasket 61052 Screw plug 61056 Hexagon head screw 61073 Screw plug 63000 Turbine diffuser 68002 Foot...

Page 111: ...000 86516 77023 77022 72003 72004 Available within the spare part set HZTL443402 Mod A Part no Designation 72000 Compressor casing 72003 Washer 72004 Hexagon nut 72005 Screw plug 72006 Gasket 72021 Socket screw 77000 Wall insert 77002 Stud 77012 Screw plug 77016 Hexagon head screw 77022 Hexagon nut 77023 Sleeve 77040 O ring 79000 Diffuser 79020 O ring 79021 O ring 86505 Speed sensor 86507 Plate 86...

Page 112: ...EN Rev E March 2022 Air suction branch axial or 82007 p 82008 p 82000 82140 82005 p 82006 p 82004 82171 82170 p pre assembled HZTL443458 Mod A Part no Designation 82000 Air suction branch 82004 Orifice 82005 p Screw plug 82006 p Gasket 82007 p Screw plug 82008 p Washer 82140 Cleaning nozzle 82170 Screw plug 82171 Gasket Table 65 Page 112 119 ...

Page 113: ...EN Rev E March 2022 Air suction branch radial or 82007 p 82140 82008 p 82006 p 82004 82171 82005 p 82170 82000 p pre assembled HZTL443404 Mod A Part no Designation 82000 Air suction branch 82004 Orifice 82005 p Screw plug 82006 p Gasket 82007 p Screw plug 82008 p Gasket 82140 Cleaning nozzle 82170 Screw plug 82171 Gasket Table 66 Page 113 119 ...

Page 114: ...1 81170 81006 p 81135 81000 81008 81007 81272 81269 81273 81266 p pre assembled HZTL443403 Mod A Part no Designation 81000 Filter silencer complete 81004 Orifice 81005 p Screw plug 81006 p Gasket 81007 Screw plug 81008 Gasket 81135 Silencer body 81136 Absorption segment 81137 Cover sheet metal 81140 Cleaning nozzle 81170 Screw plug 81171 Gasket 81266 Cover grid 81269 Connection rods 81272 Hexagon ...

Page 115: ...70 81140 81005 p 81135 81008 81137 81007 81266 81136 81271 81270 p pre assembled HZTL443469 Mod A if provided Part no Designation 81000 Filter silencer complete 81004 Orifice 81005 p Screw plug 81006 p Gasket 81007 Screw plug 81008 Gasket 81135 Silencer body 81136 Absorption segment 81137 Cover sheet metal 81140 Cleaning nozzle 81170 Screw plug 81171 Gasket 81265 Filter ring 81266 Cover grid 81270...

Page 116: ...le 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 head screw 3 90961 Hexagon head screw 3 90656 Hexagon head screw 1 90415 Hexagon nut 6 90431 Hexagon nut 3 90432 Hexagon nut 1 90430 Nut 1 90161 Protective bag 1 90250 Special key 1 90251 Special ke...

Page 117: ...on branch 75 Fig 26 Measuring axial clearance A 76 Fig 27 Removing wall insert 1 77 Fig 28 Removing wall insert 2 78 Fig 29 Removing wall insert 3 78 Fig 30 Removing the compressor casing 1 79 Fig 31 Removing the compressor casing 2 79 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 Fig 35 Removing turbine diffuser and...

Page 118: ...e 28 Malfunctions during operation Lubricat ing 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 tem...

Page 119: ...served HZTL4062_EN Revision E March 2022 Table 57 Customer spare part set 97070 104 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 Table 69 Customer tool set 90000 116 Page 119 119 Page 119 119 ...

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