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

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

HZTL4062_EN

Revision A

March 2019

5.1.2

Fitting the cover plate

Fig. 33: Fitting the cover plate

Part number

Thread and tightening torque

42087

M12x60

80 Nm

Table 19: Tightening 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. 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 sealing of the lubricating oil supply is
not guaranteed.

Shut off lubricating oil supply to low-pressure stage at engine side.

Page

Summary of Contents for Power2 850-M46

Page 1: ...n Manual Chapter Document ID 1 Introduction HZTL4004_EN_D 2 Safety HZTL4025_EN_B 3 Safety data sheets HT592742_A 4 Product description HZTL4061_EN_B 4 1 Low pressure stage PT002745 HZTL4062_EN_A PT002746 HZTL4062_EN_A 4 2 High pressure stage PT002743 HZTL4063_EN_B PT002744 HZTL4063_EN_B ...

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: ...nition 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 operati...

Page 12: ...r 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: ...espiratory 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 ev...

Page 14: ...es 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: ... 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 ha...

Page 16: ...h 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 withou...

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 construct...

Page 18: ...uring 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 us...

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

Page 20: ...ed 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 t...

Page 21: ...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 Touchin...

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

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

Page 24: ...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 suitable climbing aids and working plat...

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

Page 26: ...ration of the tur bocharger or for the performance of maintenance work Oils greases coolants detergents and solvents acids and similar substances can be classified as hazardous substances WARNING Handling operating materials and supplies Swallowing or inhaling 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 c...

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

Page 28: ......

Page 29: ...s Page 1 5 Safety data sheets Copyright 2020 ABB All rights reserved HT592742_A January 2020 Power2 850 M46 HT592742 Name Hardware ID Page Low pressure stage PT002745 2 Low pressure stage PT002746 3 High pressure stage PT002743 4 High pressure stage PT002744 5 ...

Page 30: ...M46 HT592742 Low pressure stage PT002745 Power2 850 M46 HT592742 Low pressure stage PT002745 32 420 420 64 2020 1900 64 HZTL53380M 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: ...M46 HT592742 Low pressure stage PT002746 Power2 850 M46 HT592742 Low pressure stage PT002746 32 420 420 64 2020 1900 64 HZTL53380M 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 32: ...743 Power2 850 M46 HT592742 High pressure stage PT002743 32 612 612 64 2020 700 64 HZTL53380M 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 650 During operation tBmax C 620 Compressor inlet temperature after intercooler During operation tCmax C 60 ...

Page 33: ...744 Power2 850 M46 HT592742 High pressure stage PT002744 32 612 612 64 2020 700 64 HZTL53380M 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 650 During operation tBmax C 620 Compressor inlet temperature after intercooler During operation tCmax C 60 ...

Page 34: ......

Page 35: ... out of operation 17 4 Monitoring during operation 18 4 1 Lubricating oil pressure 18 4 2 Lubricating oil temperature 19 4 3 Speed measurement 20 5 Operation and service 22 5 1 Noise emission 22 5 2 Service work 23 5 3 Expected replacement intervals 25 5 4 Stopping the engine 25 6 Periodic maintenance 26 6 1 Foreword to maintenance 26 6 2 Cleaning the compressor during operation 27 6 3 Cleaning tu...

Page 36: ...BB All rights reserved HZTL4061_EN Rev B June 2019 10 Taking out of operation for a long period 47 10 1 General 47 10 2 Lubricating oil 47 10 3 Process for taking out of operation 47 11 Disposing of low pressure and high pressure stage components 48 12 Spare parts 49 Figures 50 Tables 51 ...

Page 37: ...ved HZTL4061_EN Rev B June 2019 1 Introduction 1 1 Related documents Chapter Document number Operation Manual 1 Introduction HZTL4004 Operation Manual 2 Safety HZTL4025 Operation Manual 3 Safety data sheet Serial number of Power2 Table 1 Related documents This chapter is only present in serialised operation manuals Page 3 51 ...

Page 39: ...ressure 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 th...

Page 40: ...rved HZTL4061_EN Rev B June 2019 1 3 Layout and function of the low pressure stage Fig 2 Layout and function of the low pressure stage 01 Filter silencer air suction branch 06 Gas inlet casing 02 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 6 51 ...

Page 41: ... pressure stage 6 the exhaust gas coming from the high pressure stage Power2 HP flows through the gas inlet casing 06 and the nozzle ring 07 and reaches the turbine 08 The LP turbine uses the energy contained in the exhaust gas to drive the rotor The exhaust gases then reach the atmosphere through the gas outlet casing 05 and the ex haust gas pipe connected to it The rotor runs in two radial plain...

Page 42: ...s reserved HZTL4061_EN Rev B June 2019 1 4 Layout and function of the high pressure stage Fig 4 Layout and function of the high pressure stage 01 Air suction branch 06 Gas inlet casing 02 Compressor 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 8 51 ...

Page 43: ...Fig 4 Layout and function of the high pressure stage 8 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 exhaust 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...

Page 44: ...er2 HP warning plates If warning plates are not present in the designated locations or not readable proceed as fol lows u Order new warning plates from ABB Turbocharging Service Stations u Remove any 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 st...

Page 45: ...g 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 Fig 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 hig...

Page 46: ...EN Rev B June 2019 2 Removal and installation u For more information on how to remove and install the low pressure stage see document Operation Manual Power2 4 1 Low pressure stage u For more information on how to remove and install the high pressure stage see docu ment Operation Manual Power2 4 2 High pressure stage Page 12 51 ...

Page 47: ...ressure and high pressure stage must be pre lubricated in order to avoid bearing damage caused by dry running u Adhere to the admissible oil pressure range see Table 5 Oil pressure range 18 An electrically driven oil pump is recommended for pre lubrication Power2 Pre lubrication time 850 2 min Table 2 Pre lubrication time 3 1 3 Post lubrication Post lubrication is necessary after switching the eng...

Page 48: ...isk of oil leakage during standstill The following measures are recommended for reducing the risk of oil leakage during stand still Reduction of the pressure in the bearing space by a means of an 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 49: ...ine or property can be caused by dirt and solid ma terial particles in the oil u For the initial commissioning phase and after all service work flush the complete lubricating system with warm oil u 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 ...

Page 50: ...arging 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 the assembly of the low pre...

Page 51: ... after the turbine for combustion residues or wa ter residues and clean it Remove any foreign objects that may be present u Check and clean filter silencer or air supply line and remove any foreign 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...

Page 52: ... measuring point The measuring point M is at the oil supply channel of the high and low pressure stage that is not used for the oil supply Power2 Status Engine Status Low pressure and high pressure 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...

Page 53: ...l temperature at the outlet Toil inlet C 850 Admissible 90 150 Temporarily admissible 1 h Alarm 90 95 150 155 Not admissible stop engine 95 155 Not admissible preheat oil prior before start 30 Table 6 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 accord...

Page 54: ...6 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 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...

Page 55: ...engine performance until the maximum speed of all low and high pressure stages does not exceed 70 of nBmax u If the engine cannot be stopped it can continue to be driven with this reduced engine 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 temperatures in...

Page 56: ...tance of 1 metre from the low pressure and high pressure stage The highest value of the emission sound pressure level1 reaches a maximum of 105 dB A near the compressor end compressor casing filter 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 stan...

Page 57: ... 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 u 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 after the ...

Page 58: ...pecifications on the rating plate The following work must be carried out by an ABB Turbocharging Service Station Replacement of the bearing parts Replacement of the turbine and the compressor 5 2 6 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 m...

Page 59: ...u For information on the expected replacement intervals of the components of the high pressure stage see document Operation Manual Power2 4 2 High pressure stage 5 4 Stopping the engine CAUTION 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 c...

Page 60: ...tate 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 61: ...l 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 ...

Page 62: ... 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 Surging of the compressor Should repeated surging of the compressor stage occur during compressor cleaning first the cleaning parameters water flow rate...

Page 63: ...igger water injection according to the instructions of the enginebuilder u Observe water pressure before connection to pressure stage u Operate engine for at least five additional minutes after 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 unsucces...

Page 64: ...nders Incompletely burnt fuel Sodium vanadyl vanadate It is advantageous to use fuels with low ash sulphur sodium and vanadium contents The fuel must also be correctly stored prepared and handled ABB 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 possible Consequences of cont...

Page 65: ...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 affect parts of the low pressure and high pressure stage u Never use salt water but only pure water for clean...

Page 66: ...e inlet in the LP stage N m2 Engine load Max gas inlet temperature when starting cleaning C Holding time at reduced load min 850 9500 2500 3200 800 25 430 10 Table 10 Operating point for turbine 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 g...

Page 67: ...aning connection of the tur bocharger is to be set as a rough approximation 3 Cleaning the low pressure turbine stage LP stage u If present open the drain pipe in the low pressure stage during cleaning 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 W...

Page 68: ...nutes or not at all If the drainage of the gas outlet casing is omitted the low pressure stage speed and or the gas inlet temperature must be monitored during the cleaning process If the load is too 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 cle...

Page 69: ...eet metal covering Cleaning the filter ring if present u Remove filter ring 81265 u Clean filter ring 81265 as required or every 500 hours of operation and replace 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 81265 with water and mild detergent or in the case of heavy con tamination soak...

Page 70: ...ter rings as well as damaged connecting rods replaced by an ABB Turbocharging Service Station Fitting the filter silencer u Assemble the insert units E by inserting the absorption segments 81136 into the sheet metal coverings 81137 u Bend the sheet metal coverings 81137 back into the original shape u Insert the insert units E into the slotted guides in the filter silencer body 81135 u Place the co...

Page 71: ... Table 15 Tightening torque 81272 81273 u 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 u Fit lock nuts 81273 to screws 81272 and tighten with the tightening torque ...

Page 72: ... 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 permitted This causes the compressor or turbine blades to be somewhat shortened To pre vent significant loss of efficiency spec...

Page 73: ...igh pressure stage speed Possible causes Remedy Engine Defects on the connected cylinders Contact enginebuilder High pressure stage Heavy contamination of the turbine Clean Damaged rotor components or bear ing Contact ABB Turbocharging Service Sta tion Change of operating state of low pressure stage Check the operating point of the low pressure stage Pipes Defects such as leaks in the exhaust gas ...

Page 74: ...ssure stage Insufficient air for example because filter silencer is blocked by contamin ation Clean Compressor turbine contaminated Exhaust gas back pressure too high Clean or repair boiler or exhaust gas si lencer Turbine damaged or eroded Contact ABB Turbocharging Service Sta tion Charge air cooler inter cooler Cooler contaminated Clean Cooling water volume too low Fill Inlet temperature of cool...

Page 75: ...ter silencer contaminated there fore 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...

Page 76: ...ion gases Correct the influx of ventilation gases in accordance with the enginebuilder s in structions Table 27 Malfunctions during operation Compressor 1 contamination Reduced fatigue strength of 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 influx of ventilation gases containing corr...

Page 77: ...nuously or periodic ally their components may be damaged u Gradually reduce the engine load u Have the cause clarified and remedied immediately by an ABB Turbochar ging Service Station u Have parts 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 reduci...

Page 78: ...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...

Page 79: ... B June 2019 8 Disassembly and assembly u For more information on the disassembly and assembly of the low pressure stage see document Operation Manual Power2 4 1 Low pressure stage u For more information on the disassembly and assembly of the high pressure stage see document Operation Manual Power2 4 2 High pressure stage Page 45 51 ...

Page 80: ...B June 2019 9 Taking out of operation at short notice u For more information on briefly taking the low pressure stage out of operation see docu ment Operation Manual Power2 4 1 Low pressure stage u For more information on briefly taking the high pressure stage out of operation see doc ument Operation Manual Power2 4 2 High pressure stage Page 46 51 ...

Page 81: ...ludes cleaning and applying preservative oil to the relevant compon ents 10 3 Process for taking out of operation Different measures are required depending on the process used to take the low pressure 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 o...

Page 82: ... 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 Handling dam...

Page 83: ... HZTL4061_EN Rev B June 2019 12 Spare parts u For more information on spare parts for the low pressure stage see document Operation Manual Power2 4 1 Low pressure stage u For more information on spare parts for the high pressure stage see document Operation Manual Power2 4 2 High pressure stage Page 49 51 ...

Page 84: ...Layout and function of the high pressure stage 8 Fig 5 Power2 HP diagram 9 Fig 6 Locations of Power2 LP warning plates 10 Fig 7 Locations of Power2 HP warning plates 10 Fig 8 Location of Power2 LP rating plate 11 Fig 9 Location of Power2 HP rating plate 11 Fig 10 Lubricating oil pressure measuring point 18 Fig 11 Functional principle 20 Fig 12 Load time chart 32 Fig 13 Cleaning the filter silencer...

Page 85: ...ctions when starting Rubbing of rotating parts 38 Table 19 Malfunctions during operation Lubricat ing oil pressure too low 39 Table 20 Malfunctions during operation Power2 LP speed reductions 39 Table 21 Malfunctions during operation Power2 HP speed reductions 39 Table 22 Malfunctions during operation Power2 LP speed increases 39 Table 23 Malfunctions during operation Power2 HP speed increases 39 ...

Page 86: ......

Page 87: ...Axial clearance A prior to disassembly 13 4 6 Removing wall insert 14 4 7 Removing the compressor casing 16 4 8 Removing the cartridge group 17 4 9 Removing turbine diffuser and nozzle ring 19 4 10 Installing the nozzle ring and turbine diffuser 21 4 11 Installing the cartridge group 23 4 12 Installing the compressor casing 26 4 13 Installing the wall insert 27 4 14 Axial clearance A after assembl...

Page 88: ...er 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 43 ...

Page 89: ...BB Turbo 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 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 t...

Page 90: ...ble location u Secure with lifting gear wherever possible Wear safety helmet Fig 1 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 bear...

Page 91: ...at the orifices specified for the low pressure stage have been installed in both oil supply lines u Check that the gaskets of the oil supply and the oil drain have been correctly installed 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 cleaning and oil pipes according to ...

Page 92: ...cing 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 35000 50000 Ga...

Page 93: ...nd 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 profile speed ...

Page 94: ...ification 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 customer ...

Page 95: ...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 4...

Page 96: ... 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 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 10 43 ...

Page 97: ...ssary u If present Disconnect supply line for compressor cleaning from filter silencer Fig 4 Removing the filter silencer 1 Fit the swivel lifting eye 90231 to the silencer 81000 Attach the lifting gear 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 Loo...

Page 98: ...tion 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 5 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 bra...

Page 99: ...the tolerance Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts u Have the components assessed and if necessary replaced by an ABB Tur bocharging Service Station Fig 6 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...

Page 100: ... 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 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 fit...

Page 101: ...s 90955 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 9 Removing wall insert 3 9 Fit support angle 90480 with screws 90955 and nut 90415 10 Put down the wall insert 77000 11 Remove plate 90032 screw 90656 nut 90432 and plates 90031 Remove lifting g...

Page 102: ...move 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 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 sc...

Page 103: ... that the blades do not rub on the turbine diffuser during disas sembly assembly by rotating the rotor Fig 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 lift...

Page 104: ...into 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 u The cover must be on a level surface u The cover may not be used to trans...

Page 105: ...e ring 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 16 Removing turbine diffuser and nozzle ring 2 4 Loosely screw in three press off screws 90902 5 Secure guide tube 90422 to br...

Page 106: ...033 3 Secure lifting gear to swivel lifting eye 90231 4 Fit four plates 90031 and secure with plate 90032 screw 90656 and nut 90432 5 Press off turbine diffuser evenly using the press off screws 90902 Fig 18 Removing turbine diffuser and nozzle ring 4 6 Carefully move out turbine diffuser 63000 7 Put down turbine diffuser Remove plate 90032 screw 90656 nut 90432 and plates 90031 Remove press off s...

Page 107: ...orque 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 the tightening 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 Fig 17 Remo...

Page 108: ...arch 2019 Fig 20 Installing the nozzle ring and turbine diffuser 2 Part number Thread and tightening torque 61056 M10x90 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 and fit screws Observe the tightening torque Page 22 43 ...

Page 109: ...om the rubbing or jamming of the blade tips on the casing u Check that the blades do not rub on the turbine diffuser during disas sembly assembly by rotating the rotor Fig 21 Installing O rings u Fit new O rings 42017 42018 Fig 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 l...

Page 110: ...7 M12x60 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 bracket 90030 5 Remove the guide stud 90321 6 Coat thread of remaining screws 42087 with high temperature grease and fit...

Page 111: ... 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 with new ones u If the control dimension is still out of tolerance contact an ABB Tur bocharging Service Station Fig 24 Measuring control dimension X After installing the cartridg...

Page 112: ...ightening torque 61037 M16 250 Nm 61037 nuts that are difficult to access Pre tightening torque 60 Nm Tightening torque angle 90 5 72021 M10x20 70 Nm Table 11 Tightening torque 61037 72021 1 Secure lifting gear to swivel lifting eye 90231 and insert compressor casing Installation of bracket and plates see Fig 10 Removing the compressor casing 1 16 2 Fit nuts 61037 Observe the tightening torque 3 R...

Page 113: ...wall insert during disassembly assembly by rotating the rotor Fig 26 Installing wall insert 1 Part number Thread and tightening torque 77016 M5x35 5 Nm Table 12 Tightening torque 77016 1 Coat the threads of screws 77016 with Loctite 243 and secure diffuser 79000 with screws 77016 Observe the tightening torque 2 Fit new O rings 77040 79020 79021 3 Secure lifting gear to swivel lifting eye 90231 4 F...

Page 114: ... 2019 Fig 27 Installing wall insert 2 Part number Tightening torque 72002 M16x334 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 con nector 86515 4 Fit four studs 72002 in the upper area Observe the tightening torque Page 28 43 ...

Page 115: ...lerance 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 28 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 Axia...

Page 116: ... branch Part number Thread and tightening torque 72004 M16 200 Nm Table 15 Tightening torque 72004 1 Remove the two opposing nuts 72004 and washers 72003 that were used to secure the wall insert 2 Loop 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 l...

Page 117: ...0 Nm Table 16 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 o...

Page 118: ... Low pressure stage 4 Disassembly and assembly 4 17 Table of tightening torques Copyright 2019 ABB All rights reserved HZTL4062_EN Revision A March 2019 4 17 Table of tightening torques Fig 31 Overview of tightening torques Page 32 43 ...

Page 119: ...esignated screw fittings 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 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 72021 M10x20 70 Nm 77016 M5x35 5 Nm 77022 ...

Page 120: ...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 121: ...f ABB Turbo Systems and must be manufactured by the operator on the basis of the drawing see Fig 32 Cover plate gasket sleeves and screws 35 Parts required 1 Cover plate 01 recommended material 1 4541 1 4571 1 Gasket 02 temperature resistant up to 550 C 8 additional screws 03 to the screws 42087 from the scope of delivery 15 sleeves 04 Fig 32 Cover plate gasket sleeves and screws Cover plate gaske...

Page 122: ...ing 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 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...

Page 123: ...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 ABB Turbocharging Service Station 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 env...

Page 124: ... the Operation Manual the customer spare part set 97070 is required These parts are only available in the complete set Part number Designation Quantity 42012 79020 O ring 2 42017 O ring 1 42018 O ring 2 42087 Hexagon head screw 1 56017 Hexalobular head screw 3 56018 Clamp 3 61037 Hex nut 3 61056 Hexagon head screw 8 72003 Washer 3 72004 77022 Hex nut 4 77016 Hexagon head screw 5 77040 O ring 1 790...

Page 126: ...2 View of low pressure stage with part numbers Copyright 2019 ABB All rights reserved HZTL4062_EN Revision A March 2019 6 2 View of low pressure stage with part numbers Fig 35 Low pressure stage with part numbers only available in customer spare part set 97070 Page 40 43 ...

Page 127: ...are part set Clamp 61001 Gas outlet casing 61009 Hexagon head screw 61037 in customer spare part set Hexagon nut 61050 Spiral wound gasket 61056 in customer spare part set Hexagon head screw 63000 Turbine diffuser 68002 Foot turbine end 72000 Compressor casing 72002 Stud 72003 in customer spare part set Washer 72004 in customer spare part set Hexagon nut 72021 Socket screw 77000 Wall insert 77016 ...

Page 128: ...ne diffuser and nozzle ring 1 19 Fig 16 Removing turbine diffuser and nozzle ring 2 19 Fig 17 Removing turbine diffuser and nozzle ring 3 20 Fig 18 Removing turbine diffuser and nozzle ring 4 20 Fig 19 Installing the nozzle ring and turbine diffuser 1 21 Fig 20 Installing the nozzle ring and turbine dif fuser 2 22 Fig 21 Installing O rings 23 Fig 22 Installing cartridge group 1 23 Fig 23 Inserting...

Page 129: ... Table 7 Tightening torque 56017 21 Table 8 Tightening torque 61056 22 Table 9 Tightening torque 42087 24 Table 10 Control dimension X 25 Table 11 Tightening torque 61037 72021 26 Table 12 Tightening torque 77016 27 Table 13 Tightening torque 72002 28 Table 14 Axial clearance A 29 Table 15 Tightening torque 72004 30 Table 16 Tightening torque 72004 77022 31 Table 17 Tightening torques 33 Table 18 ...

Page 130: ......

Page 131: ...e 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 18 4 8 Measuring axial clearance A 19 4 9 Installing the nozzle ring 20 4 10 Installing the cartridge group 21 4 11 Installing the compressor casing 24 4 12 Installing the wall insert 25 4 13 Installing the air suction bran...

Page 132: ...ther 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 37 ...

Page 133: ... 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 134: ...tion 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 o...

Page 135: ...nsion 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 ...

Page 136: ...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 137: ...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 138: ...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 139: ... 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 140: ... B October 2018 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 37 ...

Page 141: ...her 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 ...

Page 142: ...e 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 ...

Page 143: ...mbly 4 4 Removing wall insert Copyright 2018 ABB All rights reserved HZTL4063_EN Revision B October 2018 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 37 ...

Page 144: ...ket 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 145: ...ve 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 ...

Page 146: ...y only be used for intermediate storage of the cartridge group u The cover must be on a level surface u The cover may not be used to transport the cartridge group Fig 11 Moving out cartridge group 3 9 Lower the cartridge group into the holders of the turned over toolbox cover 90010 and leave it secured to the crane Pay attention to note concerning aligning the cover 10 Remove plate 90032 screw 906...

Page 147: ...2 High pressure stage 4 Disassembly and assembly 4 6 Removing the cartridge group Copyright 2018 ABB All rights reserved HZTL4063_EN Revision B October 2018 Fig 12 Moving out cartridge group 4 12 Remove O rings 42017 42018 Page 17 37 ...

Page 148: ...ssembly 4 7 Removing the nozzle ring Copyright 2018 ABB All rights reserved HZTL4063_EN Revision B October 2018 4 7 Removing the nozzle ring Fig 13 Removing the nozzle ring 1 Slacken and remove screws 56017 with box spanner insert 90770 2 Remove nozzle ring 56001 Page 18 37 ...

Page 149: ...ance 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 14 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 cle...

Page 150: ...ved HZTL4063_EN Revision B October 2018 4 9 Installing the nozzle ring Fig 15 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 20 37 ...

Page 151: ...idge group Fig 16 Installing O rings u Fit new O rings 42017 42018 Fig 17 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 152: ...EN Revision B October 2018 Fig 18 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 22 37 ...

Page 153: ...e 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 wi...

Page 154: ...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 155: ...vision B October 2018 4 12 Installing the wall insert Fig 21 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 25 37 ...

Page 156: ...ig 22 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 26 37 ...

Page 157: ...anch 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 Conne...

Page 158: ...tening torques Fig 24 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 P...

Page 159: ...Raise 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 o...

Page 160: ...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 25 Cover plate gasket and sleeves 30 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 25 Cover plate gasket and sleeves Cover plate gasket and sleeves dimensions mm Ø1 ...

Page 161: ...que 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 27 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 162: ...ollowing data when making queries and ordering spare parts Serial number of Power2 HT Serial number of the low or high pressure stage PT Designation and part number Spare parts can be ordered from an ABB Turbocharging Service Station 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 en...

Page 163: ...essure stage For the operations described in the Operation Manual the customer spare part set 97070 is required These parts are only available in the complete set Part number Designation Quantity 42010 O ring 1 42012 77040 O ring 2 42017 O ring 2 42018 O ring 4 42099 Socket screw 8 56017 Hexalobular head screw 3 61090 72004 Hex nut 6 64001 Lamellar ring 2 72003 Washer 3 Table 16 Customer spare par...

Page 164: ...View of high pressure stage with part numbers Copyright 2018 ABB All rights reserved HZTL4063_EN Revision B October 2018 6 2 View of high pressure stage with part numbers Fig 28 High pressure stage with part numbers only available in customer spare part set 97070 Page 34 37 ...

Page 165: ...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 166: ...group 2 15 Fig 11 Moving out cartridge group 3 16 Fig 12 Moving out cartridge group 4 17 Fig 13 Removing the nozzle ring 18 Fig 14 Measuring axial clearance A 19 Fig 15 Installing the nozzle ring 20 Fig 16 Installing O rings 21 Fig 17 Installing the cartridge group 1 21 Fig 18 Installing the cartridge group 2 22 Fig 19 Measuring control dimension X 23 Fig 20 Installing the compressor casing 24 Fig...

Page 167: ...ervals h 6 Table 5 Weights of the assemblies 10 Table 6 Axial clearance A 19 Table 7 Tightening torque 56017 20 Table 8 Tightening torque 42099 22 Table 9 Control dimension X 23 Table 10 Tightening torque 61090 24 Table 11 Tightening torque 72002 26 Table 12 Tightening torque 72004 27 Table 13 Tightening torques 28 Table 14 Cover plate gasket 30 Table 15 Tightening torque 42099 31 Table 16 Custome...

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