ABB PT003915 Operation Manual Download Page 1

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Turbo Systems Switzerland Ltd

Operation Manual / Power2 340-H44

High-pressure stage PT003915

Document identification

Document number

HZTL4054

Revision

Language

English

Original Operation Manual

Product identification

Serial number

PT003915

Customer part number

1211506

Delivery date (yyyy-mm-dd)

2022-04-13

Weight

280

Operating limits according to rating plate

Speed limit in test rig operation only

Mmax

786

1/s

Speed limit during operation

Bmax

785

1/s

Gas inlet temperature limit in test rig operation only

Mmax

650

°C

Gas inlet temperature limit during operation

Bmax

650

°C

Compressor inlet temperature after intercooler

Cmax

°C

Summary of Contents for PT003915

Page 1: ...ial number PT003915 Customer part number 1211506 Delivery date yyyy mm dd 2022 04 13 Weight 280 kg Operating limits according to rating plate Speed limit in test rig operation only nMmax 786 1 s Speed...

Page 2: ......

Page 3: ...ons 15 2 5 Intended use 16 2 6 Deflagration on gas engines 17 2 7 Warning plates on the high pressure stage 18 2 8 Rating plate of the high pressure stage 19 2 9 Periodic check of the pressure vessels...

Page 4: ...blies 72 9 4 Removing the gas outlet casing 73 9 5 Removing air inlets 74 9 6 Removing the compressor casing 75 9 7 Removing the cartridge group 76 9 8 Installing the cartridge group 79 9 9 Installing...

Page 5: ...High pressure stage Table of contents Copyright 2022 ABB All rights reserved HZTL4054_EN Rev F March 2022 13 1 Ordering spare parts 97 13 2 Spare part Illustrations 99 14 Tools 110 15 Gas piping opti...

Page 6: ...prevention and environmental protection Target group The Operation Manual is aimed at engineers and trained mechanics responsible for the proper operation of the engine and for the Power2 connected t...

Page 7: ...ressure stages This may result in sections and descriptions of components that are not relevant for a specific Power2 high pressure stage Please contact a Turbo Systems service station if you have any...

Page 9: ...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 b...

Page 10: ...function of the high pressure stage Fig 2 Layout of the high pressure stage 01 Air suction branch 09 Gas outlet flange 02 Bellows 10 Gas outlet flange 03 Compressor casing 11 Nozzle ring 04 Diffuser 1...

Page 11: ...ctional view see Fig 2 Layout of the high pressure stage 8 the exhaust gas flows through the turbine casing 14 and the nozzle ring 11 and reaches the turbine 08 The HP turbine uses the energy containe...

Page 12: ...ment to be worn for a task The mandatory signs are described in chapter Safety and must be complied with Definition of Caution Warning Caution and warning signs are described in chapter Safety Terms u...

Page 13: ...n over specified tightening angle Hand tight tighten without tools Oil Apply screw locking paste e g Loctite Apply high temperature grease Apply other paste in accordance with specifications Oil free...

Page 14: ...rosion Inhibitor VCI WARNING Health protection when handling VCI VCI products are not hazardous in terms of the Ordinance on Hazardous Substances Nevertheless the following points must be observed whe...

Page 15: ...e group must be checked and repack aged by a Turbo Systems service station u Inspect the package for damage If the package is damaged the low pressure or high pressure stage or the cartridge group mus...

Page 16: ...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...

Page 17: ...Respiratory mask to protect against Dusts Gases Safety helmet Ear protection Table 3 Personal protective equipment to be worn specific to the respective task 2 4 Definition of safety instructions WAR...

Page 18: ...erating limits of Power2 were determined on the basis of information from the enginebuilder about the intended use This data is given on the rating plate and is gener ally different for the low pressu...

Page 19: ...ar guideline value High pressure stages from Turbo Systems can tolerate a deflagration with a transient pres sure increase of 15 bar guideline value After a deflagration event Turbo Systems recommends...

Page 20: ...ated locations or not readable proceed as fol lows u Order new warning plates from Turbo Systems service stations u Remove any warning plates that have become unreadable u Clean and degrease the areas...

Page 21: ...tion Table 5 Operating limits Recommended inspection and replacement intervals 3 Inspection interval of plain bearings in 1000 h 4 Replacement interval of compressor in 1000 h 5 Replacement interval o...

Page 22: ...pecial applications Operation above nMmax and tMmax is not permitted Failure to observe the recommended replacement intervals increases the risk of unpredict able component failures Locations of the r...

Page 23: ...y helmet Fig 9 Attachment of loads on the crane hook Fig 10 Attachment angle If there are two or more suspension points the attachment angle of 45 must not be ex ceeded This prevents excessive loading...

Page 24: ...ust be checked periodically Suitable working materials and personal protective equipment must be kept in a perfect condition Only authorised personnel may remain in the vicinity of the Power2 when the...

Page 25: ...ar ear protection if the sound pressure level exceeds 85 dB A Wear ear protection Hazards due to hot surfaces Surfaces of the low pressure and high pressure stage attached parts and operating fluids l...

Page 26: ...sulation and for providing protection against contact with hot surfaces u Compliance with the instructions and specifications given by the en ginebuilder to protect against contact with hot surfaces...

Page 27: ...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 da...

Page 28: ...otwear 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 f...

Page 29: ...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 starti...

Page 30: ...aling vapours of operating materials and supplies or con tact with them may be harmful to health u Do not breathe in these substances and avoid contact with the skin u Ensure proper ventilation u Obse...

Page 31: ...ibres from insulation materials can have adverse effects on the health or cause irritations Unsuitable and combustible insulation materials are a fire hazard u Only use suitable and non combustible in...

Page 32: ...tems Fig 11 Swivel lifting eye example Thread M Length L Minimum load limit Quantity M12 21 mm 200 kg 2 Table 8 Swivel lifting eyes Lifting gear with a sufficient load limit must be used for removing...

Page 33: ...led from the air line To protect the bellows the high pressure stage must not be lifted up together with the radial air suction branch and the bellows 2 If present Unplug the plug to the speed sensor...

Page 34: ...not clean pressure screws The pressure screws are equipped with a permanent sliding layer that must not be removed In case of non compliance it cannot be ensured that the necessary tension force is r...

Page 35: ...ush 42193 2 Check whether the threaded rods 42191 can be moved 3 Screw the threaded rods back into the centering bush by a few revolutions 4 Manually lift threaded rods 42191 until the centering bushe...

Page 36: ...CAUTION Inserting the gaskets Gaskets that are forgotten damaged or improperly inserted will lead to oil leaks u Always use new gaskets and insert them carefully into the slot Fig 16 Gaskets in the s...

Page 37: ...tening elements of the high pressure stage 1 Insert expansion bush 42190 into bearing casing 2 Screw the clamping nut 42201 flush onto the threaded rod 42191 The hexagon of the thread screw is at the...

Page 38: ...e bracket 4 Check value x If value x is not reached the high pressure stage must be lifted up from the bracket and realigned 5 Screw threaded rod into bracket up to value L using hexagon If value L is...

Page 39: ...ge Copyright 2022 ABB All rights reserved HZTL4054_EN Rev F March 2022 3 3 3 Steps for fastening the high pressure stage Fig 19 Steps for fastening the high pressure stage 1 Tighten the clamping nuts...

Page 40: ...pressure stage and cause serious injuries to persons or even fatal accidents u When using a radial gas outlet casing only operate the high pressure stage with a completely fitted support 61300 Fig 20...

Page 41: ...e necessary tension force is reached u Do not clean pressure screws u Do not lubricate pressure screws In order to correctly fit the clamping nuts the pressure screws 04 must not protrude from the cla...

Page 42: ...Nm Table 12 1 Screw in pressure screws crosswise by hand until reaching the stop 2 Tighten pressure screws crosswise to 50 of the tightening torque specified in the table 3 Tighten pressure screws cr...

Page 43: ...ing an electrically driven oil pump u Switch on the oil pump u Build up oil pressure Lubricating oil pressure 45 u Do not exceed a pre lubrication time of 2 minutes u Start the engine u Let the oil pu...

Page 44: ...available u Check for damage and contamination Lubricating system CAUTION Contaminated oil Serious damage to engine or property can be caused by dirt and solid ma terial particles in the oil u For th...

Page 45: ...ruc tions Wear safety gloves to protect against thermal hazards 4 2 4 Checks when starting up the engine u Measure speed oil pressure and charging pressure at various engine performances u Measure the...

Page 46: ...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...

Page 47: ...ues Fig 23 Oil monitoring 01 Contact surface of high pressure stage 02 Oil inlet 03 Oil outlet M Oil pressure measuring point T Oil temperature measuring point 1 If the drain pipe is vented the oil te...

Page 48: ...e at the outlet The oil temperature at the outlet is mainly dependant on Lubricating oil temperature and pressure at the oil inlet Engine load and speeds of the low pressure and the high pressure stag...

Page 49: ...enable the constant monitoring of the speeds of the low pres sure and the high pressure stage 5 3 2 Layout and overview Fig 24 Overview speed measurement on high pressure stage 86505 Speed sensor 421...

Page 50: ...difference is exceeded the following steps must be carried out u Reduce the engine performance immediately until the maximum speed of all low and high pressure stages no longer exceeds 70 of nBmax u...

Page 51: ...r from the speed sensor u Unscrew the defective speed sensor u Screw in new speed sensor to the stop u For the tightening torque of the low pressure stage speed sensor see document Operation Manual Po...

Page 52: ...es 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 s...

Page 53: ...yright 2022 ABB All rights reserved HZTL4054_EN Rev F March 2022 Suggestion for noise insulation bellows Fig 25 Noise insulation bellows 01 Compressor casing 02 Bellows 03 Charge air duct scavenging a...

Page 54: ...timely machine damage even if the prescribed service intervals are ob served u Agree on a specific service interval with Turbo Systems To prevent machine damage caused by ageing and downtime we recomm...

Page 55: ...nt 60 6 2 5 Service work according to specifications on the rating plate The following work must be carried out by a Turbo Systems service station Replacement of the bearing parts Replacement of the t...

Page 56: ...expected for replacing the bearing 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...

Page 57: ...nt 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 high pressure stag...

Page 58: ...en gines u Observe the oil pressure for engine idling 0 5 poil 2 5 bar u Stop the engine u Carry out post lubrication of the low pressure and high pressure stage in accordance with the following table...

Page 59: ...be maintained Recommended cleaning inter val Operating state LP HP compressor 24 72 h Engine load 50 85 LP filter silencer 500 h Engine stopped HP bellows At every disassembly Engine stopped Table 18...

Page 60: ...ired compressor efficiency Higher exhaust gas temperatures Increased fuel consumption Increased rotor unbalance Periodic cleaning of the compressor during operation prevents or delays any great increa...

Page 61: ...cleaning 7 2 4 Wet cleaning of compressor 01 Water pipe to filter silencer or air suction branch 02 Pressurised air inlet pipe 03 Valve activator 27000 External water pressure vessel 27005 Sealing plu...

Page 62: ...he bellows 82300 is described in chapter Disassembly and assembly Fig 26 Bellows The following maintenance work must be carried out on the bellows 82300 u Remove insulation if present u Perform a visu...

Page 63: ...essure stage Rotor unbalance Contact a Turbo Systems service sta tion Turbine or compressor damaged Bearing damaged Table 21 Malfunctions when starting Vibrations Rubbing of rotating parts Normal beha...

Page 64: ...a Turbo Systems service sta tion Change of operating state of high pressure stage Check the operating point of the high pressure stage Pipes Defects such as leaks in the ex haust gas pipes or charge a...

Page 65: ...ture too high Engine performance and engine speed unchanged Possible causes Remedy Engine Malfunction in the injection system Repair or contact manufacturer Low pressure or high pressure stage Insuffi...

Page 66: ...er silencer contaminated there fore pressure drop too high Clean Compressor turbine contaminated Compressor turbine damaged Contact a Turbo Systems service sta tion Exhaust gas back pressure too high...

Page 67: ...the compressor wheel compressor blade breakage Possible causes Remedy Low pressure or high pressure stage Material of the compressor wheel corroded due to the influx of ventila tion gases containing c...

Page 68: ...ing If the low pressure or high pressure stages surge continuously or periodic ally their components may be damaged u Gradually reduce the engine load u Have the cause clarified and remedied immediate...

Page 69: ...e stage contaminated Clean Bearing damaged Contact a Turbo Systems service sta tion Rotor rubbing Foreign object in the pressure stage Table 35 Malfunctions when stopping Runout noises Runout time too...

Page 70: ...ensor 86505 refer to chapter Ordering spare parts Replace the speed sensor Table 37 Speed measurement poor signal amplitude Measured speed too high Possible causes Remedy Low pres sure or high pres su...

Page 71: ...is described in this document u Only perform work for which you have previously received instruction or training u Have further work carried out only by trained personnel from a Turbo Sys tems servic...

Page 72: ...2 Material required Customer spare part set Before starting work make sure the required customer spare part set is available see chapter Spare parts 97 Customer tool set Before starting work make sure...

Page 73: ...ly 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...

Page 74: ...rts or assemblies are rounded up standard values Fig 28 Weights of the assemblies Designation Weight kg 01 Radial air suction branch 30 02 Axial air suction branch 12 03 Bellows 18 04 Compressor casin...

Page 75: ...tion for assembly Fig 29 Removing the gas outlet casing 1 Loop the lifting gear around the gas outlet casing 61001 2 Loosen screw 61003 and remove with Verbus Ripp washer 61004 3 Remove the support 61...

Page 76: ...position for assembly Fig 30 Removing the air inlets 1 Loop the lifting gear around the radial air suction branch 82000 2 Loosen hexagon head screws 72013 and remove with washers 72014 3 Remove the be...

Page 77: ...compressor casing 72000 see Measur ing radial clearances N and R 85 u Remove expansion bushes and threaded rods from the bearing casing Fig 31 Removing the compressor casing 1 Loosen screws 72011 and...

Page 78: ...ly Do not remove oil orifice if present To limit the oil flow rate through the bearing casing during operation engine under load to the admissible values an oil orifice is mandatory at the oil inlet o...

Page 79: ...group 1 Treat threads of studs 51006 with penetrating oil and leave to take effect 2 Loosen nuts 51007 and remove Verbus Ripp washers 51003 together with fastening strips 51002 3 Attach swivel lifting...

Page 80: ...s outlet flange 57002 must be removed first 2 Screw in swivel lifting eyes 01 on the turbine casing 51000 and attach the lifting gear 3 Turn the turbine casing 180 and lay it down on a soft base 4 Loo...

Page 81: ...o be fixed during operation it must be clamped between the heat shield 43001 and the turbine casing 51000 Fig 34 Nozzle ring compression PD 42001 Bearing casing 43001 Heat shield 51000 Turbine casing...

Page 82: ...nozzle ring Part number Tightening torque 51005 M8 25 Nm Table 43 Tightening torque 51005 1 Install the gas outlet flange 57002 with the screws 51005 in the turbine cas ing 51000 2 Tighten the screws...

Page 83: ...ards Wear safety helmet Fig 36 Installing the cartridge group Part number Tightening torque 51007 M10 45 Nm Table 44 Tightening torque 51007 1 Insert new metal C ring 51105 into turbine casing 51000 2...

Page 84: ...M8 25 Nm 72011 M10 75 Nm 77022 M8 40 Nm Table 45 Tightening torques 42007 72011 77022 1 Fit new O ring 77005 into wall insert 77000 2 Screw two swivel lifting eyes 01 into compressor casing 72000 and...

Page 85: ...ace the O ring 82010 with a new one see Ordering spare parts 97 u Measure clearance N see Measuring radial clearances N and R 85 Fig 38 Installing the air inlet Part number Tightening torque 72013 M12...

Page 86: ...Nm Table 47 Tightening torques 51009 61003 1 Clean the sealing surfaces of the C rings 57004 51026 on the turbine casing 51000 and the gas outlet casing 61001 2 Insert new C rings 57004 51026 and pos...

Page 87: ...earance and measure simultaneously at the top N1 and the bottom N2 2 Calculate clearance N and compare it with the permissible values in the table 3 Push the feeler gauges 01 into the gap without clea...

Page 88: ...rmissible clearances A and B 1 Move the rotor to and fro up to the stop In order to obtain a correct measurement elev ate the turbine a little 2 Measure clearance A and compare it with the permissible...

Page 89: ...owing tightening torques Nm must be observed for the designated bolted connec tions Part number Tightening torque Nm 01 72005 82005 82007 M18x1 5 60 Nm 02 82022 M12 85 Nm 03 72013 M12 85 Nm 04 77022 M...

Page 90: ...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 c...

Page 91: ...ys have repairs to the cartridge group carried out by a Turbo Sys tems service station NOTICE Quick recommissioning To enable you to put a defective low pressure or high pressure stage back into opera...

Page 92: ...gh pressure stage make sure that the oil connections of the high pressure stage are sealed with a gasket under the cover plate 01 or with O rings inside the cover plate 01 If the O rings of the high p...

Page 93: ...late drawing The cover plate is not included in the Turbo Systems scope of delivery and must be manufac tured by the operating company according to the following drawing Material General structural st...

Page 94: ...ver plate drawing Copyright 2022 ABB All rights reserved HZTL4054_EN Rev F March 2022 Slots for O rings in cover plate Fig 45 Figure for cover plate slots for O rings A B C D E F G H J K R1 172 86 54...

Page 95: ...are largely protected against corrosion Preparations for mothballing WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or con tact wi...

Page 96: ...w pressure and high pressure stage are completely removed either as whole units or in single parts For the measures always necessary for preparing the low pressure and high pressure stage for mothball...

Page 97: ...rm the customer of the presence of such substance s with sufficient information available to the supplier RoHS2 Directive 2011 65 EC in English only The EU Directive 2011 65 EC recast restricts the us...

Page 98: ...engine oil electronic parts speed sensor and associated components and thermal insulation u Dispose of metals as scrap metal for recycling u Dispose of non metallic materials as waste u Dispose of res...

Page 99: ...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 T...

Page 100: ...he customer spare part set 97070 is re quired These parts are only available in the complete set 97070 Designation Quantity 42010 O ring 1 42012 O ring 1 42198 O ring 1 42199 O ring 1 51005 Socket scr...

Page 101: ...in English Cartridge 42198 42199 42196 42197 42193 10900 42010 42009 42189 42188 42012 42190 42191 42201 Available within the spare part set HZTL443584 Mod A Part no Designation 10900 Cartridge 42009...

Page 102: ...4 42188 42008 42301 42007 79000 Available within the spare part set HZTL443281 Mod E Part no Designation 42001 Bearing casing 42003 Socket screw 42004 Lug 42005 Sealing bush 42006 Spring type pin 4200...

Page 103: ...32101 32109 42302 Available within the spare part set HZTL443583 Mod A Part no Designation 21000 Turbine 21002 Piston ring 21006 Piston ring 21011 Sleeve 25000 Compressor wheel 32101 Radial bearing 3...

Page 104: ...07 56005 56001 51028 Available within the spare part set HZTL443282 Mod A if provided THV03 THV05 Part no Designation 51000 Turbine casing 51002 Fastening strip 51003 Verbusripp washer 51004 Verbusrip...

Page 105: ...aning 52155 52100 52140 52135 52150 52130 52125 52120 52145 52115 52110 52160 HZTL443585 Mod A Part no Designation 52100 Cleaning unit 52110 Compensator 52115 Metall C Ring 52120 Metall C Ring 52125 C...

Page 106: ...ABB All rights reserved HZTL4054_EN Rev F March 2022 Gas outlet casing axial 61205 61007 61001 61005 61072 61007 61001 Available within the spare part set HZTL443347 Mod B Part no Designation 61001 Ga...

Page 107: ...2022 ABB All rights reserved HZTL4054_EN Rev F March 2022 Gas outlet casing radial 61003 61004 61300 61001 61005 61205 HZTL443289 Mod B Part no Designation 61001 Gas outlet casing 61003 Hexagon head...

Page 108: ...asing 72012 72011 81080 77000 77005 72014 72013 77022 72006 72000 72005 Available within the spare part set HZTL443283 Mod B Part no Designation 72000 Compressor casing 72005 Screw plug 72006 Gasket 7...

Page 109: ...rations Copyright 2022 ABB All rights reserved HZTL4054_EN Rev F March 2022 Air suction branch axial 82010 82008 82000 82007 Available within the spare part set HZTL443285 Mod A Part no Designation 82...

Page 110: ..._EN Rev F March 2022 Air suction branch radial 82300 82022 82021 82130 82140 82145 82000 82008 82007 HZTL443284 Mod B Part no Designation 82000 Air suction branch 82007 Screw plug 82008 Gasket 82021 W...

Page 111: ...Illustrations Copyright 2022 ABB All rights reserved HZTL4054_EN Rev F March 2022 Speed measurement system 86528 86505 86526 86515 HZTL443348 Mod A if provided Part no Designation 86505 Speed sensor...

Page 112: ...2 90245 Compressor wheel key 1 90380 Press on bush 1 90381 Snap ring pliers 1 90401 Piston ring pliers 1 90402 Positioning pin 1 90403 Plate 1 90405 Washer 3 90407 Support 3 90416 Pressure piece 1 904...

Page 113: ...ressure stage 15 Gas piping option Copyright 2022 ABB All rights reserved HZTL4054_EN Rev F March 2022 15 Gas piping option The gas piping documentation can be found in the Operation Manual of the Pow...

Page 114: ...stage 37 Fig 20 Steps for fastening the high pressure stage 38 Fig 21 Preparing the clamping nut for the tighten ing procedure 39 Fig 22 Tightening pressure screws 40 Fig 23 Oil monitoring 45 Fig 24...

Page 115: ...ration Power2 HP speed reductions 62 Table 26 Malfunctions during operation Power2 LP speed increases 62 Table 27 Malfunctions during operation Power2 HP speed increases 63 Table 28 Malfunctions durin...

Page 116: ...March 2022 Table 53 Dimensions of cover plate slots for O rings mm 92 Table 54 Customer spare part set 97070 98 Table 55 99 Table 56 100 Table 57 101 Table 58 102 Table 59 103 Table 60 104 Table 61 1...

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