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ABB PT004042, Operation Manual

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Operation Manual / Power2 550-M / High-pressure stage

3 Removal and installation / 3.3 Installing the high-pressure stage

© Copyright 2022 ABB. All rights reserved.

HZTL4058_EN

Rev.F

March 2022

 WARNING

Support (61300)

In radial gas outlet casings, the gas forces cause high torques to act on the
high-pressure stage. If the high-pressure stage is fastened improperly, this
can damage the high-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: Steps for fastening the high-pressure stage

Part number

Thread size and tightening torque

01

M16

260 Nm

61003

M20

365 Nm

Table 10: Tightening torque (01, 61003)

3. Fit the support (61300) using the fixing screws (01). Observe tightening torque.

4. Tighten the screw (61003) of the connection between gas outlet casing (61001) and sup-

port (61300).

u

Connect all gas pipes and air lines.

Page 

38

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119

Summary of Contents for PT004042

Page 1: ...n Serial number PT004042 Customer part number Delivery date yyyy mm dd 2022 05 24 Weight 750 kg Operating limits according to rating plate Speed limit in test rig operation only nMmax 527 1 s Speed limit during operation nBmax 527 1 s Gas inlet temperature limit in test rig operation only tMmax 650 C Gas inlet temperature limit during operation tBmax 620 C Compressor inlet temperature after interc...

Page 2: ......

Page 3: ...ions 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 20 2 10 Lifting of loads 21 2 11 Prerequisites for operation and maintenance 22 2 12 Hazards during operation and maintenance 23 2 13 Safe operation 25 2 14 Safe maintenance 26 3 Removal and install...

Page 4: ...quired 76 9 3 Weights of assemblies 78 9 4 Removing the gas outlet casing 79 9 5 Removing air inlets 80 9 6 Removing the compressor casing 81 9 7 Removing the cartridge group 82 9 8 Installing the cartridge group 85 9 9 Installing the compressor casing 88 9 10 Installing the air inlets 89 9 11 Installing the gas outlet casing 90 9 12 Measuring radial clearances N and R 91 9 13 Measuring clearance ...

Page 5: ...sure stage Table of contents Copyright 2022 ABB All rights reserved HZTL4058_EN Rev F March 2022 13 Spare parts 102 13 1 Ordering spare parts 102 13 2 Spare part Illustrations 104 14 Tools 115 15 Gas piping option 116 Figures 117 Tables 118 ...

Page 6: ...t prevention and environmental protection Target group The Operation Manual is aimed at engineers and trained mechanics responsible for the proper operation of the engine and for the Power2 connected to it Availability of the Operation Manual The Operation Manual must be available where the Power2 is used All persons operating or working on the Power2 must have read and fully understood the Operat...

Page 7: ...pressure stages This may result in sections and descriptions of components that are not relevant for a specific Power2 high pressure stage Please contact a Turbo Systems service station if you have any questions regarding a design variant see Contact information at www abb com turbocharging Accuracy of illustrations The illustrations in this document are general in nature and intended for ease of ...

Page 8: ...Operation Manual Power2 550 M High pressure stage 1 Introduction 1 3 Essential information Copyright 2022 ABB All rights reserved HZTL4058_EN Rev F March 2022 Page 6 119 ...

Page 9: ...2 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 turbine 22 ...

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 12 Support 05 Axial thrust bearing 13 Turbine end bearing flange 06 Bearing casing 14 Turbine casing 07 Radial plain bearings 15 Compressor end bearing flange 08 Turbine 16 Compressor wheel Page 8 119...

Page 11: ...ectional 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 contained in the exhaust gas to drive the rotor The exhaust gases then flow through the gas outlet flange 10 the gas outlet casing 09 and the exhaust gas pipe connected to it before they reach the turbine of...

Page 12: ...pment 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 used The following terms are used in this document Two stage turbocharging Power2 Low pressure stage Power2 LP High pressure stage Power2 HP Low pressure and high pressure stage Turbo Systems Turbo Sy...

Page 13: ...en over specified tightening angle Hand tight tighten without tools Oil Apply screw locking paste e g Loctite Apply high temperature grease Apply other paste in accordance with specifications Oil free grease free and dry Affix Measure Note Visually inspect Please note text for numbered work step See document Dispose of in an environmentally compatible professional way and in compliance with locall...

Page 14: ...rrosion Inhibitor VCI WARNING Health protection when handling VCI VCI products are not hazardous in terms of the Ordinance on Hazardous Substances Nevertheless the following points must be observed when handling VCI u Observe information in material safety data sheet u Ensure proper space ventilation u Do not eat drink or store food at the workplace while working with VCI u Clean hands and face af...

Page 15: ...ge 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 must be checked and repackaged by a Turbo Sys tems service station After every 3 years the following work steps must be performed by a Turbo Systems service station Inspect the component Replace the des...

Page 16: ...d 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 fr...

Page 17: ...d Respiratory mask to protect against Dusts Gases Safety helmet Ear protection Table 3 Personal protective equipment to be worn specific to the respective task 2 4 Definition of safety instructions WARNING Definition of Warning Non compliance or inaccurate compliance with working or operating in structions indicated by this symbol and the word WARNING can lead to seri ous injuries to personnel and...

Page 18: ...jects all warranty claims for any non intended ap plications 1 Euromot The European Association of Internal Combustion Engine Manufacturers 2 Directive 94 9 EC concerning equipment and protective systems intended for use in po tentially explosive atmospheres ATEX The Euromot Position as of November 2003 ATEX Euromot Position 191103 WARNING Unapproved operation Operation of the Power2 outside of th...

Page 19: ...e of 15 bar guideline value After a deflagration event Turbo Systems recommends verifying the following points on the low pressure and high pressure stages Position of the turbine and compressor casings to the bearing casing Shifting of the bearing casing in relation to the bracket Cracks in casings If during external inspection anomalies are found or if a particularly strong deflagration event ha...

Page 20: ...nated locations or not readable proceed as fol lows u Order new warning plates from Turbo Systems service stations u Remove any warning plates that have become unreadable u Clean and degrease the areas designated for the warning plates u Fit new warning plates and remove protective sheets Non insulated high and low pressure stages High and low pressure stages supplied to the enginebuilder without ...

Page 21: ...ation Table 4 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 of turbine in 1000 h Table 5 Recommended inspection and replacement intervals Further data 6 Power2 designation 7 Power2 serial number 8 Power2 stage 9 Serial number of the low or high pressure stage ...

Page 22: ...special 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 rating plates on the high pressure stage Fig 8 Location of Power2 HP rating plate One rating plate each is attached on the left and the right side of the bearing casing 2 9 Periodic check of the press...

Page 23: ...ty helmet Fig 9 Attachment of loads on the crane hook Fig 10 Attachment angle If there are two or more suspension points the attachment angle of 45 must not be ex ceeded This prevents excessive loading due to diagonal pull u Before looping around the components of the low pressure and high pressure stage al low them to cool down maximum 80 C u Attach components of the low pressure and high pressur...

Page 24: ...must be checked periodically Suitable working materials and personal protective equipment must be kept in a perfect condition Only authorised personnel may remain in the vicinity of the Power2 when the engine is run ning Competence of personnel The Power2 may only be operated and serviced by trained and authorised personnel Basic mechanical training is a prerequisite Modifications to the Power2 Mo...

Page 25: ...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 26: ...n sulation and for providing protection against contact with hot surfaces u Compliance with the instructions and specifications given by the en ginebuilder to protect against contact with hot surfaces on the low pres sure and high pressure stage is compulsory Wear safety gloves to protect against thermal hazards Hazards due to rotating parts WARNING Physical hazards due to rotating parts Contact w...

Page 27: ...g commissioning and operation u Visually inspect your working environment before starting work u Remove any obstacles and objects littering the workplace u Check all pipes to and from the Power2 for damage and leaks before commissioning u Check Power2 for recognisable damage or defects every 12 hours of operation or at least once a day u Report any damage and any alterations of operational charact...

Page 28: ...ootwear to protect against mechanical hazard and risk of fall ing Wear protective clothing WARNING Risk of falling When work is performed on the low pressure or high pressure stage there is a risk of falling u Do not climb onto the low pressure or high pressure stage or onto at tached parts and do not use them as climbing aids u Use suitable climbing aids and working platforms for work above body ...

Page 29: ...g work Safety during disassembly assembly maintenance and repair u Observe the procedures for set up service and inspection work and the inspection inter vals u Inform the operating staff before starting any service or repair work Make sure the en gine is not started while work is being conducted on the Power2 u Before taking off any cover or removing any guard from the low pressure or high pres s...

Page 30: ...haling 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 loca...

Page 31: ...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 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 ...

Page 32: ...ems Fig 11 Swivel lifting eye example Thread M Length L Minimum load limit Quantity M16 20 30 mm 750 kg 2 Table 7 Swivel lifting eyes Lifting gear with a sufficient load limit must be used for removing and installing low pres sure and high pressure stages The following weight specifications apply to the heaviest variant possible Depending on the specification the weight specified on the rating pla...

Page 33: ...he bellows 2 If present Unplug the plug to the speed sensor 86505 and secure the rolled up cable 2 m to the high pressure stage This protects the plug from being crushed 3 Treat the threads of the threaded rods 42191 and fixing screws 02 of the sup port 61300 with penetrating oil and allow it to take effect Do not oil the pressure screws of the clamping nut 42201 4 Attach lifting gear to high pres...

Page 34: ...e it cannot be ensured that the necessary tension force is reached u Do not clean pressure screws u Do not lubricate pressure screws If a screw jams the previously loosened screw must be tightened again a little Fig 14 Loosening the clamping nut 1 Working in a circle break loose each pressure screw 20 2 Working in a circle loosen each pressure screw by 45 in 4 rounds 3 Working in a circle loosen e...

Page 35: ...bush 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 bushes 42193 are in the bearing casing If necessary shake the threaded rods until the centering bushes 42193 release themselves from the engine support 5 Screw down clamping nuts 42201 to the end of the e...

Page 36: ...s 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 slots of the bearing casing 42001 Bearing casing 42198 O ring 42199 O ring 01 Oil supply 02 Oil drains The oil is supplied 01 and drained 02 through the bracket u Insert the O rings 42198 and 42199 in...

Page 37: ...stening 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 top 3 Place thrust washer 01 of clamping nut onto expansion bush 4 Lead threaded rod 42191 with screwed on clamping nut through thrust washer expan sion bush and bearing casing 5 Screw the centering ...

Page 38: ...the 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 not reached or the threaded rod jams while being screwed in the threaded rod must be loosened by no more than revolution this will loosen the centering bush which may have jammed the rod Then conti...

Page 39: ...age Copyright 2022 ABB All rights reserved HZTL4058_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 42201 see section Tightening the clamping nut 2 Connect the cable connector 86515 to the speed sensor Page 37 119 ...

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 Steps for fastening the high pressure stage Part number Thread size and tightening torque 01 M16 260 Nm 61003 M20 365 Nm Table 10 Tightening torque 01 61003 3 Fit the support 61300 using the fixing s...

Page 41: ...he 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 clamping nuts 03 in the direction of the thrust washer 02 u Make sure the pressure screws do not protrude in the direction of the thrust washer Fig 21 Preparing the clamping nut for the tightening proce...

Page 42: ...3 Nm Table 11 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 crosswise to 100 of the tightening torque specified in the table 4 Work in a circle to tighten all pressure screws to 100 of the tightening torque specified in the table 5 Tighten pressure screws to 10...

Page 43: ...sing 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 pump run until the pump driven by the engine generates sufficient pressure Turbo Systems recommends integrating the entire pre lubrication cycle into the engine con trol 4 1 3 Oil filtering Lubricating...

Page 44: ...f 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 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...

Page 45: ...truc 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 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 dif...

Page 46: ...r 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 oil ...

Page 47: ...tronically the relevant signals should be triggered at the warning and alarm values 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 temperature measuring point can be installed at the out let in the vent tank Otherwise the measurement should be taken in ...

Page 48: ...l temperature at the inlet Lubricating oil temperature 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 turbocharger speed Exhaust gas temperature The maximum admissible oil temperature at the outlet is listed in the following table The specified oil outlet temperature is to be considered as alarm value...

Page 49: ...s 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 42188 Screw plug 86515 Cable connector 42189 Gasket 86526 F I converter 01 Plug with integrated voltage limiter 86528 Tachometer Alternative mounting position for speed sensor 32109 Sealing disc with ca...

Page 50: ...f 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 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 surg...

Page 51: ...or 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 Power2 Low pressure stage Disassembly and assembly Table of tightening torques u For the tightening torque of the high pressure stage speed sensor see document Operation Manual Power2 High pressure sta...

Page 52: ...hes 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 standard noise reducing measures2 have been fitted Bellows at the air outlet has been properly acoustically insulated by the en...

Page 53: ...pyright 2022 ABB All rights reserved HZTL4058_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 air duct 04 Insulation cushion 05 Insulation mat at least 15 mm 06 Sheet metal cover Page 51 119 ...

Page 54: ...ntimely machine damage even if the prescribed service intervals are ob served u Agree on a specific service interval with Turbo Systems To prevent machine damage caused by ageing and downtime we recommend having an in spection carried out by a Turbo Systems service station no later than 5 years after the last service 6 2 1 Service work every 25 50 hours CAUTION Unknown operational changes Impairme...

Page 55: ... present 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 turbine and the compressor 6 2 6 Entries in the engine logbook The monitoring of the engine enables conclusions to be drawn on the behaviour of the low pressure and high pressure stage The follow...

Page 56: ...ing 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 Turbine casing 25000 5000...

Page 57: ...ent 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 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 ...

Page 58: ...ow pressure and high pressure stage is not suffi ciently dissipated by the circulating lubricating oil machine damage could occur u Observe the post lubrication times and the oil pressure specified for post lubrication see chapter Monitoring during operation Lubricating oil pressure Post lubrication Post lubrication is required u Observe the oil pressure specified for post lubrication Lubricating ...

Page 59: ...turbine and nozzle ring LP filter silencer 500 h Engine stopped HP bellows At every disassembly Engine stopped Table 17 Maintenance intervals If the recommended cleaning intervals are incompatible with operation of the engine con tact Turbo Systems If present Compressor cleaning We recommend cleaning the HP compressor after the LP compressor On V engines with several low pressure and or high press...

Page 60: ...aired compressor efficiency Higher exhaust gas temperatures Increased fuel consumption Increased rotor unbalance Periodic cleaning of the compressor during operation prevents or delays any great increase in the contamination but never replaces the regular service work where the low and high pressure stages are completely dismantled and the compressors are mechanically cleaned Cleaning process The ...

Page 61: ...er water injection according to the instructions of the enginebuilder u The water pressure before the connection to the pressure stage must be observed see table Cleaning parameters u After cleaning operations a waiting period of at least five minutes is required for the pressure stage to dry The cleaning process can be repeated up to three times The success of the cleaning can be recognised based...

Page 62: ... compressor casing and air suction branch u Always replace bellows with a damaged sealing point with a new bellows 7 4 Cleaning turbines and nozzle rings during operation 7 4 1 Introduction The combustion of fuels such as marine diesel oil MDO and heavy fuel oil HFO in diesel engines causes contamination of the turbine components of the low and high pressure stages Poor quality fuel in conjunction...

Page 63: ...Lower engine performance Increased rotor unbalance Experience in operation shows that with periodic cleaning during operation the interval between overhauls can be extended The wet cleaning of a turbine described in the following can be used for 4 stroke applications with heavy deposits such as MDO and HFO applica tions for example Generally turbine cleaning is not required for the other applicati...

Page 64: ...s 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 cleaning The turbine end components are cleaned at reduced engine load The exhaust gas temper...

Page 65: ...oad between 20 50 so that the turbine inlet temperature is between 380 430 C Fig 27 Load time chart u Once the turbine inlet temperature of the high pressure stage is stable and lying below 430 C wait at least another 10 minutes for the parts of the low and high pressure stages to cool down u Start the cleaning cycle according to the following description Wet cleaning operation u Only clean the lo...

Page 66: ...quantity on the flowmeter 11 according to the table in section Cleaning parameters u Shut off the water supply again by switching the 3 way valve 04 to scavenging air mode after injecting the required volume of water The injection process is complete u Shut the drain hole if present via the drain pipe 08 09 u After cleaning continue to operate the engine for at least 10 minutes without any load ch...

Page 67: ...r with a Turbo Systems service station The action of the cleaning water on the peripheral units such as boiler must be clarified by the operator Draining 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 during cleaning typical gas out...

Page 68: ...TI C Lead time at reduced load t i min Injection time t i min Drying time t i min Water flow rate per high pres sure stage at pWater 3 bar VW dm min Overpres sure above pTE of the ex ternal scav enging air bar 550 HP 430 10 10 10 See the follow ing table de pending on the engine load and turbine specific ation 1 Table 21 Cleaning parameters Power2 550 HP water volumes during turbine cleaning Depen...

Page 69: ...ressure stage Rotor unbalance Contact a Turbo Systems service sta tion Turbine or compressor damaged Bearing damaged Table 24 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 permi...

Page 70: ... a Turbo Systems service sta tion Change of operating state of high pressure stage Check the operating point of the high pressure stage Pipes Defects such as leaks in the ex haust gas pipes or charge air ducts Repair Table 27 Malfunctions during operation Power2 LP speed reductions Drop in high pressure stage speed Possible causes Remedy Engine Defects on the connected cylinders Contact enginebuil...

Page 71: ...ature too high Engine performance and engine speed unchanged Possible causes Remedy Engine Malfunction in the injection system Repair or contact manufacturer Low pressure or high pressure stage Insufficient air for example because filter silencer is blocked by contam ination Clean Compressor turbine contaminated Exhaust gas back pressure too high Clean or repair boiler or exhaust gas si lencer Tur...

Page 72: ...ter silencer contaminated there fore pressure drop too high Clean Compressor turbine contaminated Compressor turbine damaged Contact a Turbo Systems service sta tion Exhaust gas back pressure too high Clean or repair boiler or exhaust gas si lencer Table 32 Malfunctions during operation Charge air pressure too low Charge air pressure too high Engine performance and engine speed unchanged suction c...

Page 73: ...ion gases Correct the influx of ventilation gases in accordance with the enginebuilder s in structions Table 34 Malfunctions during operation Compressor 1 contamination Reduced fatigue strength of the compressor wheel compressor blade breakage Possible causes Remedy Low pressure or high pressure stage Material of the compressor wheel corroded due to the influx of ventila tion gases containing corr...

Page 74: ...inuous or periodic surging 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 immediately by a Turbo Systems service station u Have parts assessed for damage and if necessary replaced by a Turbo Systems service station Sporadic surge blows Surging of the low press...

Page 75: ...re stage contaminated Clean Bearing damaged Contact a Turbo Systems service sta tion Rotor rubbing Foreign object in the pressure stage Table 37 Malfunctions when stopping Runout noises Runout time too short Possible causes Remedy Low pressure or high pressure stage Pressure stage contaminated Clean Bearing damaged Contact a Turbo Systems service sta tion Rotor rubbing Foreign object in the pressu...

Page 76: ...sensor 86505 refer to chapter Ordering spare parts Replace the speed sensor Table 39 Speed measurement poor signal amplitude Measured speed too high Possible causes Remedy Low pres sure or high pres sure stage Sensor tip contaminated since it is magnetic and can attract metallic particles This reduces the distance to the signal emitting sealing disc which can lead to ampli fication of the noise co...

Page 77: ...t 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 service station u Mark the casing position for assembly Oil orifice When disassembling the high pressure stage an oil orifice fitted in the oil inlet must not be removed see Removing the cartridge group 82...

Page 78: ...2 Material required Customer spare part set Before starting work make sure the required customer spare part set is available see chapter Spare parts 102 Customer tool set Before starting work make sure the required tool set is available see chapter Tools 115 Not all tools are marked with a part number Identification is guaranteed by the tool list This list is enclosed with the tool set WARNING Ser...

Page 79: ...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 commercially available products Use assembly devices only for the described applications Lifting gear Equipment for the lifting and transporting of loads lifting slings chain block crane Lifting gear...

Page 80: ... or assemblies are rounded up standard values Fig 30 Weights of the assemblies Designation Weight kg 01 Radial air suction branch 95 02 Axial air suction branch 40 03 Bellows 60 04 Compressor casing 160 05 Wall insert 30 06 Diffuser 12 07 Cartridge group 160 08 Nozzle ring 6 09 Turbine casing 220 10 Gas outlet flange 30 11 Radial gas outlet casing 65 12 Support 22 13 Axial gas outlet casing 40 Tab...

Page 81: ...ition for assembly Fig 31 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 61300 4 Loosen nuts 51009 and remove with Verbus Ripp washers 51004 and lugs 51015 5 Remove the gas outlet casing 61001 6 Remove the metal C rings 57004 and 51026 u Measure clearance R see Measuring ra...

Page 82: ... position for assembly Fig 32 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 bellows 82300 together with the radial air suction branch 82000 or the axial air suction branch 82000 with the O ring 82010 respectively u Measure clearance N see Measuring radial clearances N and R 91...

Page 83: ... compressor casing 72000 see Measur ing radial clearances N and R 91 u Remove expansion bushes and threaded rods from the bearing casing Fig 33 Removing the compressor casing 1 Loosen screws 72011 and remove together with fastening strips 72012 2 Screw two swivel lifting eyes 01 into compressor casing 72000 and secure lifting gear 3 Remove compressor casing 72000 and place on soft surface 4 Loosen...

Page 84: ...bly 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 of the bearing casing if the oil inlet pressure is 3 bar overpressure If an oil orifice is fitted in the oil inlet of the bearing casing it must not be removed Oil orifice in the bearing casing 01 Bea...

Page 85: ... 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 eyes 01 to the cartridge group 10900 4 Secure lifting gear to swivel lifting eye and loop around the cartridge group 10900 see illustration above 5 Remove the cartridge group and turn it 90 6 Place ...

Page 86: ...as 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 Loosen and remove screws 51005 5 With screws 51005 press off the gas outlet flange 57002 from the turbine casing 51000 The nozzle ring 56001 loosens if it has not already been removed 6 Remove the gas o...

Page 87: ...to be fixed during operation it must be clamped between the heat shield 43001 and the turbine casing 51000 Fig 36 Nozzle ring compression PD 42001 Bearing casing 43001 Heat shield 51000 Turbine casing 56001 Nozzle ring Compression PD 0 09 0 37 mm Table 44 Nozzle ring compression PD 1 Measure dimensions A B and S on cleaned surfaces 2 Calculate compression PD u If the calculated value PD lies outsi...

Page 88: ... nozzle ring Part number Tightening torque 51005 M10 50 Nm Table 45 Tightening torque 51005 1 Install the gas outlet flange 57002 with the screws 51005 in the turbine cas ing 51000 2 Tighten the screws 51005 3 Attach swivel lifting eyes 01 on the turbine casing 51000 and the lifting gear 4 Turn the turbine casing 180 5 Fit the lamellar sealing ring 56005 in the nozzle ring 56001 Make sure the lame...

Page 89: ...zards Wear safety helmet Fig 38 Installing the cartridge group Part number Tightening torque 51007 M12 75 Nm Table 46 Tightening torque 51007 1 Insert new metal C ring 51105 into turbine casing 51000 2 Screw in swivel lifting eyes 01 on cartridge group 10900 and secure lifting gear 3 Lift cartridge group out of service support 90012 and remove expansion bush 42190 4 Rotate cartridge group by 90 an...

Page 90: ... M10 50 Nm 72011 M12 130 Nm 77022 M10 75 Nm Table 47 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 secure lifting gear 3 Lower compressor casing 72000 onto wall insert 77000 and fit with washer 77021 and nuts 77022 4 Thoroughly clean the fastening strips 72012 before assembly 5 Fit the diffuser...

Page 91: ...lace the O ring 82010 with a new one see Ordering spare parts 102 u Measure clearance N see Measuring radial clearances N and R 91 Fig 40 Installing the air inlet Part number Tightening torque 72013 M12 85 Nm Table 48 Tightening torque 72013 1 Install the radial air suction branch 82000 with the bellows 82300 or the axial air suc tion branch together with the O ring 82010 respectively 2 Tighten sc...

Page 92: ...5 Nm Table 49 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 position with high vacuum grease 3 Coat the threaded stud 51008 with high temperature grease 4 Loop the lifting gear around the gas outlet casing 61001 5 Place gas outlet casing 61001 on turbine casing ...

Page 93: ...learance 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 clearance and measure simultaneously at the top R2 and the bottom R1 4 Calculate clearance R and compare it with the permissible values in the table CAUTION Clearances outside the tolerance Serious damag...

Page 94: ...ermissible 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 values in the table 3 Raise the compressor and push the turbine down at the same time 4 Raise the turbine and push the compressor down at the same time 5 Measure clearance B and compare it with the ...

Page 95: ...wing 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 M10 75 Nm 05 42007 M10 50 Nm 06 72011 M12 130 Nm 07 42009 M20 65 Nm 08 51007 M12 75 Nm 09 51005 M10 50 Nm 10 51009 M12 75 Nm 11 51028 61005 M18x1 5 60 Nm 12 61003 M20 365 Nm 13 86505 M12x1 5 15 Nm 14 42...

Page 96: ... 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 the engine u Follow the directives of the enginebuilder If the engine has to be brought back into operation a...

Page 97: ...ays 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 operation quickly Turbo Systems recommends having a replacement cartridge group available in stock A replacement cartridge group can be in stalled within a short period of time and the low pressure or hig...

Page 98: ...igh 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 pressure stage are used slots must be cut in the contact surface of the cover plate see Fig 47 Figure for cover plate slots for O rings 98 2 Close the opening in the turbine casing 51000 with the cove...

Page 99: ...ate 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 steel in accordance with DIN EN 10025 2 Fig 46 Cover plate drawing B1 0 5 B2 B3 B4 0 2 B5 B6 B7 ØD1 0 2 ØD2 R1 M 120 5 100 230 29 3 2 310 70 4 367 31 173 M10 Table 54 Cover plate dimensions mm Page 97 11...

Page 100: ...ver plate drawing Copyright 2022 ABB All rights reserved HZTL4058_EN Rev F March 2022 Slots for O rings in cover plate Fig 47 Figure for cover plate slots for O rings A B C D E F G H J K R1 251 125 5 78 39 5 2 31 5 5 2 4 5 5 2 4 5 24 Table 55 Dimensions of cover plate slots for O rings mm Page 98 119 ...

Page 101: ...ludes cleaning and applying preservative oil to the relevant components 11 3 Process for taking out of operation Different measures are required depending on the process used to take the low pressure and high pressure stage out of operation The low pressure and high pressure stage remains on the engine Take countermeasures if there is a risk that the rotor will turn due to the stack draught One op...

Page 102: ...rm the customer of the presence of such substance s with sufficient information available to the supplier RoHS2 Directive 2011 65 EC in English only The EU Directive 2011 65 EC recast restricts the use of certain hazardous substances in electrical and electronic equipment RoHS2 Products and related accessories manufac tured by Turbo Systems Switzerland Ltd do not fall within the Scope of RoHS2 due...

Page 103: ...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 residues of lubricants as waste oil u Dispose of electronic components as electronic waste WARNING Handling damaged thermal insulation Damaged thermal insulation can lead to dust exposure The glass fibre...

Page 104: ...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 Turbo Systems Service Station u If different model variants are not taken into account in this document contact an Turbo Systems Service Station u Dispose of placed and unusable parts in an environmen...

Page 105: ...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 screw 3 51026 Metal C ring 1 51105 Metal C ring 1 56005 Lamellar sealing ring 1 57004 Metal C ring 1 77005 O ring 1 82010 O ring 1 only for P135 61007 Metal C ring 1 only for axial gas outlet casing Tabl...

Page 106: ...e 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 Screw plug 42010 O ring 42012 O ring 42188 Hexagon head screw 42189 Gasket 42190 Expansion bush 42191 Threaded rod 42193 Centering bush 42196 Orifice oil inlet 42197 Safety ring 42198 O ring 42199 O...

Page 107: ...04 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 42007 Socket screw 42008 Socket screw 42009 Screw plug 42010 O ring 42188 Hexagon head screw 42189 Gasket 42196 Orifice oil inlet 42197 Safety ring 42301 Bearing cover 42304 O ring 42400 Heat shield 4240...

Page 108: ...2 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 32102 Radial bearing 32107 Thrust bearing sleeve 32108 Piston ring 32109 Sealing disc 32110 Bearing flange 32112 Bearing flange 32113 Socket screw 32114 Socket screw 32115 Hexagon head screw 32116 Lug...

Page 109: ...007 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 Verbusripp washer 51005 Socket screw 51006 Stud 51007 Hexagon nut 51008 Stud 51009 Hexagon nut 51015 Fastening strip 51026 Metal C ring 51028 Screw plug 51105 Metal C ring 56001 Nozzle ring 56005 Lamellar sea...

Page 110: ...eaning 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 Connection part 52130 Stud 52135 Hexagon nut 52140 Hexagon head screw 52145 Extension sleeve 52150 Stud 52155 Hexagon nut 52160 Hex socket head cap screw Table 61 Page 108 119 ...

Page 111: ... ABB All rights reserved HZTL4058_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 Gas outlet casing 61005 Screw plug 61007 Metal C ring 61072 V clamp 61205 Protective grid Table 62 Page 109 119 ...

Page 112: ...t 2022 ABB All rights reserved HZTL4058_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 screw 61004 Verbusripp washer 61005 Screw plug 61205 Protective grid 61300 Support Table 63 Page 110 119 ...

Page 113: ...casing 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 72011 Hexagon head screw 72012 Fastening strip 72013 Hexagon head screw 72014 Washer 77000 Wall insert 77005 O ring 77022 Hexagon nut 81080 Warning plate Table 64 Page 111 119 ...

Page 114: ...trations Copyright 2022 ABB All rights reserved HZTL4058_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 82000 Air suction branch 82007 Screw plug 82008 Gasket 82010 O ring Table 65 Page 112 119 ...

Page 115: ...8_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 Washer 82022 Hexagon head screw 82130 Insulation cushion 82140 Cleaning nozzle 82145 Verbusripp washer 82300 Compensator Table 66 Page 113 119 ...

Page 116: ...t Illustrations Copyright 2022 ABB All rights reserved HZTL4058_EN Rev F March 2022 Speed measurement system 86528 86505 86526 86515 HZTL443348 Mod A if provided Part no Designation 86505 Speed sensor 86515 Cable connector 86526 F I converter 86528 Tachometer Table 67 Page 114 119 ...

Page 117: ... 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 90417 Set screw 1 90432 Hexagon nut 3 90663 Extraction plate 2 90665 Press off tool long 3 Table 68 Customer tool set 90000 This tool set can be ordered from any Turbo Systems Service Station The follow...

Page 118: ...pressure stage 15 Gas piping option Copyright 2022 ABB All rights reserved HZTL4058_EN Rev F March 2022 15 Gas piping option The gas piping documentation can be found in the Operation Manual of the Power2 low pressure stage Page 116 119 ...

Page 119: ...astening 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 Overview speed measurement on high pressure stage 47 Fig 25 Noise insulation bellows 51 Fig 26 Bellows 60 Fig 27 Load time chart 63 Fig 28 Wet cleaning operation 64 Fig 29 Swivel lifting eye example 77 Fig 30 Weights of the asse...

Page 120: ... operation Power2 LP speed reductions 68 Table 28 Malfunctions during operation Power2 HP speed reductions 68 Table 29 Malfunctions during operation Power2 LP speed increases 68 Table 30 Malfunctions during operation Power2 HP speed increases 69 Table 31 Malfunctions during operation Exhaust gas temperature too high 69 Table 32 Malfunctions during operation Charge air pressure too low 70 Table 33 ...

Page 121: ... March 2022 Table 55 Dimensions of cover plate slots for O rings mm 98 Table 56 Customer spare part set 97070 103 Table 57 104 Table 58 105 Table 59 106 Table 60 107 Table 61 108 Table 62 109 Table 63 110 Table 64 111 Table 65 112 Table 66 113 Table 67 114 Table 68 Customer tool set 90000 115 Page 119 119 Page 119 119 ...

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