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Operation Manual / Power2 800-M / 4 Product description

Operation and service

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HZTL4061_EN

Revision A

September 2016

Operation and service

5.1

Noise emission

WARNING

Danger due to noise
Exposure to noise can harm the hearing system, impair health and the psy-

chological state and may lead to lack of attention and irritation.



When the engine is running, always wear ear protection.



Always wear ear protection if the sound pressure level exceeds 85 dB(A).

Wear ear protection.

The emission sound pressure level (A-weighted) is measured at a distance 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-pressure

stage to observe this limit value:



Air inlet system and piping fitted



All standard, noise-reducing measures

have been fitted

The enginebuilder is also responsible for insulating other components such as the charge

air/scavenging air lines and the cooler.

Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7:

A-rated emission sound pressure level

The enginebuilder must provide acoustically equivalent measures in case of deviating insula-

tion versions

Summary of Contents for Power2 850-M16

Page 1: ...nglish Original Operation Manual Chapter Document ID 1 Introduction HZTL4004_EN_D 2 Safety HZTL4025_EN_A 3 Safety data sheets HT579962_A 4 Product description HZTL4061_EN_A 4 1 Low pressure stage PT002040 HZTL4062_EN_ 4 2 High pressure stage PT002039 HZTL4063_EN_A ...

Page 2: ...als 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 and the operating limits increases the risk of unpre dictable component failures ...

Page 3: ...l 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 Storage of new low pressure and high pressure stages 6 1 6 Contact information 8 ...

Page 4: ...or 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 Operation Manual 1 2 Symbols definitions Symbols The following symbols are used in this document u Indicates an action step 1 Indicates a n...

Page 5: ...is 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 Turbo Systems in this document Official service stations of ABB Turbo Systems Official service stations are identified in this document as ABB Turbocharging Service Sta tions They are regularly audite...

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 high temperature grease See document Apply other paste in accord ance with specifications Dispose of in an environmentally compatible professional way and in compliance with locally applic able regulat...

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: ...dge 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 be observed when handling VCI u Ensure proper space ventilation u Do not eat drink or store food at the workplace while working with VCI u Wear safety gloves u Clean hands and face after working wit...

Page 9: ...s 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 Turbocharging Service Station u Check 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 an ABB Turbocharging Service ...

Page 10: ...l 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 ABB Turbo Systems Ltd Bruggerstrasse 71a CH 5401 Baden Switzerland www abb com turbocharging Page 8 8 ...

Page 11: ...inition 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 pressure stage 7 1 9 Periodic check of the pressure vessels 8 1 10 Lifting of loads 9 1 11 Prerequisites for operation and maintenance 10 1 12 Hazards during operation and maintenance 11 1 13 Safe operat...

Page 12: ...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 free...

Page 13: ...Respiratory 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 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 e...

Page 14: ...ses 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 operating limits can be hazardous to personnel u Power2...

Page 15: ...f 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 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 h...

Page 16: ...th 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 replaced with new warning plates The information that is required can be found in the Oper ation Manual Product description Low pressure and high pressure stages supplied to the enginebuilder witho...

Page 17: ... agreed 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 1000 h 5 Replacement interval of turbine in 1000 h Table 4 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 construc...

Page 18: ...during 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 Locations of the rating plates The locations of the rating plates are defined in the Operation Manual Chapter 4 Product description 1 9 Periodic check of the pressure vessels The pressure vessels u...

Page 19: ...y 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 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 pressure ...

Page 20: ...ked 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 Modifications ...

Page 21: ...ear 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 Tou...

Page 22: ...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 with rotating parts can cause severe injury The low pressure stage must never be used without the filter silencer or air inlet casing respectively With the engine stopped the rotor can rotate due to the stack draught alone ...

Page 23: ...carry out any tests with regard to insulation resistance or voltage on the electrical components 1 13 Safe operation Mechanical hazards during operation During standard operation no mechanical hazards are caused by the low pressure and high pressure stage provided that it has been properly installed 1 13 1 Safety during commissioning and operation Safety during commissioning and operation u Visual...

Page 24: ...hich you have received instruction or 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 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 suit...

Page 25: ...cedures 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 sure stage switch off the engine and wait until the low pressure stage and the high...

Page 26: ...ing 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 l...

Page 27: ...res 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 whe...

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Page 29: ... M16 Safety data sheets Contents Page 1 3 Safety data sheets Copyright 2018 ABB All rights reserved HT579962_A August 2018 Power2 850 M16 HT579962 Name Hardware ID Page Low pressure stage PT002040 2 High pressure stage PT002039 3 ...

Page 30: ...16 HT579962 Low pressure stage PT002040 Power2 850 M16 HT579962 Low pressure stage PT002040 32 420 420 64 2018 1800 64 HZTL53380D Additional Safety Data Maximum permissible temperatures Exhaust gas inlet temperature At engine overload 110 in test rig operation only unless otherwise agreed with the enginebuilder tMmax C 550 During operation tBmax C 520 ...

Page 31: ...39 Power2 850 M16 HT579962 High pressure stage PT002039 32 612 612 64 2018 700 64 HZTL53380D Additional Safety Data Maximum permissible temperatures Exhaust gas inlet temperature At engine overload 110 in test rig operation only unless otherwise agreed with the enginebuilder tMmax C 620 During operation tBmax C 600 Compressor inlet temperature after intercooler During operation tCmax C 60 ...

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Page 33: ... 14 3 3 Commissioning after taking out of operation 16 4 Monitoring during operation 17 4 1 Lubricating oil pressure 17 4 2 Lubricating oil temperature 18 4 3 Speed measurement 19 5 Operation and service 21 5 1 Noise emission 21 5 2 Service work 22 5 3 Expected replacement intervals 24 5 4 Stopping the engine 24 6 Periodic maintenance 25 6 1 Foreword to maintenance 25 6 2 Cleaning the compressor d...

Page 34: ...assembly and assembly 47 9 Taking out of operation at short notice 49 10 Mothballing the low pressure and high pressure stage 51 10 1 Taking the engine out of operation for up to 12 months 51 10 2 Taking the engine out of operation for more than 12 months 52 11 Disposing of low pressure and high pressure stage components 53 12 Spare parts 55 Figures 57 Tables 59 ...

Page 35: ...the low pressure 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 turbo charging Power2 supplies the engine with the air volume and associated charging pressure required for operation Here the exhaust gases of the internal combustion engine flow th...

Page 36: ...ion A September 2016 1 2 Layout and function of the low pressure stage Figure 2 Layout and function of the low pressure stage 01 Filter silencer air suction branch 06 Gas inlet casing 02 Compressor wheel 07 Nozzle ring 03 Diffuser 08 Turbine 04 Bearing bush with heat shield 09 Bearing casing 05 Gas outlet casing 10 Compressor casing ...

Page 37: ...s 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 con tained in the exhaust gas to drive the rotor The exhaust gases then reach the atmosphere through the gas outlet casing 05 and the exhaust gas pipe connected to it The rotor runs in two radial plain bearings which are located betw...

Page 38: ... Revision A September 2016 1 3 Layout and function of the high pressure stage Figure 4 Layout and function of the high pressure stage 01 Air suction branch 06 Gas inlet casing 02 Compressor wheel 07 Nozzle ring 03 Diffuser 08 Turbine 04 Bearing bush with hood diffuser 09 Bearing casing 05 Gas outlet casing 10 Compressor casing ...

Page 39: ...stration see Figure 4 the exhaust gas flows through the gas inlet casing 06 and the nozzle ring 07 and reaches the turbine 08 The HP turbine uses the energy contained in the exhaust gas to drive the rotor The ex haust gases then flow through the gas outlet casing 05 and the exhaust gas pipe connected to it before reaching the turbine of the low pressure stage Power2 LP The rotor runs in two radial...

Page 40: ...rning plates If warning plates are not present in the designated locations or not readable proceed as follows Order new warning plates from ABB Turbocharging Service Stations Remove any warning plates that have become unreadable Clean and degrease the areas designated for the warning plates Fit new warning plates and remove protective sheets Non insulated high and low pressure stages High and low ...

Page 41: ...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 stage High pressure stage Figure 9 Location of Power2 HP rating plate One rating plate each is attached on the left and the right side of the foot bearing casing and to the air suction branch of the hi...

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Page 43: ...ZTL4061_EN Revision A September 2016 2 Removal and installation For more information on how to remove and install the low pressure stage see document Operation Manual Power2 4 1 Low pressure stage For more information on how to remove and install the high pressure stage see document Operation Manual Power2 4 2 High pressure stage ...

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Page 45: ...The directives of the enginebuilder on the selection of the lubricating oil and the oil change intervals must be followed 3 1 2 Pre lubrication post lubrication Pre lubrication Before the engine is started the plain bearings of the low pressure and high pressure stage must be pre lubricated You can do this by using an electrically driven oil pump Switch on the oil pump Build up oil pressure see Ta...

Page 46: ...e 180 C Table 2 Post lubrication time 3 1 3 Oil filtering Power2 Filter mesh width mm 850 0 034 Table 3 3 1 4 Oil pressure Comply precisely with the oil pressure before the low pressure and high pressure stage for trouble free operation The admissible values are specified in chapter Monitoring during operation 17 3 1 5 Oil orifice Metering orifices are installed in the oil inlet of the low pressur...

Page 47: ...ting system must be thoroughly flushed with warm oil Use special running in filters when running in the engine and after all ser vice work on the lubricating system Check that the oil filter is clean before commissioning Check the oil pressure in the oil supply pipes Warning plates Check whether warning plates are present and legible Check whether the protective sheets have been removed 3 2 3 Chec...

Page 48: ... ble oil leak If there is a leak contact an ABB Turbocharging Service Station 3 3 Commissioning after taking out of operation If present Remove cover plates blind flanges on the compressor casing on the gas inlet as well as on the gas outlet Remove the locking screws on the water connections and fit the water pipe General Check the exhaust gas pipe before and after the turbine for combustion resid...

Page 49: ...the appropriate signals are to be trig gered at the warning and alarm values Figure 10 Lubricating oil pressure 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 The oil pressure ranges at measuring point M are listed below Power2 Status for operation Oil pressure at measuring point M poil in bar 850 Normal ope...

Page 50: ...rature at the outlet is mainly dependant on Lubricating oil temperature and pressure at the oil inlet Engine load and speed of the low pressure and the high pressure stages Exhaust gas temperature The maximum admissible oil temperature at the outlet is listed in the following table The spec ified oil outlet temperature is to be considered as alarm value for the operation of the low and high pressu...

Page 51: ... Cable 06 Plug The speed measurement 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 princi ple and is installed in a radial direction in relation to the compressor wheel The electronics must be provided with a power supply and deliver a square pulse signal The signal frequency depends on the number o...

Page 52: ...duce the engine performance until the maximum speed of all low and high pressure stages does not exceed 70 of nBmax 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 If a low pressure or high pressure stage surges continuously the engine performance must be reduced further Measure the temperatures...

Page 53: ...at a distance 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 pressure stage to observe this limit value Air inlet system and piping fitted A...

Page 54: ...r day harsh environ mental conditions poor fuel quality or high system vibrations can lead to untimely machine damage even if the prescribed service intervals are ob served Agree on a shortened service interval with ABB Turbo Systems To prevent machine damage caused by ageing and downtime we recommend having an in spection carried out by an ABB Turbocharging Service Station no later than 5 years a...

Page 55: ...to specifications 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 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 valu...

Page 56: ...or 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 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 coul...

Page 57: ...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 the recommended cleaning intervals are incompatible with operation of the engine con tact ABB Turbo Systems 2 If present Compressor cleaning We recommend cleaning the HP compressor after the LP compressor...

Page 58: ...mination 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 during oper...

Page 59: ...ater but only pure water for cleaning CAUTION Volume of water Uncontrolled volumes of water can damage the pressure stages and the engine Never connect the water line without the orifice specified for the low pressure and high pressure stages Compressor pumps Should repeated surging of the compressor stage occur during compressor cleaning first the cleaning parameters water flow rate as well as th...

Page 60: ...ter injection according to the instructions of the enginebuilder Observe water pressure before connection to pressure stage 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 exhaust gas temperature If the cleaning is still unsuccessful after th...

Page 61: ...mponents stems from the following combustion products Soot Molten ash Cinders 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 Turbo Systems recommends using fuels with a mass ratio of vanadium to sodium of less than 3 1 so that the melting temperature of...

Page 62: ...ty depending on the type of contamination Erosion The contamination is removed by the mechanical action of the 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 when cleaning Salt water and cooling water treatment substances damage and adversely affec...

Page 63: ...tage 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 cleaning NOTICE 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 pulse is ...

Page 64: ...control valves and monitored by a flowmeter If this is not possible the specified water pressure at the cleaning connection of the turbocharger is to be set as a rough ap proximation 3 Cleaning the low pressure turbine stage LP stage If present open the drain pipe in the low pressure stage during cleaning Switch the 3 way valve during cleaning from scavenging air to water supply Carry out the clea...

Page 65: ...ing the gas outlet casing of the low pressure stage The following points must be observed with regard to draining the gas outlet casing The exhaust gas temperature downstream of the low pressure stage drops drastically dur ing cleaning typical gas outlet temperatures during cleaning 50 150 C Depending on the engine load the drainage can take place through the drain pipe This drainage may occur aft...

Page 66: ...p pG is the density of the exhaust gas at the inlet into the gas inlet casing VG corresponds to the flow rate at the nozzle ring inlet ANR corresponds to the surface of the flow channel at the nozzle ring inlet The values are specified in the following table Power2 Surface of the flow channel at the nozzle ring inlet of the HP turbine stage m2 Surface of the flow channel at the nozzle ring inlet o...

Page 67: ...eet metal covering 81272 Screw 81265 Filter ring if present 81273 Lock nut E Insert unit absorption segment sheet metal covering NOTICE Disassembly and assembly The disassembly and assembly of the filter silencer is described in chapter Disassembly and assembly Cleaning the filter ring if present Remove filter ring 81265 Clean filter ring 81265 as required or every 500 hours of operation and repla...

Page 68: ...ption segments 81136 must only be cleaned lightly with pressurized air with a soft brush or a moist cleaning cloth Have any heavily contaminated absorption segments and filter rings as well as damaged connecting rods replaced by an ABB Turbocharging Service Station Fitting the filter silencer Assemble the insert units E by inserting the absorption segments 81136 into the sheet metal coverings 8113...

Page 69: ...3 40 Table 15 Tightening torque 81272 81273 Connect the connecting 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 the screws 81272 up to the maximum tightening torque shown above Fit lock nuts 81273 to screws 81272 and tighten with the tightening torque ...

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Page 71: ...ure stage Rotor unbalance Contact ABB Turbocharging Service Sta tion Turbine or compressor damaged Bearing damaged Table 17 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 permitt...

Page 72: ...uilder Low pressure stage Heavy contamination of the turbine Clean Damaged rotor components or bear ing Contact ABB Turbocharging 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 20 Malfunctions during operation Power2 LP speed reductions Drop...

Page 73: ... the low pressure stage Repair Table 23 Malfunctions during operation Power2 HP speed increases Exhaust gas temperature 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 contamina tion Clean Comp...

Page 74: ...er silencer contaminated therefore pressure drop too high Clean Compressor turbine contaminated Compressor turbine damaged Contact ABB Turbocharging Service Sta tion Exhaust gas back pressure too high Clean or repair boiler or exhaust gas si lencer Table 25 Malfunctions during operation Charge air pressure too low Charge air pressure too high Engine performance and engine speed unchanged suction c...

Page 75: ...enti lation gases Correct the feed of ventilation gases ac cording to instructions of enginebuilder Table 27 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 cor roded due to the feeding in of ventila tion gases containing co...

Page 76: ...r periodical ly their components may be damaged Gradually reduce the engine load Have the cause clarified and remedied immediately by an ABB Turbo charging Service Station Have parts assessed for damage and if necessary replaced by an ABB Turbocharging Service Station Sporadic surge blows Surging of the low pressure stage can occur during certain operating states such as when reducing the engine p...

Page 77: ...bbing 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 Clean Bearing damaged Contact ABB Turbocharging Service Sta tion Rotor rubbing Foreign object in the pressure stage Table 31 Malfunctions when stopping Runout time too short 7 5 Speed measurement sy...

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Page 79: ...1_EN Revision A September 2016 8 Disassembly and assembly For more information on the disassembly and assembly of the low pressure stage see document Operation Manual Power2 4 1 Low pressure stage For more information on the disassembly and assembly of the high pressure stage see document Operation Manual Power2 4 2 High pressure stage ...

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Page 81: ..._EN Revision A September 2016 9 Taking out of operation at short notice For more information on briefly taking the low pressure stage out of operation see docu ment Operation Manual Power2 4 1 Low pressure stage For more information on briefly taking the high pressure stage out of operation see docu ment Operation Manual Power2 4 2 High pressure stage ...

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Page 83: ... and circulated with the pre lubrication pump before the engine is taken out of operation no measures need to be taken either Residues of old engine oil are flushed away in this way and the bearing parts are largely protected against corrosion Preparations for mothballing If the acid number TAN is greater than 2 mg KOH g the following mothballing measures are necessary after taking the engine out ...

Page 84: ...necessary for preparing the low pressure and high pressure stage for mothballing see section Taking the engine out of operation for up to 12 months subsec tion Preparations for mothballing If the low pressure and the high pressure stage remain attached to the engine see section Taking the engine out of operation for up to 12 months subsection Rotation of the rotor in the stack draught If the compl...

Page 85: ...l alloys 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 Dispose of metals as scrap metal for recycling Dispose of non metallic materials as waste Dispose of residues of lubricants as waste oil Dispose of electronic components as electronic waste WARNIN...

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Page 87: ...reserved HZTL4061_EN Revision A September 2016 12 Spare parts For more information on spare parts for the low pressure stage see document Operation Manual Power2 4 1 Low pressure stage For more information on spare parts for the high pressure stage see document Operation Manual Power2 4 2 High pressure stage ...

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Page 89: ... LP diagram 5 Fig 4 Layout and function of the high pressure stage 6 Fig 5 Power2 HP diagram 7 Fig 6 Locations of Power2 LP warn ing plates 8 Fig 7 Locations of Power2 HP warn ing plates 8 Fig 8 Location of Power2 LP rating plate 9 Fig 9 Location of Power2 HP rating plate 9 Fig 10 Lubricating oil pressure measur ing point 17 Fig 11 Functional principle 19 Fig 12 Load time chart 31 Fig 13 Cleaning ...

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Page 91: ...g Vibrations 39 Table 18 Malfunctions when starting Rubbing of rotating parts 39 Table 19 Malfunctions during operation Lubricating oil pressure too low 40 Table 20 Malfunctions during operation Power2 LP speed reductions 40 Table 21 Malfunctions during operation Power2 HP speed reduc tions 40 Table 22 Malfunctions during operation Power2 LP speed increases 41 Table 23 Malfunctions during operatio...

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Page 93: ...15 4 5 Axial clearance A prior to disassembly 16 4 6 Removing wall insert 17 4 7 Removing the compressor casing 19 4 8 Removing the cartridge group 20 4 9 Removing turbine diffuser and nozzle ring 22 4 10 Installing the nozzle ring and turbine diffuser 24 4 11 Installing the cartridge group 26 4 12 Installing the compressor casing 29 4 13 Installing the wall insert 30 4 14 Axial clearance A after ...

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Page 95: ...015 1 Further applicable documents Chapter Document number Operation Manual Power2 1 Introduction HZTL4004 Operation Manual Power2 2 Safety HZTL4021 Operation Manual Power2 3 Safety data sheet Power2 serial number HT Operation Manual Power2 800 M 4 Product description HZTL4061 Table 1 Related documents This chapter is only available in serialised operation manuals ...

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Page 97: ...n the ABB Turbo Systems scope of delivery Swivel lifting eye S Power2 Thread Length L Minimum load limit 850 LP M24 30 mm 1800 kg Table 2 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 rati...

Page 98: ...ctions of the enginebuilder Disconnect all gas air cleaning and oil pipes according to the instructions of the enginebuilder Disconnect the cable connector from the speed sensor Attach one lifting gear to each of the two bearing casing suspension points Loosen the fixing elements on the foot Lift the low pressure stage from the engine Put down the low pressure stage so that all contact surfaces of...

Page 99: ... the orifices specified for the low pressure stage have been installed in both oil supply lines Check that the gaskets of the oil supply and the oil drain have been correctly installed in the bracket Align the low pressure stage on the engine Tighten the fixing elements on the foot according to the instructions of the enginebuilder Attach all gas air cleaning and oil pipes according to the instruc...

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Page 101: ...ng parts 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 100...

Page 102: ...l quality and fuel 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 pressure stage System specific operating conditions combustion quality exhaust gas composition For bearing parts Lubricating oil quality oil filtering oil condition oil monitoring Load pro...

Page 103: ...g casing position for assembly ABB Turbo Systems recommends marking the casing positions prior to disassembly Identification 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 in the toolbox WARNING Servicing the assembly devices Assembly devices must be checked for damage before and after use Visually ...

Page 104: ...t the surface Definition of terms Suspension point Defined loading point on a component or an assembly blind hole thread eyelet lug Assembly device Devices that are fitted on the low pressure or high pressure stage in order to obtain a suspension point Assembly devices are specially constructed and designed for the defined use they are not trading goods Use assembly devices only for the described ...

Page 105: ...Weights of assemblies The specified weights of the individual parts or assemblies are rounded up standard values Figure 3 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 5 Weights of the assemblies ...

Page 106: ...branch Disconnect air line according to the instructions of the enginebuilder Dismantle insulation as far as necessary If present Disconnect supply line for compressor cleaning from air suction branch Figure 4 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 107: ...If present Disconnect supply line for compressor cleaning from filter silencer Figure 5 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 a...

Page 108: ...ance Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts Have the components assessed and if necessary replaced by an ABB Turbocharging Service Station Figure 6 Measuring axial clearance A The axial clearance A must be measured prior to removal and after installation of the cartridge group Measure and note axial clearance A Axial clear...

Page 109: ...property can result from rubbing or jamming of the compressor wheel at the wall insert Check that the compressor wheel does not rub against the wall insert during disassembly assembly by rotating the rotor Figure 7 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 fitt...

Page 110: ...rews 90955 and nuts 90415 Fit four plates 90031 and secure with plate 90032 screw 90656 and nut 90432 7 Fit lifting gear to swivel lifting eye 90231 8 Remove nut 72004 and carefully move out wall insert Figure 9 Removing wall insert 3 9 Fit support angle 90480 with screws 90955 and nuts 90415 10 Put down wall insert 77000 11 Remove plate 90032 screw 90656 nut 90432 and plates 90031 Remove lifting ...

Page 111: ...wo 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 Figure 11 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 screw...

Page 112: ...he blades do not rub on the turbine diffuser during disassembly assembly by rotating the rotor Figure 12 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 113: ...o the fixtures in the 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 CAUTION Damage to cartridge group and toolbox cover The turned over toolbox cover may only be used as intermediate storage for the cartridge group The cover must be on a level surface The cover may not be used to transport th...

Page 114: ...oosen 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 Figure 16 Removing turbine diffuser and nozzle ring 2 4 Loosely screw in three press off screws 90902 5 Secure guide tube 90422 to bracket 900...

Page 115: ...ifting 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 Figure 18 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 press off screws 9...

Page 116: ...Nm Table 7 Tightening torque 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 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 For installation of bracket and plate see 22 6 Insert tu...

Page 117: ...Figure 20 Installing the nozzle ring and turbine diffuser 2 Part number Thread and tightening torque 61056 M10 50 Nm Table 8 Tightening torque 61056 1 Remove plate and bracket 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 fit screws and tighten all screws ...

Page 118: ...rubbing or jamming of the blade tips on the casing Check that the blades do not rub on the turbine diffuser during disassembly assembly by rotating the rotor Figure 21 Installing O rings Fit new O rings 42017 42018 Figure 22 Installing 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 lifting...

Page 119: ...87 M12 80 Nm Table 9 Tightening torque 42087 1 Screw in a guide stud 90321 in the upper area on the left and right 2 Insert cartridge group via the guide stud 3 Coat a screw 42087 with high temperature grease and screw in to secure the cartridge group 4 Remove plates 90031 and brackets 90030 5 Remove the guide stud 90321 6 Coat thread of remaining screws 42087 with high temperature grease fit scre...

Page 120: ...ut of tolerance the cartridge group has not been correctly installed and can be the cause of serious damage to the machine or property Remove and reinstall the cartridge group Always replace jammed gasket rings with new ones If the control dimension is still out of tolerance contact an ABB Turbocharging Service Station Figure 24 Measuring control dimension X After installing the cartridge group th...

Page 121: ...casing Part number Thread and tightening torque 61037 M16 250 Nm 61037 nuts that are difficult to access Pre tightening torque 60 Nm Tightening torque angle 90 5 72021 M10 70 Nm Table 11 Tightening torque 61037 72021 1 Secure lifting gear to swivel lifting eye 90231 and insert compressor casing For installation of bracket and plate see 19 2 Fit and tighten nuts 61037 3 Remove plates 90031 and brac...

Page 122: ...inst the wall insert during disassembly assembly by rotating the rotor Figure 26 Installing the wall insert 1 Part number Thread and tightening torque 77016 M5 5 Nm Table 12 Tightening torque 77016 1 Coat thread of screws 77016 with Loctite 542 and secure diffuser 79000 with screws 77016 2 Install new O rings 77040 79020 79021 3 Fit lifting gear to swivel lifting eye 90231 4 Fit four plates 90031 ...

Page 123: ...r 2015 Figure 27 Installing the wall insert 2 Part number Tightening torque 72002 M16 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 speed measurement cable from provisional holder and insert cable connector 86515 4 Screw in and tighten four studs 72002 in the upper area ...

Page 124: ...e Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts Have the components assessed and if necessary replaced by an ABB Turbocharging Service Station Figure 28 Measuring axial clearance A The axial clearance A must be measured prior to removal and after installation of the cartridge group Measure and note axial clearance A Axial clearan...

Page 125: ...m Table 15 Tightening torque 72004 77022 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 silencer 81000 Attach the lifting gear to the swivel lifting eye 90231 and loop through the eyelets at the rear of t...

Page 126: ...ch Part number Thread and tightening torque 72004 M16 200 Nm Table 16 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 Reinstall dismantled insulation Reinstall all air lines acco...

Page 128: ...ower2 850 M 4 1 Low pressure stage 4 Disassembly and assembly Page 36 49 Copyright 2015 ABB All rights reserved HZTL4062_EN Revision December 2015 4 17 Table of tightening torques Figure 31 Overview of tightening torques ...

Page 129: ...signated screw fittings Part number Thread and tightening torque 42087 M12 80 Nm 56017 M8 25 Nm 61037 M16 250 Nm 61037 nuts that are difficult to access Pre tightening torque 60 Nm Tightening torque angle 90 5 61056 M10 50 Nm 72002 M16 50 Nm 72004 M16 200 Nm 72004 nuts that are difficult to access Pre tightening torque 60 Nm Tightening torque angle 60 5 72021 M10 70 Nm 77016 M5 5 Nm 77022 M16 200 ...

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Page 131: ...rea Sound an alarm and depending on the situation stop the engine Seal oil leaks Soak up oil and dispose of in an environmentally compatible manner Wear safety gloves against thermal risks 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 the engine Foll...

Page 132: ... scope of delivery of ABB Turbo Systems and must be manufactured in accordance with the drawing see Figure 32 by the operator Required parts 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 Figure 32 Cover plate gasket sleeves and screws Cover plate gasket sleeves an...

Page 133: ...orque 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 Figure 34 Installing the casing 4 Reinstall compressor casing wall insert and alternative air inlet CAUTION Escaping lubricating oil If the cover plate is fitted complete s...

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Page 135: ...en into account in this document contact an ABB Turbocharging Service Station Dispose of placed and unusable parts in an environmentally friendly and professional manner in accordance with the local regulations Dispose of the packaging of new parts in an environmentally friendly and professional manner in accordance with the local regulations Required customer spare part set 97070 for a low pressu...

Page 136: ... 850 M 4 1 Low pressure stage 6 Spare parts Page 44 49 Copyright 2015 ABB All rights reserved HZTL4062_EN Revision December 2015 6 2 View of low pressure stage with part numbers Figure 35 Low pressure stage with part numbers ...

Page 137: ...r head screw 56018 in customer spare part set Clamp 61001 Gas outlet casing 61009 Hexagon head screw 61037 Hex nut 61050 Spiral wound gasket 61056 in customer spare part set Hexagon head screw 63000 Turbine diffuser 68002 Foot turbine end 72000 Compressor casing 72002 Stud 72003 in customer spare part set Washer 72004 in customer spare part set Hex nut 72021 Socket screw 77000 Wall insert 77022 in...

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Page 139: ...emoving turbine diffuser and nozzle ring 1 22 Fig 16 Removing turbine diffuser and nozzle ring 2 22 Fig 17 Removing turbine diffuser and nozzle ring 3 23 Fig 18 Removing turbine diffuser and nozzle ring 4 23 Fig 19 Installing the nozzle ring and turbine diffuser 1 24 Fig 20 Installing the nozzle ring and turbine diffuser 2 25 Fig 21 Installing O rings 26 Fig 22 Installing cartridge group 1 26 Fig ...

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Page 141: ...al clearance A 16 Table 7 Tightening torque 56017 24 Table 8 Tightening torque 61056 25 Table 9 Tightening torque 42087 27 Table 10 Control dimension X 28 Table 11 Tightening torque 61037 72021 29 Table 12 Tightening torque 77016 30 Table 13 Tightening torque 72002 31 Table 14 Axial clearance A 32 Table 15 Tightening torque 72004 77022 33 Table 16 Tightening torque 72004 34 Table 17 Tightening tor...

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Page 143: ... air suction branch together with bellows 11 4 4 Removing wall insert 12 4 5 Removing the compressor casing 14 4 6 Removing the cartridge group 15 4 7 Removing the nozzle ring 17 4 8 Measuring axial clearance A 18 4 9 Installing the nozzle ring 19 4 10 Installing the cartridge group 20 4 11 Installing the compressor casing 23 4 12 Installing the wall insert 24 4 13 Installing the air suction branc...

Page 144: ...her applicable documents Chapter Document number Operation Manual Power2 1 Introduction HZTL4004 Operation Manual Power2 2 Safety HZTL4021 Operation Manual Power2 3 Safety data sheet Power2 serial number HT Operation Manual Power2 800 M 4 Product description HZTL4061 Table 1 Related documents This chapter is only available in serialised operation manuals Page 2 35 ...

Page 145: ... ABB Turbo Systems scope of delivery Swivel lifting eye S Power2 Thread Length Minimum load limit Lmin Lmax 850 HP M12 15 mm 20 mm 700 Table 2 Swivel lifting eyes to be used Lifting gear with a sufficient load limit must be used for removing and installing the high pressure stage The following weight specification is the heaviest variant possible This standard value may deviate from the data on th...

Page 146: ...ion must be removed trans ported and put down separately Fig 1 Suspension of complete high pressure stage u Remove insulation u Disconnect all gas air water and oil pipes in accordance with the enginebuilder s instruc tions u Unplug the cable connector at the speed sensor u Remove air suction branch together with bellows see Fig 4 Removing the air suction branch 11 u Check lifting gear u Attach on...

Page 147: ...sion points 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 been correctly fitted at the oil inlet and the oil outlet in the bracket u Check that the sleeves of the bearing casing fixing screws have been correctly fitted u Align the high pressure stage o...

Page 148: ...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 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 25000 50000 G...

Page 149: ...d profile 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 specific operating conditions combustion quality exhaust gas composition Atmospheric humidity after the intercooler For bearing parts Lubricating oil quality oil filtering oil condition oil monitor...

Page 150: ...entification 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 placed Customer spare part set Before starting operations make sure the required custom...

Page 151: ... are fitted on the low pressure or high pressure stage in order to obtain a suspension point Assembly devices are specially constructed and designed for the defined use they are not trading goods Use assembly devices only for the described ap plications Lifting gear Equipment for the lifting and transporting of loads ropes chain block crane Lifting gear is not supplied by ABB Turbo Systems Page 9 ...

Page 152: ...n A August 2017 4 2 Weights 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 85 02 Bellows 40 03 Wall insert 60 04 Compressor casing 70 05 Cartridge group with hood diffuser and nozzle ring 130 Table 5 Weights of the assemblies Page 10 35 ...

Page 153: ...er with 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 air suction branch Fig 4 Removing the air suction branch 1 Loop around air suction branch and secure to lifting gear 2 Loosen nuts 72004 and remove with washers 72003 3 Remove and put down the air s...

Page 154: ... 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 Fig 6 Removing wall insert 2 4 Fit bracket 90030 with screws 90662 and nuts 90415 5 Attach lifting gear to swivel lifting eye 90657 6 Remove lock nut 72004 7 Carefully move out wall insert 77000 When d...

Page 155: ...embly 4 4 Removing wall insert Copyright 2017 ABB All rights reserved HZTL4063_EN Revision A August 2017 Fig 7 Removing wall insert 3 8 Fit support angle 90450 with screws 90658 washers 72003 and nuts 72004 9 Put down the wall insert 77000 10 Remove the O ring 77040 Page 13 35 ...

Page 156: ...et 90030 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 casing to crane 4 Using press off nuts 61090 and ring spanner 90426 fully press off compressor casing 5 Move out compressor casing 72000 and put down When doing this do not roll com pressor casing ...

Page 157: ...e the O ring 42010 2 Undo and remove 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 screw 90656 and nut 90415 6 Secure lifting gear to swivel lifting eye 90657 Fig 10 Moving out cartridge group 2 7 Evenly press off cartridge group by screwing three press off screws 90901 into the d...

Page 158: ...ay be only 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 11 Moving out cartridge group 3 9 Put down the cartridge group in the holders of the turned over toolbox cover 90010 Pay attention to note concerning aligning the cover 10 Remove plate 90032 screw 90656 nut 90415 and plates 90031 11...

Page 159: ...assembly 4 7 Removing the nozzle ring Copyright 2017 ABB All rights reserved HZTL4063_EN Revision A August 2017 4 7 Removing the nozzle ring Fig 12 Removing the nozzle ring 1 Slacken and remove screws 56017 with box spanner insert 90770 2 Remove nozzle ring 56001 Page 17 35 ...

Page 160: ...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 Service Station Fig 13 Measuring axial clearance A The axial clearance A must be measured after removal and before installation of the cart ridge group u Measure and note axial clearance A Axial clea...

Page 161: ...ved HZTL4063_EN Revision A August 2017 4 9 Installing the nozzle ring Fig 14 Installing the nozzle ring Part number Thread and tightening torque 56017 M8 Tx40 25 Nm Table 7 Tightening torque 56017 1 Fit nozzle ring 56001 2 Coat threads of screws 56017 with high temperature grease and tighten the screws with the box spanner insert 90770 Page 19 35 ...

Page 162: ...idge group Fig 15 Installing O rings u Fit new O rings 42017 42018 Fig 16 Installing the cartridge group 1 1 Clean slots for lamellar rings 64001 and fit new lamellar rings Arrange joints so that they are offset by 180 2 Fit bracket 90030 and plates 90031 Bracket assembly see Fig 9 Moving out cart ridge group 1 15 3 Fit lifting gear to swivel lifting eye 90657 4 Lift cartridge group and carefully ...

Page 163: ..._EN Revision A August 2017 Fig 17 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 screw 90656 nut 90415 and plates 90031 7 Remove screws 90900 and bracket 90030 8 Fit screws 42099 Observe the tightening torque 9 Fit a new O ring 42010 Page 21 35 ...

Page 164: ... control dimension X must be measured Control dimension X mm 49 0 0 2 Table 9 Control dimension X CAUTION Control dimension outside the tolerance value If the control dimension 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 replace jammed gasket rings wit...

Page 165: ...asing Part number Thread and tightening torque 61090 M12 120 Nm 61090 nuts that are difficult to access Pre tightening torque 50 Nm Tightening angle 30 5 Table 10 Tightening torque 61090 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 see Fig 8 Removing the compressor casing 14 3 Fit nuts 61090 Observe the t...

Page 166: ...vision A August 2017 4 12 Installing the wall insert Fig 20 Installing the wall insert 1 1 Fit bracket 90030 Installation of bracket see Fig 6 Removing wall insert 2 12 2 Secure lifting gear to swivel lifting eye 90657 and lift wall insert 77000 3 Remove support angle 90450 4 Fit a new O ring 77040 5 Move in wall insert 77000 until bracket can be removed Page 24 35 ...

Page 167: ...g 21 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 insert 77000 as far as it will go 9 Detach speed measurement cable from provisional holder and insert cable connector 86515 10 Fit three studs 72002 again in upper area and tighten Page 25 35 ...

Page 168: ...nch 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 bellows is not radially pre tensioned 3 Fit washers 72003 and nuts 72004 and tighten 4 Remove the lifting gear u Fit all air lines in accordance with the enginebuilder s instructions u If present Connec...

Page 169: ...ening torques Fig 23 Tightening torques The following tightening torques Nm must be observed for the designated screw fittings Part number Thread and tightening torque 42099 M12x80 80 Nm 56017 M8 Tx40 25 Nm 61090 M12 120 Nm 61090 nuts that are difficult to access Pre tightening torque 40 Nm Tightening angle 40 5 72002 M12x95 50 Nm 72004 M12 120 Nm 82022 M12x45 210 Nm Table 13 Tightening torques Pa...

Page 170: ...aise 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...

Page 171: ...t are required are not part of the scope of delivery of ABB Turbo Systems and must be manufactured by the operator on the basis of the drawing see Fig 24 Cover plate gasket and sleeves 29 Parts required 1 Cover plate 01 recommended material 1 4541 1 4571 1 Gasket 02 temperature resistant up to 550 C 8 Sleeves 03 Fig 24 Cover plate gasket and sleeves Cover plate gasket and sleeves dimensions mm Ø1 ...

Page 172: ...ue 42099 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 sleeve 03 and screws 42099 Fig 26 Installing the casing 4 Re fit the compressor casing the wall insert and air suction branch with bellows CAUTION Escaping lubricating oil Complete sealing of the ...

Page 173: ...n u If different model variants are not taken into account in this document contact an ABB Turbocharging Service Station u Dispose of placed and unusable parts in an environmentally friendly and professional manner in accordance with the local regulations u Dispose of the packaging of new parts in an environmentally friendly and professional manner in accordance with the local regulations Required...

Page 174: ...View of high pressure stage with part numbers Copyright 2017 ABB All rights reserved HZTL4063_EN Revision A August 2017 6 2 View of high pressure stage with part numbers Fig 27 High pressure stage with part numbers only available in customer spare part set 97070 Page 32 35 ...

Page 175: ...t screw 51001 Gas inlet casing radial 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 61050 Spiral wound gasket 61090 in customer spare part set Hexagon nut 61300 Support 64001 in customer spare part set Lamellar ring 72000 Compressor casing 72003 in customer spare part set...

Page 176: ...ving out cartridge group 2 15 Fig 11 Moving out cartridge group 3 16 Fig 12 Removing the nozzle ring 17 Fig 13 Measuring axial clearance A 18 Fig 14 Installing the nozzle ring 19 Fig 15 Installing O rings 20 Fig 16 Installing the cartridge group 1 20 Fig 17 Installing the cartridge group 2 21 Fig 18 Measuring control dimension X 22 Fig 19 Installing the compressor casing 23 Fig 20 Installing the w...

Page 177: ...ervals h 6 Table 5 Weights 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 Tightening torque 72002 25 Table 12 Tightening torque 72004 26 Table 13 Tightening torques 27 Table 14 Cover plate gasket 29 Table 15 Tightening torque 42099 30 Table 16 Custome...

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