Operation Manual
Power2 650-M46
HT595154_A English
Original Operation Manual
Chapter
Document-ID
HZTL4003_EN_D
HZTL4021_EN_G
HT595154_A
1
2
3
4
Introduction
Safety
Safety data sheets
Product description
HZTL4064_EN_D
4.1
4.2
4.3
Low-pressure stage
PT002947
PT002948
HZTL4065_EN_B
HZTL4065_EN_B
High-pressure stage
Gas piping
PT002945
PT002946
HZTL4066_EN_A
HZTL4066_EN_A
HZTL4067_EN_-
ABB Turbocharging
Operation Manual / Power2 / 1 Introduction
Table of contents
Introduction
Registered trademarks................................................................................................ 4
Power2 layout and function......................................................................................... 5
Contact information..................................................................................................... 8
© Copyright 2017 ABB. All rights reserved.
HZTL4003_EN
Revision D
June 2017
Operation Manual / Power2 / 1 Introduction
1 Introduction / 1.1 Purpose of the manual
1
Introduction
1.1
Purpose of the manual
Operation Manual
The Operation Manual explains the two-stage turbocharging (Power2) from ABB Turbo Sys-
tems and contains instructions for safe operation.
The Operation Manual is a complement to and expansion of existing national regulations for
occupational safety, accident 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
Operation Manual.
1.2
Symbols, definitions
Symbols
The following symbols are used in this document:
u Indicates an action step.
1. Indicates a numbered action step.
→
Refers to a page number.
Accuracy of illustrations
The illustrations in this document are general in nature and intended for ease of understand-
ing. Differences in detail are therefore possible.
Definition of mandatory signs
Mandatory signs show the protective equipment to be worn for a task. The mandatory signs
are described in chapter Safety and must be complied with.
© Copyright 2017 ABB. All rights reserved.
HZTL4003_EN
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Operation Manual / Power2 / 1 Introduction
1 Introduction / 1.2 Symbols, definitions
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
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 audited and certified by ABB Turbo Systems. Also see chapter Con-
© Copyright 2017 ABB. All rights reserved.
HZTL4003_EN
Revision D
June 2017
Operation Manual / Power2 / 1 Introduction
1 Introduction / 1.3 Registered trademarks
Definition of pictograms
The following pictograms can occur in this document. These point out actions that must be
taken in accordance with the meaning of the relevant pictogram.
Pictogram
Meaning
Pictogram
Meaning
Tighten with specified torque
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 regulations
Oil free, grease free and dry
Table 1: Definition of pictograms
1.3
Registered trademarks
The trademarks of outside companies are used in this document. These are marked with the
® symbol.
© Copyright 2017 ABB. All rights reserved.
HZTL4003_EN
Revision D
June 2017
Operation Manual / Power2 / 1 Introduction
1 Introduction / 1.4 Power2 layout and function
1.4
Power2 layout and function
Fig. 1: Power2 with bellows layout and function
Power2
Two-stage turbocharging
21
22
23
24
HP compressor
HP turbine
Gas pipe (bellows)
LP turbine
Power2 LP Low-pressure stage
Power2 HP High-pressure stage
A
Exhaust gas inlet from internal combus-
tion engine
B
C
D
Exhaust gas outlet
Air or air/gas mixture inlet
25
26
LP compressor
Intercooler
Air or air/gas mixture outlet and supply
- - - Not included in the ABB Turbo Sys-
to the charge air cooler
tems scope of delivery
The diagram shows the position of the low-pressure (Power2 LP) and high-pressure stage
(Power2 HP) within two-stage turbocharging (Power2). The low-pressure stage is always op-
erated in combination with a high-pressure stage connected in series. The two-stage 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) of
the high-pressure stage and subsequently through the bellows (23) of the gas pipe to the
turbine (24) of the low-pressure stage. The compressor (25) of the low-pressure stage sucks
in fresh air or the air/gas mixture, respectively. This precompressed air or air/gas mixture
flows through the intercooler (26) into the compressor (21) of the high-pressure stage. Here
the air or air/gas mixture is compressed further and leaves the two-stage turbocharging
(Power2) in the direction of the charge air cooler.
© Copyright 2017 ABB. All rights reserved.
HZTL4003_EN
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June 2017
Operation Manual / Power2 / 1 Introduction
1 Introduction / 1.5 Storage of new low-pressure and high-pressure
stages
1.5
Storage of new low-pressure and high-pressure
stages
Storage of new low-pressure and high-pressure stages and cartridge groups for up to
6 months
New low-pressure and high-pressure stages and cartridge groups from ABB Turbo Systems
can be stored in their closed packages for 6 months from the date of delivery without addi-
tional mothballing measures (indicated by VCI label on package).
Fig. 2: Volatile Corrosion Inhibitor (VCI)
Only dry rooms with 40...70 % atmospheric humidity, in which no water condensation can
form, are suitable as storage locations.
Storage of new low-pressure and high-pressure stages and cartridge 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 with VCI.
Every 6 months, the following mothballing measures are required:
u Open package.
u Remove VCI corrosion protection emitter from package and replace with a new VCI corro-
sion protection emitter of the same kind. New VCI corrosion protection emitters can be
u Old VCI corrosion protection emitters must be disposed of in an environmentally compat-
ible, professional way and in compliance with locally applicable regulations.
u Close package. The more tightly the package is sealed, the longer the protection dura-
tion.
© Copyright 2017 ABB. All rights reserved.
HZTL4003_EN
Revision D
June 2017
Operation Manual / Power2 / 1 Introduction
1 Introduction / 1.5 Storage of new low-pressure and high-pressure
stages
Long-term storage of replacement low-pressure and high-pressure stages or
replacement cartridge groups
ABB Turbo Systems will prepare low-pressure and high-pressure stages or cartridge groups
for long-term storage if requested in the purchase order. The package is equipped with a hy-
grometer (see illustration).
Fig. 3: Package with hygrometer
Every 6 months, the following measures are required:
u Check the hygrometer (02) in the sight-glass. There is an opening (01) in the wooden
crate to enable you to perform this check. If the 70% indicator field has 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 Station.
After every 3 years, the following steps must be carried out by an ABB Turbocharging Service
Station:
¡
¡
¡
Checking the component
Replacing the desiccant
Repackaging the component.
Replacement components which are ready for operation
If the 70% field of the hygrometer (02) has not changed colour and the package is not dam-
aged, the replacement low-pressure or high-pressure stage or the replacement cartridge
group can be put into operation without previously having been checked by an ABB Tur-
bocharging Service Station.
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Operation Manual / Power2 / 1 Introduction
1 Introduction / 1.6 Contact information
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
© Copyright 2017 ABB. All rights reserved.
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Operation Manual / Power2 / 2 Safety
Table of contents
Safety
Safety ...................................................................................................................... 2
CE conformity................................................................................................................. 2
Intended use .................................................................................................................. 4
Periodic check of the pressure vessels..................................................................... 9
Prerequisites for operation and maintenance....................................................... 11
Safe operation.............................................................................................................. 14
© Copyright 2019 ABB. All rights reserved.
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Rev.G
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Operation Manual / Power2 / 2 Safety
1 Safety / 1.1 Introduction
1
Safety
1.1
Introduction
The two-stage turbocharging system (Power2) manufactured by ABB Turbo Systems is state
of the art and complies with the respective health and safety standards in effect at the time
the system was built. Thus Power2 is safe to operate. Nevertheless, there may be some re-
sidual risks during operation of the Power2 and work on Power2 components, such as low-
pressure stage and high-pressure stage, which:
¡
¡
¡
¡
Are caused by Power2 itself or its accessories.
Are caused by the operating equipment used or supplies and materials.
Are a consequence of insufficient compliance with safety instructions.
Are a consequence of insufficient or inappropriate performance of maintenance and in-
spection work.
The operating company is responsible for defining measures that regulate safe access to
and safe handling of the Power2.
All instructions contained in this chapter must be observed for safe and trouble-free opera-
tion of the Power2 and during all work on the Power2 components.
All further safety instructions contained and specifically identified in every chapter of this
document (see section Definition of safety instructions) must also be observed.
1.2
CE conformity
Information
Low-pressure and high-pressure stages from ABB Turbo Systems comply with the Machinery
Directive 2006/42/EC and are partly completed machinery as defined by Article 2 g.
© Copyright 2019 ABB. All rights reserved.
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Operation Manual / Power2 / 2 Safety
1 Safety / 1.3 Definition of mandatory signs
1.3
Definition of mandatory signs
To be worn at all times
Protective clothing
Safety footwear to protect
against mechanical hazard and
risk of falling
Table 1: Personal protective equipment to be worn at all times
To be worn specific to the respective task
Safety glasses
Safety goggles
Safety gloves to protect
against
Respiratory mask to protect
against
- Dusts
- Gases
- Mechanical hazard
- Chemical hazard
- Thermal hazard
- Electrical hazard
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 even to fatal accidents.
u Warning signs must always be observed.
CAUTION
Definition of Caution
Non-compliance or inaccurate compliance with working or operating in-
structions indicated by this symbol and the word CAUTION can lead to seri-
ous damage to engine or property with grave consequences.
u Caution signs must always be observed.
© Copyright 2019 ABB. All rights reserved.
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Operation Manual / Power2 / 2 Safety
1 Safety / 1.5 Intended use
1.5
Intended use
Use on internal combustion engines
Power2 from ABB Turbo Systems is intended for charging internal combustion engines.
To ensure compliance with the machinery directive 2006/42/EC when using on gas engines,
the Power2 must be operated in an engine room classified as "not at risk of explosion". This
is in accordance with the position paper [2] relating to ATEX issued by EUROMOT [1].
The specific operating 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-pressure stage and high-pressure stage.
ABB accepts no liability and rejects all warranty claims for any non-intended uses.
[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 must only be operated within the operating limits.
u Power2 must only be operated by trained personnel.
The intended use of the Power2 includes compliance with all regulations and conditions.
In particular, the following must be observed:
¡
¡
The Operation Manual
The instructions of the enginebuilder
State of the art
The Power2 is designed and built according to the state of the art and is safe to operate.
Perfect condition
The Power2 must be used in a technically perfect condition and in compliance with its inten-
ded use.
ABB Turbo Systems excludes any liability for damage resulting from unauthorized modifica-
tions to the Power2 or improper operation.
© Copyright 2019 ABB. All rights reserved.
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Rev.G
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Operation Manual / Power2 / 2 Safety
1 Safety / 1.6 Deflagration on gas engines
1.6
Deflagration on gas engines
Low-pressure stages from ABB Turbo Systems can tolerate a deflagration with a transient
pressure increase of 12 bar (guideline value).
High-pressure stages from ABB Turbo Systems can tolerate a deflagration with a transient
pressure increase of 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 has taken place, it is also recommended to check the bearings of the low-pressure and
high-pressure stages before the next start. This inspection and evaluation must be carried
out by an ABB Turbocharging Service Station.
© Copyright 2019 ABB. All rights reserved.
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Rev.G
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Operation Manual / Power2 / 2 Safety
1 Safety / 1.7 Warning plates on the low-pressure and high-pressure
stage
1.7
Warning plates on the low-pressure and high-
pressure stage
Warning plates are attached to the low-pressure and high-pressure stage, and must be com-
plied with. 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 without insulation
must be retrofitted with warning plates to be affixed to the insulation. This is the responsib-
ility of the enginebuilder.
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Rev.G
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Operation Manual / Power2 / 2 Safety
1 Safety / 1.8 Rating plate of the high-pressure and low-pressure stage
1.8
Rating plate of the high-pressure and low-
pressure stage
Rating plate of the low-pressure stage
Fig. 2: Rating plate
Operating limits
1
Operating limits at engine overload (110 %). In test rig operation only, unless otherwise
agreed with the enginebuilder.
2
Operating limits during operation
Table 3
Recommended replacement intervals
3
4
5
Replacement interval of plain bearings in 1000 h
Replacement interval of compressor in 1000 h
Replacement interval of turbine in 1000 h
Table 4
Further data
6
Power2 designation
7
Power2 serial number
8
Power2 stage
9
10
11
12
Serial number of the low or high-pressure stage
Year of construction of the low or high-pressure stage
Weight of the low or high-pressure stage
Part number of the customer of the low or high-pressure stage
Table 5
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Rev.G
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Operation Manual / Power2 / 2 Safety
1 Safety / 1.8 Rating plate of the high-pressure and low-pressure stage
Rating plate of the high-pressure stage
Fig. 3: Rating plate
Operating limits
1
Operating limits at engine overload (110 %). In test rig operation only, unless otherwise
agreed with the enginebuilder.
2
Operating limits during operation
Table 6
Recommended inspection and replacement intervals
3
4
5
Inspection interval of plain bearings in 1000 h
Replacement interval of compressor in 1000 h
Replacement interval of turbine in 1000 h
Table 7
Further data
6
Power2 designation
7
Power2 serial number
8
Power2 stage
9
10
11
12
Serial number of the low or high-pressure stage
Year of construction of the low or high-pressure stage
Weight of the low or high-pressure stage
Part number of the customer of the low or high-pressure stage
Table 8
© Copyright 2019 ABB. All rights reserved.
HZTL4021_EN
Rev.G
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Operation Manual / Power2 / 2 Safety
1 Safety / 1.9 Periodic check of the pressure vessels
Explanations of the rating plate
The recommended replacement intervals and the corresponding operating limits are jointly
defined with the enginebuilder. This information is specific to the system.
The operating limits of the low-pressure stage are generally different from the operating
limits of the high-pressure stage.
Operation above the indicated values nBmax, tBmax can considerably shorten the recommended
replacement intervals. In such cases ABB recommends contacting the nearest ABB Tur-
bocharging Service Station.
nMmax, tMmax normally apply only when running at overload (110%) during trials on the engine
test bed. These limit values can also be permitted during operation for special applications.
Operation above nMmax and tMmax is not permitted.
Non-observance of the recommended replacement intervals increases the risk of unpredict-
able component failures.
Locations of the rating plates
The locations of the rating plates are defined in the Operation Manual, Chapter 4 Product
description.
1.9
Periodic check of the pressure vessels
The pressure vessels used by ABB Turbocharging, such as those for wet or dry cleaning, are
so-called "simple pressure vessels".
¡
The locally applicable legal regulations regarding periodic checks of the pressure vessels
must be observed.
¡
The operating company is responsible for the safe operation of the pressure vessel.
WARNING
Danger due to pressure vessels
The operating company must make sure the pressure vessels are in proper
working condition and monitor them. Necessary repair or maintenance work
must be performed promptly, and the required safety measures must be
taken.
u Pressure equipment must not be operated if defects are present.
© Copyright 2019 ABB. All rights reserved.
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Operation Manual / Power2 / 2 Safety
1 Safety / 1.10 Lifting of loads
1.10
Lifting of loads
WARNING
Suspended loads
Loads that are not attached according to regulations can cause injury to
personnel or fatal accidents.
u Loads must always be fastened to properly functional lifting gear with a
sufficient load limit.
u Pay attention to the correct attachment of loads on the crane hook.
u People must not stand beneath suspended loads.
Wear safety gloves to protect against mechanical hazards.
Wear safety helmet.
Fig. 4: Attachment of loads on the crane hook
Fig. 5: 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 stage as described in the re-
spective action steps.
u Use a suitable edge guard if there are sharp edges.
u The assembly devices must be completely screwed in and must not unscrew during use.
u Use assembly devices only for the described applications.
u Put down dismantled components of the low-pressure and high-pressure stage in such a
way that they cannot tip over.
© Copyright 2019 ABB. All rights reserved.
HZTL4021_EN
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Operation Manual / Power2 / 2 Safety
1 Safety / 1.11 Prerequisites for operation and maintenance
1.11
Prerequisites for operation and maintenance
Responsibility of the operating company
In awareness of its responsibility, the operating company must ensure that only authorised
personnel work on the Power2, who:
¡
Are versed in the general and locally applicable regulations for occupational safety and
accident prevention
¡
¡
¡
Are equipped with the prescribed personal protective equipment
Have read and understood the Operation Manual
Have been instructed in the use of the Power2.
The safety-conscious work of the personnel and adherence to the Operation Manual 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
Modifications to the Power2 must be approved by ABB Turbo Systems.
Original parts and safety
Original parts and accessories must be specially designed by ABB Turbo Systems for the
ABB Power2.
WARNING
Use original parts
Operation of the Power2 with non-original parts can impair the safety of the
Power2 and can cause serious damage to property and injury to personnel.
u Only use original parts from ABB Turbo Systems.
ABB Turbo Systems accepts no liability for any damage resulting from the use of non-ori-
ginal parts and corresponding accessories.
© Copyright 2019 ABB. All rights reserved.
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Operation Manual / Power2 / 2 Safety
1 Safety / 1.12 Hazards during operation and maintenance
1.12
Hazards during operation and maintenance
Noise hazards
The turbocharger's noise emission is influenced by its installation and operating conditions.
A noise level exceeding 85 dB(A) is harmful.
WARNING
Noise hazards
Exposure to noise can harm the hearing system, impair health and the psy-
chological state and may lead to lack of attention and irritation.
u When the engine is running, always wear ear protection.
u Always wear 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
Touching hot surfaces or contact with hot operating fluids can cause severe
burns.
u Do not touch hot surfaces. Observe the warning plate on the low-pres-
sure and high-pressure stage.
u Wear heat-resistant safety gloves and protective clothing.
u Wait for the low-pressure and high-pressure stage to cool down before
carrying out any work.
Wear safety gloves to protect against thermal hazards.
© Copyright 2019 ABB. All rights reserved.
HZTL4021_EN
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Operation Manual / Power2 / 2 Safety
1 Safety / 1.12 Hazards during operation and maintenance
WARNING
Hot surfaces on the non-insulated low-pressure and high-pressure stage
Non-insulated low-pressure and high-pressure stages can cause serious in-
juries to personnel (burns).
ABB Turbo Systems supplies the low-pressure and high-pressure stage with
or without insulation in accordance with the purchase order received from
the enginebuilder. If supply is without insulation, the enginebuilder is re-
sponsible for providing the low-pressure and high-pressure stage with
proper insulation 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 with rotating parts can cause severe injury. The low-pressure stage
must never be used without the filter silencer or air inlet casing, respectively.
With the engine stopped, the rotor can rotate due to the stack draught
alone.
u Operate the low-pressure and high-pressure stage in compliance with the
specifications.
u Secure the rotor against unintentional rotation during maintenance.
Wear safety gloves to protect against mechanical hazards.
© Copyright 2019 ABB. All rights reserved.
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Operation Manual / Power2 / 2 Safety
1 Safety / 1.13 Safe operation
1.13
Safe operation
Mechanical hazards during operation
During standard operation, no mechanical hazards are caused by the low-pressure and high-
pressure stage, provided that it has been properly installed.
Low-pressure and high-pressure stages are not designed for sudden pressure loss that may
occur due to the piping system between the compressor or the turbine stages bursting.
1.13.1
Safety during commissioning and operation
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 of operational characteristics to the responsible
department immediately.
u In case of damage, take the Power2 out of operation immediately and safeguard against
accidental/unauthorised use.
u When switching on operating energy supplies (hydraulics, pneumatics, electricity), pay at-
tention to the risks that may occur as a consequence of this energy input.
© Copyright 2019 ABB. All rights reserved.
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Operation Manual / Power2 / 2 Safety
1 Safety / 1.14 Safe maintenance
1.14
Safe maintenance
Occupational safety
WARNING
Injuries to persons
Severe injuries to personnel or fatal accidents can be caused by mechanical
influences as a consequence of hazardous and inadequate operational pro-
cedures or non-compliance with safety and health standards.
u When working on the Power2, always wear safety footwear and protect-
ive clothing to protect against mechanical hazards.
u Keep personal protective equipment in perfect condition.
u Obey mandatory signs.
u Observe the general rules for occupational safety and prevention of acci-
dents.
u Only perform operations that are described in this chapter.
u Only perform operations for which you have received instruction or train-
ing.
Wear safety footwear to protect against mechanical hazard and risk of fall-
ing.
Wear protective clothing.
WARNING
Risk of falling
When work is performed on the low-pressure or high-pressure stage, there
is a risk of falling.
u Do not climb onto the low-pressure or high-pressure stage or onto at-
tached parts and do not use them as climbing aids.
u Use suitable climbing aids and working platforms for work above body
height.
u Only perform work on the low-pressure or high-pressure stage when you are in a physic-
ally and psychologically stable condition.
u Only work with suitable tools, equipment and appliances that function properly.
u Keep the workplace clean; clear away any loose objects and obstacles on the floor.
u Keep the floor, equipment and the low-pressure and high-pressure stage clean.
u Have oil binding agents ready and provide or keep oil pans at hand.
Use of assembly devices
Assembly devices are specially constructed and designed for the defined use; they are not
commercially available products.
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Operation Manual / Power2 / 2 Safety
1 Safety / 1.14 Safe maintenance
u Use assembly devices only for the described applications.
Welding work
u Wear personal protective equipment (PPE) for welding operations.
u When performing welding work in the vicinity of the low-pressure stage, always cover the
filter silencer to prevent the filter mat from being damaged.
u Keep flammable objects and substances out of the vicinity of flying sparks.
u Cover all connections on the low-pressure and high-pressure stage so that no foreign ob-
jects can enter the low-pressure or high-pressure stage.
Safety during cleaning
If cleaning agents or solvents are used for cleaning, the corresponding material safety data
sheet and the safety instructions in section Hazards due to operating materials and supplies
must be observed.
u Observe the material safety data sheet for the cleaning agent or solvent.
u Wear personal protective equipment (PPE) according to the material safety data sheet.
u Inspect the 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 any cover or removing any guard from the low-pressure or high-pres-
sure stage, switch off the engine and wait until the low-pressure stage and the high-pres-
sure stage have come to a standstill.
u Make sure that the oil supply is interrupted, especially with an external oil supply.
u Only restart the engine after all parts have been properly fitted again and oil supply is en-
sured.
CAUTION
Mechanical operations on the low-pressure and high-pressure stage
Components of the low-pressure or high-pressure stage can be damaged or
destroyed due to improper use.
u Only perform operations that are described in this manual.
u Only perform operations for which you have received instruction or train-
ing.
Safety when taking out of operation or preparing for mothballing
u Observe the material safety data sheet for the cleaning and mothballing agents.
© Copyright 2019 ABB. All rights reserved.
HZTL4021_EN
Rev.G
November 2019
Operation Manual / Power2 / 2 Safety
1 Safety / 1.14 Safe maintenance
u Wear personal protective equipment (PPE) according to the material safety data sheet.
Mechanical hazards when working on the low-pressure and high-pressure stage
WARNING
Physical hazards due to rotating parts
The rotor can rotate due to the stack draught alone. Contact with rotating
parts can cause severe injury.
u Secure rotor against turning.
Hazards due to operating materials and supplies
Operating materials and supplies are substances required for the operation 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 contact with the skin.
u Ensure proper ventilation.
u Observe the information in the material safety data sheet for the operat-
ing materials and supplies.
u Wear personal protective equipment (PPE) according to the material
safety data sheet.
u Comply with local legislation.
Wear safety goggles.
Wear safety gloves to protect against chemical hazards.
Wear a respiratory mask to protect against gases.
© Copyright 2019 ABB. All rights reserved.
HZTL4021_EN
Rev.G
November 2019
Operation Manual / Power2 / 2 Safety
1 Safety / 1.14 Safe maintenance
WARNING
Danger of fire or explosion
Flammable and combustible operating materials and supplies can catch fire
or resulting vapours can lead to an explosion.
u Observe the information in the material safety data sheet for the operat-
ing materials and supplies.
u Comply with local legislation.
u Do not allow any exposed flame or ignition source during cleaning work.
u Carry out cleaning in the open or provide sufficient ventilation.
CAUTION
Environmental hazard
Improper handling of operating materials and supplies can lead to environ-
mental damage.
u Observe the information 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-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 when removing old insulation materials.
u Dispose of insulation materials properly and in an environmentally com-
patible manner in compliance with the legal regulations.
Wear safety goggles.
Wear a respiratory mask to protect against dusts.
Wear safety gloves to protect against chemical hazards.
© Copyright 2019 ABB. All rights reserved.
HZTL4021_EN
Rev.G
November 2019
Operation Manual / Power2 650-M46 / Safety data sheets
Contents
Page 1 / 5
Safety data sheets
Power2 650-M46
HT595154
Name
Hardware ID
Page
© Copyright 2020 ABB. All rights reserved.
HT595154_A
April 2020
Operation Manual / Power2 650-M46 / Safety data sheets
Page 2 / 5
Safety data sheet
Power2 650-M46
HT595154
Low-pressure stage
PT002947
Power2 650-M46
HT595154
Low-pressure stage
PT002947
20
80
80
420
420
1900
2020
1250855
Additional Safety Data:
Maximum permissible temperatures
At engine overload (110 %) in test rig
tMmax [°C]
tBmax [°C]
operation only, unless otherwise agreed
with the enginebuilder
550
520
Exhaust gas inlet
temperature
During operation
© Copyright 2020 ABB. All rights reserved.
HT595154_A
April 2020
Operation Manual / Power2 650-M46 / Safety data sheets
Page 3 / 5
Safety data sheet
Power2 650-M46
HT595154
Low-pressure stage
PT002948
Power2 650-M46
HT595154
Low-pressure stage
PT002948
20
80
80
420
420
1900
2020
1250856
Additional Safety Data:
Maximum permissible temperatures
At engine overload (110 %) in test rig
tMmax [°C]
tBmax [°C]
operation only, unless otherwise agreed
with the enginebuilder
550
520
Exhaust gas inlet
temperature
During operation
© Copyright 2020 ABB. All rights reserved.
HT595154_A
April 2020
Operation Manual / Power2 650-M46 / Safety data sheets
Page 4 / 5
Safety data sheet
Power2 650-M46
HT595154
High-pressure stage
PT002945
Power2 650-M46
HT595154
High-pressure stage
PT002945
20
80
80
559
538
750
2020
1248261
Additional Safety Data:
Maximum permissible temperatures
At engine overload (110 %) in test rig
operation only, unless otherwise agreed
with the enginebuilder
tMmax [°C]
tBmax [°C]
tCmax [°C]
650
620
55
Exhaust gas inlet
temperature
During operation
Compressor inlet
temperature after During operation
intercooler
© Copyright 2020 ABB. All rights reserved.
HT595154_A
April 2020
Operation Manual / Power2 650-M46 / Safety data sheets
Page 5 / 5
Safety data sheet
Power2 650-M46
HT595154
High-pressure stage
PT002946
Power2 650-M46
HT595154
High-pressure stage
PT002946
20
80
80
559
538
750
2020
1248262
Additional Safety Data:
Maximum permissible temperatures
At engine overload (110 %) in test rig
operation only, unless otherwise agreed
with the enginebuilder
tMmax [°C]
tBmax [°C]
tCmax [°C]
650
620
55
Exhaust gas inlet
temperature
During operation
Compressor inlet
temperature after During operation
intercooler
© Copyright 2020 ABB. All rights reserved.
HT595154_A
April 2020
Operation Manual / Power2 650-M / 4 Product description
Table of contents
Product description
Power2 layout and function......................................................................................... 5
Layout and function of the low-pressure stage ..................................................... 6
Layout and function of the high-pressure stage.................................................... 8
Locations of the rating plates................................................................................... 11
Removal and installation .................................................................................... 12
Commissioning .................................................................................................... 13
Inspection procedures................................................................................................ 15
Monitoring during operation.............................................................................. 18
Speed measurement .................................................................................................. 20
Operation and service ......................................................................................... 26
Noise emission ............................................................................................................ 26
Service work.................................................................................................................. 27
Expected replacement intervals .............................................................................. 29
Stopping the engine................................................................................................... 29
Foreword to maintenance......................................................................................... 30
Malfunctions when starting...................................................................................... 35
Malfunctions during operation ................................................................................ 36
Speed measurement system..................................................................................... 41
Taking out of operation at short notice........................................................... 43
Taking out of operation for a long period........................................................ 44
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
Table of contents
General .......................................................................................................................... 44
Lubricating oil.............................................................................................................. 44
Process for taking out of operation........................................................................ 44
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
1 Introduction / 1.1 Related documents
1
Introduction
1.1
Related documents
Chapter
Operation Manual / 1 Introduction
Operation Manual / 2 Safety
Document number
HZTL4003
HZTL4021
Operation Manual / 3 Safety data sheet *)
Table 1: Related documents
Serial number of Power2
*) This chapter is only present in serialised operation manuals.
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
1 Introduction / 1.1 Related documents
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
1 Introduction / 1.2 Power2 layout and function
1.2
Power2 layout and function
Fig. 1: Power2 layout and function
Power2
Two-stage turbocharging
21
22
24
25
HP compressor
HP turbine
LP turbine
Power2 LP Low-pressure stage
Power2 HP High-pressure stage
A
Exhaust gas inlet from internal combus-
LP compressor
tion engine
B
C
D
Exhaust gas outlet
Air or air/gas mixture inlet
26
Intercooler
Air or air/gas mixture outlet and supply
- - - Not included in the ABB Turbo Sys-
tems scope of delivery
to the charge air cooler
The diagram shows the position of the low-pressure (Power2 LP) and high-pressure stage
(Power2 HP) within two-stage turbocharging (Power2). The low-pressure stage is always op-
erated in combination with a high-pressure stage connected in series. The two-stage 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) of
the high-pressure stage and then to the turbine (24) of the low-pressure stage. The com-
pressor (25) of the low-pressure stage sucks in fresh air or the air/gas mixture, respectively.
This precompressed air or air/gas mixture flows through the intercooler (26) into the com-
pressor (21) of the high-pressure stage. Here the air or air/gas mixture is compressed fur-
ther and leaves the two-stage turbocharging (Power2) in the direction of the charge air
cooler.
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
1 Introduction / 1.3 Layout and function of the low-pressure stage
1.3
Layout and function of the low-pressure stage
Fig. 2: Layout and function of the low-pressure stage
01 Air suction branch
02 Injection ring for air
03 Compressor wheel
04 Diffuser
07 Gas inlet casing
08 Nozzle ring
09 Turbine
10 Bearing casing
05 Bearing bush with heat shield
06 Gas outlet casing
11
Compressor casing
12 Injection ring for blowby
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
1 Introduction / 1.3 Layout and function of the low-pressure stage
Mode of operation of the low-pressure stage (Power2 LP)
Fig. 3: Function of the low-pressure stage
Power2
Two-stage turbocharging
21
22
HP compressor
HP turbine
Power2 LP Low-pressure stage
Power2 HP High-pressure stage
23* Gas pipe (bellows)
A
Exhaust gas inlet from internal combus-
24
LP turbine
tion engine
B
C
D
Exhaust gas outlet
Air or air/gas mixture inlet
25
26
LP compressor
Intercooler
Air or air/gas mixture outlet and supply
- - - Not included in the ABB Turbo Sys-
to the charge air cooler
tems scope of delivery
*) If present
The low-pressure stage (Power2 LP) is a turbomachine and its main components are a tur-
bine and a compressor. These components are installed on a common shaft and form the ro-
tor.
stage (Power2 HP) flows through the gas inlet casing (07) and the nozzle ring (08) and
reaches the turbine (09). The LP turbine uses the energy contained in the exhaust gas to
drive the rotor. The exhaust gases then reach the atmosphere through the gas outlet cas-
ing (06) and the exhaust gas pipe connected to it.
The rotor runs in two radial plain bearings, which are located between the compressor and
the turbine. The axial bearing is also in the form of a plain bearing. The plain bearings are
connected to a central lubricating oil duct which is normally supplied by the lubricating oil
circuit of the engine. The oil outlet lies at the deepest point of the bearing casing (10).
The LP compressor wheel (03) connected to the shaft sucks in fresh air or an air/gas mixture
through the filter silencer or the air suction branch (01). The air is compressed in the LP com-
pressor and the downstream diffuser (04). The compressed air is passed on to the inter-
cooler (26) via the compressor casing (11). The air is cooled in the intercooler (26) and sub-
sequently supplied to the HP compressor (21).
Using the injection ring (02), an air flow can be supplied upstream of the LP compressor
stage.
The blowby air can be supplied upstream of the LP compressor stage via the injection
ring (12).
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
1 Introduction / 1.4 Layout and function of the high-pressure stage
1.4
Layout and function of the high-pressure stage
Fig. 4: Layout of the high-pressure stage
01 Air suction branch
02 Bellows
03 Compressor casing
04 Diffuser
06
07
08
09
10
Turbine
Gas piping
Nozzle ring
Compressor wheel
Gas inlet casing (turbine casing)
05 Bearing casing
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
1 Introduction / 1.4 Layout and function of the high-pressure stage
Mode of operation of the high-pressure stage (Power2 HP)
Fig. 5: Function of the high-pressure stage
Power2
Two-stage turbocharging
21
22
HP compressor
HP turbine
Power2 LP Low-pressure stage
Power2 HP High-pressure stage
23* Gas pipe (bellows)
A
Exhaust gas inlet from internal combus-
24
LP turbine
tion engine
B
C
D
Exhaust gas outlet
Air or air/gas mixture inlet
25
26
LP compressor
Intercooler
Air or air/gas mixture outlet and supply
- - - Not included in the ABB Turbo Sys-
to the charge air cooler
tems scope of delivery
*) If present
The high-pressure stage (Power2 HP) is a turbomachine, and its main components are a tur-
bine and a compressor. These components are installed on a common shaft and form the ro-
nozzle ring (08) and reaches the turbine (06). The HP turbine uses the energy contained in
the exhaust gas to drive the rotor. The exhaust gases then flow through the gas piping (07)
before reaching the turbine of the low-pressure stage (Power2 LP).
The rotor runs in two radial plain bearings which are located in the bearing casing (05)
between compressor and turbine. The plain bearings are connected to a central lubricating
oil duct which is normally supplied by the lubricating oil circuit of the engine. The oil outlet
lies at the deepest point of the bearing casing (05).
The HP compressor wheel (09) connected to the shaft sucks in the precompressed air or an
air/gas mixture from the low-pressure stage (25) through the air suction branch (01). The air
is compressed further in the HP compressor (21) and the downstream diffuser (04) and sub-
sequently supplied to the charge air cooler via the compressor casing (03).
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
1 Introduction / 1.5 Warning plates on the low-pressure and high-pres-
sure stage
1.5
Warning plates on the low-pressure and high-
pressure stage
Warning plates are affixed at the following locations of the high and low-pressure stage:
Fig. 6: Location of Power2 LP warning plates
Fig. 7: Location of Power2 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 stages
High and low-pressure stages supplied to the enginebuilder without insulation must be
equipped later with warning plates to be attached to the insulation. This is the responsibility
of the enginebuilder.
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
1 Introduction / 1.6 Locations of the rating plates
1.6
Locations of the rating plates
Low-pressure stage
Fig. 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 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 bearing casing.
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
2 Removal and installation /
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.
u For more information on how to remove and install the gas piping, see document
Operation Manual / Power2 … / 4.3 Gas piping.
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
3 Commissioning / 3.1 Oil supply
3
Commissioning
3.1
Oil supply
3.1.1
Introduction
In all operating states, a functioning and carefully executed oil supply is an important pre-
requisite for trouble-free operation of the low-pressure and high-pressure stage.
The low-pressure and high-pressure stage are usually lubricated with oil from the engine oil
circulation.
u The directives of the enginebuilder on the selection of the lubricating oil and the oil
change intervals must be followed.
3.1.2
Pre-lubrication
Before the engine is started, the plain bearings of the low-pressure 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&.
An electrically driven oil pump is recommended for pre-lubrication.
Power2
Pre-lubrication time
650
2 min
Table 2: Pre-lubrication time
3.1.3
Post-lubrication
Post-lubrication is necessary after switching the engine off, in order to avoid oil coking in
the vicinity of the shaft seal. The post-lubrication time starts as soon as the oil pressure
drops below the admissible value due to switching off the engine.
An electrically driven oil pump is recommended for post-lubrication.
Power2
Post-lubrication time
650
30 min
Table 3: Post-lubrication time
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
3 Commissioning / 3.1 Oil supply
3.1.4
Long-term lubrication
Long-term lubrication occurs if the times specified for the pre- or post-lubrication are ex-
ceeded with the engine at a standstill.
CAUTION
Oil leak while stopped
The shaft sealing system of the low-pressure and high-pressure stage has
been designed to ensure optimum tightness during operation of the engine.
During standstill, the pressure level in the bearing space may increase until it
is above the pressure outside the shaft seal, resulting in a risk of oil leakage.
u Observe the points mentioned in the following to reduce the risk 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 space by taking measures at the system
side.
Interruption of the oil supply to the turbocharger through the shut-off valve.
3.1.5
Oil filtering
Power2
Filter mesh width [mm]
650
≤ 0.034
Table 4: Filter mesh width
3.1.6
Oil pressure
Comply precisely with the oil pressure before the low-pressure and high-pressure stage for
trouble-free operation.
3.1.7
Oil orifice
Metering orifices are installed in the oil inlet of the low-pressure stage and the high-pressure
stage in order to safeguard the oil pressures.
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
3 Commissioning / 3.2 Inspection procedures
3.2
Inspection procedures
3.2.1
Introduction
Inspection procedures include preventative visual controls, monitoring and measuring work
before and during commissioning. Inspection procedures enable changes to the low and
high-pressure stage to be detected. Engine damage can be prevented.
3.2.2
Checks before commissioning
Filter mat (if 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 the lubricating system.
u Check that the oil filter is clean before commissioning.
u Check the oil pressure in the oil supply pipes.
Warning plates
u Check whether warning plates are present and legible.
u Check whether the protective sheets have been removed from new warning plates.
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
3 Commissioning / 3.2 Inspection procedures
3.2.3
Checks after commissioning (engine in idle mode)
Lubricating system
u Check the oil pressure in the oil supply pipes.
u Check oil inlet temperature.
Leaktightness of pipes
WARNING
Risk of burning from hot gas
Escaping gases are hot and will lead to serious burns in the event of contact.
u Check all pipes for leaks in accordance with the enginebuilder’s instruc-
tions.
3.2.4
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; differ-
ent operating conditions must be taken into account here.
Escape of oily fluids
Lubricants and pastes used for the assembly of the low-pressure and high-pressure stage
can liquefy or vaporise and escape as oily fluids during the initial hours of operation. Con-
tinual escape of an oily fluid indicates a possible oil leak.
If there is a leak, contact an ABB Turbocharging Service Station.
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
3 Commissioning / 3.3 Commissioning after taking out of operation
3.3
Commissioning after taking out of operation
If present
u Remove cover plates (blind flanges) from the compressor casing, the gas inlet and the
gas outlet.
u Remove the locking screws on the water connections and fit the water pipe.
General
u Check the exhaust gas pipe before and 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 oil circulation to the low-pressure and high-pressure stage into opera-
tion.
u Prepare the low-pressure and high-pressure stage for operation according to section
Checks before commissioning.
u The low-pressure and high-pressure stage is now operational.
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
4 Monitoring during operation / 4.1 Lubricating oil pressure
4
Monitoring during operation
4.1
Lubricating oil pressure
CAUTION
Assuring lubricating oil pressure
Serious damage to the engine or property can result from a missing or insuf-
ficient lubricating oil supply.
u The lubricating oil pressure must be monitored during operation and the
necessary pressure assured at the oil inlet.
Lubrication oil measuring points
The pressure measuring point M is at
the oil supply channel of the low-pres-
sure stage that is not used for the oil
supply.
The pressure measuring point M must be po-
sitioned in the oil supply line immediately at
the inlet to the high-pressure stage.
01 Contact surface
02 Oil inlet
03 Oil outlet
M
T
Oil pressure measuring point
Oil temperature measuring point
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
4 Monitoring during operation / 4.2 Lubricating oil temperature
Power2 Status
Engine
Status
Oil pressure at measur-
ing point M
Low-pressure and high-pressure stage
poil, in [bar]
LP
HP
650
Engine
Admissible
1.3 ... 2.5
1.3 ... 5.0
2.0 … 4.5
2.0 … 8.0
running
Temporarily admissible
(<15 min) after engine start (cold oil)
Temporarily admissible (<1 h )
1.0 ... 1.3
< 1.0
1.3 … 2.0
< 1.3
-> Warning signal
Not permissible
-> Alarm signal -> stop the engine immediately
Engine
Pre-lubrication
Post-lubrication
Long-term lubrication
1.3 … 2.0
1.3 … 2.0
< 0.7
1.3 … 2.0
1.3 … 2.0
< 0.7
stopped
Table 5: Oil pressure range
Depending on the design, metering orifices can be installed in the oil inlet of the low-pres-
sure and high-pressure stages in order to adjust the oil pressures.
4.2
Lubricating oil temperature
CAUTION
Machine damage
If the oil temperature at the oil inlet exceeds the admissible range, this may
lead to engine damage.
u Observe oil temperature at the oil inlet according to the following table.
Power2
Status for operation
Oil temperature at Oil temperature at
the inlet
Toil,inlet [°C]
< 90
the outlet
Toil,inlet [°C]
< 150
650
Admissible
Temporarily admissible (< 1 h) -> Alarm
Not admissible -> stop engine
90 … 95
> 95
150 … 155
> 155
Not admissible -> preheat oil prior before
< 30
- -
start
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 according to
the current regulations.
If the low-pressure or high-pressure stage has been operated outside of the admissible
range for a long period of time, ABB Turbo Systems recommends having the low-pressure or
high-pressure stage inspected by an ABB Turbocharging Service Station.
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
4 Monitoring during operation / 4.3 Speed measurement
4.3
Speed measurement
4.3.1
Introduction
Speed measurement systems enable the constant monitoring of the speeds of the low-pres-
sure and the high-pressure stage.
4.3.2
Low-pressure stage
4.3.2.1
Layout and functional principle
Fig. 10: Functional principle
01 Speed sensor
02 Cable
03 Casing flange
04 Electronics
05 Cable
06 Plug
The speed measurement system consists of a sensor (01) with integrated cables (02, 05), an
electronic unit (04) and a plug (06). The sensor operates according to the eddy current prin-
ciple, and is installed in a radial direction in relation to the compressor wheel. The electron-
ics must be provided with a power supply, and deliver a square pulse signal. The signal fre-
quency depends on the number of main blades on the compressor wheel. The signal amp-
litude depends on the level of the feed voltage.
CAUTION
Do not strain cables
If you pull the speed measurement cables too hard, contacts can be pulled
out.
u Do not strain the speed measurement cables by pulling.
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
4 Monitoring during operation / 4.3 Speed measurement
4.3.2.2
Replacing the speed measurement system
Low-pressure stage
4.3.2.2.1
Removing the speed measurement system
Fig. 11: Dimension X
u Measure and note down dimension X.
Fig. 12: Removing the speed measurement system
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
4 Monitoring during operation / 4.3 Speed measurement
Installing the speed measurement system
Fig. 13: Setting dimension X
1. Set speed sensor (86505) in the plate (86507) to dimension X.
2. Secure speed sensor with wedge lock washer (86509) and clamping nut (86505). Observe
tightening torque.
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
4 Monitoring during operation / 4.3 Speed measurement
Fig. 14: Control dimension S
3. Secure plate with wedge lock washer (86508) and socket screw (86510). Observe tighten-
ing torque.
4. Adjust dimension X until S = 0 mm is reached.
5. Position cable and secure it with rubber grommet (86516).
6. Screw in pressure nut (86505) secured with Loctite® 243. Observe tightening torque.
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
4 Monitoring during operation / 4.3 Speed measurement
4.3.3
High-pressure stage
4.3.3.1
Layout and functional principle
Fig. 15: Layout and overview
01
02
03
04
05
06
07
Bracket
Screw plug
Gasket
Sealing disc
Speed sensor (86505)
Connecting cable (86515)
Voltage limiter
Voltage pulses are induced at the electromagnetic speed sensor (05) using the sealing disc
rotating on the shaft (04). The voltage amplitudes of the pulses are limited in the voltage
limiter to a maximum value (< ± 15 V), and signal noise is suppressed (< ~ 1.4 V).
CAUTION
Do not strain cables
If you pull the speed measurement cables too hard, contacts can be pulled
out.
u Do not strain the speed measurement cables by pulling.
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
4 Monitoring during operation / 4.3 Speed measurement
4.3.4
Differences in speed between the low-pressure or high-
pressure stages on one engine
The speeds of the low-pressure stages differ significantly from the speeds of the high-pres-
sure stages.
A Power2 turbocharging system for V-engines, for example, can consist of multiple low-pres-
sure and multiple high-pressure stages. In this case the speeds of the low-pressure stages
only differ a little from each other. The same also applies to the high-pressure stages.
The difference between the highest and the lowest speed must not be more than 3 %, relat-
ive to the speed limit nBmax
.
If this admissible difference range is exceeded, the following steps must be performed:
u Reduce the 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 Measure the temperatures in the air lines and exhaust gas pipes from and to the low-
pressure and high-pressure stages and compare with normal values.
u Check the pressure loss of the alternative air inlet and compare it with normal values.
If the engine can be stopped temporarily:
u Inspect air lines, exhaust gas pipes and the low-pressure and high-pressure stages and
remedy any malfunctions.
u In any case, contacting the nearest ABB Turbocharging Service Station is recommended.
4.3.5
Malfunction of the speed measurement system
The possible reasons for malfunction of the speed measuring system are described in
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
5 Operation and service / 5.1 Noise emission
5
Operation and service
5.1
Noise emission
WARNING
Noise hazards
Exposure to noise can harm the hearing system, impair health and the psy-
chological state and may lead to lack of attention and irritation.
u When the engine is running, always wear ear protection.
u Always wear ear protection if the sound pressure level exceeds 85 dB(A).
Wear ear protection.
The emission sound pressure level (A-weighted) is measured at a distance of 1 metre from
the low-pressure and high-pressure stage.
The highest value of the emission sound pressure level1) reaches a maximum of 105 dB(A)
near the compressor end (compressor casing, filter silencer, air suction branch).
The following prerequisites must be fulfilled with regard to the low-pressure and high-pres-
sure stage to observe this limit value:
¡
¡
Air inlet system and piping fitted
All standard, noise-reducing measures2) have been fitted
The enginebuilder is also responsible for insulating other components such as the charge
air/scavenging air lines and the cooler.
1)
2)
Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7:
A-rated emission sound pressure level
The enginebuilder must provide acoustically equivalent measures in case of deviating in-
sulation versions
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
5 Operation and service / 5.2 Service work
5.2
Service work
Service work includes visual controls, monitoring, measuring and inspection as well as func-
tion checks. Service work enables the detection and rectification of changes to the low and
high-pressure stage and ensures full operability of the low and high-pressure stage.
CAUTION
Service intervals
Service work on the low-pressure and high-pressure stage that is omitted or
performed too late can cause excessive contamination and wear as well as
operating failures.
u Carry out the service work at the specified time intervals.
CAUTION
Shortened service intervals
Exceptional stresses such as several starts/stops per day, harsh environ-
mental conditions, poor fuel quality or high system vibrations can lead to
untimely machine damage even if the prescribed service intervals are ob-
served.
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
last service.
5.2.1
Service work every 25 … 50 hours
u Visual check for air, exhaust gas, water and oil leaks.
u Record operating data and enter in the engine logbook.
u In case of deviations, determine the cause.
5.2.2
Service work at 100 hours after commissioning
u Clean or replace the oil filter located in the supply pipe to the low-pressure and high-pres-
sure stage while the engine is stopped.
5.2.3
Service work according to instructions of enginebuilder
u Clean or replace the oil filter located in the supply pipe to the low-pressure and high-pres-
sure stage while the engine is stopped.
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
5 Operation and service / 5.2 Service work
5.2.4
Service work every 12000 ... 16000 hours of operation
The rotor and bearing parts must be checked and assessed by an ABB Turbocharging Service
Station.
u Dismantle low-pressure and high-pressure stage. Measure clearances.
u Clean nozzle ring and casing and check for cracks and erosion/corrosion.
Additional measures in conjunction with the high-pressure stage:
u Replace gaskets every time after disassembly.
u Check bellows between air-inlet casing and compressor casing for cracks and clean (see
also chapter Cleaning the HP bellows (if present)).
5.2.5
Service work according to specifications on the rating
plate
The following work must be carried out by an ABB Turbocharging Service Station:
¡
¡
Replacement of the bearing parts
Replacement of the turbine and the compressor
5.2.6
Entries in the engine logbook
The monitoring of the engine enables conclusions to be drawn on the behaviour of the low-
pressure and high-pressure stage.
The following operating data and measured values must be entered regularly in the engine
logbook of the enginebuilder:
¡
¡
¡
¡
¡
Performance and speed of the engine
Air intake temperature
Pressure of the charge air
Pressure loss in the charge air cooler and intercooler
Lubricating oil pressure and lubricating oil temperature
If present:
¡
¡
¡
¡
Speed of low-pressure and high-pressure stage
Air temperature before and after the compressor and after the charge air cooler
Exhaust gas temperature before and after the turbine
Atmospheric humidity of the suction air (before the low-pressure stage)
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
5 Operation and service / 5.3 Expected replacement intervals
5.3
Expected replacement intervals
u For information on the expected replacement intervals of the components of the low-
pressure stage, see document
Operation Manual / Power2 … / 4.1 Low-pressure stage.
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 could
occur.
u Observe the post-lubrication times and the oil pressure specified for
post-lubrication (see chapter Monitoring during operation / Lubricating
oil pressure).
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
6 Periodic maintenance / 6.1 Foreword to maintenance
6
Periodic maintenance
6.1
Foreword to maintenance
Maintenance work includes regular visual controls and cleaning operations which are inten-
ded to ensure the trouble-free functioning of the low-pressure and high-pressure stage.
In this process, the exterior condition and the degree of contamination of the components
on which maintenance work is to be performed are determined.
Component to be maintained
LP compressor3)
Recommended cleaning interval1) Operating state
25 … 100 h
Engine load: 50 …
100 %
HP compressor3)
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
3) If compressor cleaning present
Compressor cleaning (if present)
We recommend cleaning the HP compressor after the LP compressor.
On V-engines with several low-pressure and/or high-pressure stages per engine, ABB Turbo
Systems recommends the parallel cleaning of the LP compressors as well as the parallel
cleaning of the HP compressors.
This cleaning process is faster and reduces the risk of surging of the low-pressure and high-
pressure stages.
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
6 Periodic maintenance / 6.2 Cleaning the compressor during opera-
tion
6.2
Cleaning the compressor during operation
6.2.1
Introduction
Approval by enginebuilder
The following instructions for wet cleaning only apply to cleaning with pure water and under
the precondition that the enginebuilder approves the process.
General
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 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.
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
6 Periodic maintenance / 6.2 Cleaning the compressor during opera-
tion
6.2.2
Principle of wet cleaning
Principle of wet cleaning
To clean the compressor stage during operation, water is injected before the compressor
wheel.
The water does not act as a solvent. The coating is removed by the mechanical action of the
impacting droplets. The process is particularly suitable as long as the contamination is not
too advanced.
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.
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) as well as the engine-side system must be
checked with regard to deviations (e.g. an increased pressure loss in the charge air cooler)
and corrected if necessary.
If surging of the compressor stage continues to occur during compressor cleaning despite
correct settings, this can be remedied by reducing the engine load further during cleaning of
the compressor after consulting an ABB Turbocharging Service Station. The reduction of the
engine load can lead to a reduction in the effectiveness of the compressor cleaning.
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
6 Periodic maintenance / 6.2 Cleaning the compressor during opera-
tion
6.2.3
Wet cleaning with direct water supply
Prerequisites
Do not clean the compressors of the different high and low-pressure stages at the same
time, but one after the other.
On V-engines with several low-pressure and/or high-pressure stages per engine, ABB Turbo
Systems recommends the parallel cleaning of the LP compressors as well as the parallel
cleaning of the HP compressors. This cleaning process is faster and reduces the risk of sur-
ging of the low-pressure and high-pressure stages.
Wet cleaning operations for compressor with direct water supply
u Trigger water injection according to the instructions of the enginebuilder.
u Observe water pressure before connection to pressure stage.
u Operate engine for at least five additional minutes after cleaning.
The cleaning process can be repeated up to three times.
The success of the cleaning can be recognised based on the charging pressure or the ex-
haust gas temperature.
If the cleaning is still unsuccessful after three processes and the engine values are unsatis-
factory, it is recommended to have the low-pressure and / or high-pressure stage checked
and cleaned by an ABB Turbocharging Service Station.
Cleaning parameters for each compressor
Power2
Engine load
Water pressure
[bar]
Water injection time
[s]
650 LP
50 … 100 %
3
10
Table 8: Cleaning parameters Power2 LP
Power2
Engine load
Water pressure
[bar]
Water injection time
[s]
650 HP
50 … 100 %
pVE* + 3
10
Table 9: Cleaning parameters Power2 HP
* Compressor inlet pressure depending on the operating point
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
6 Periodic maintenance / 6.3 Cleaning turbine and nozzle ring during
operation
6.3
Cleaning turbine and nozzle ring during operation
Power2 650-M is carried out without turbine cleaning function.
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
7 Troubleshooting / 7.1 Malfunctions when starting
7
Troubleshooting
7.1
Malfunctions when starting
Delayed start-up
Possible causes
Remedy
Low-pressure
or
Pressure stage contaminated
Bearing damaged
Rotor rubbing
Foreign object in pressure stage
Clean
Contact ABB Turbocharging Service
high-pressure
stage
Station
Table 10: Malfunctions when starting – Delayed start-up
Vibrations
Possible causes
Remedy
Engine
Vibrations from engine
Rotor unbalance
Turbine or compressor damaged
Bearing damaged
Contact enginebuilder
Low-pressure
Contact ABB Turbocharging Service
or
Station
high-pressure
stage
Table 11: Malfunctions when starting – Vibrations
Rubbing of rotating parts
Normal behaviour, not a malfunction
Low-pressure
or
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, specific tolerances must be fulfilled.
high-pressure
stage
¡
If there is any doubt about the extent of the rubbing, contact an ABB
Turbocharging Service Station.
¡
Have a dimension check carried out by an ABB Turbocharging Service
Station.
Table 12: Malfunctions when starting – Rubbing of rotating parts
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
7 Troubleshooting / 7.2 Malfunctions during operation
7.2
Malfunctions during operation
Lubricating oil pressure too low
Possible causes
Remedy
Engine
Oil filter heavily contaminated
Clean
Oil pump in lubricating system de-
Check/replace
fective
Manometer displays incorrectly
Replace manometer
Low-pressure
or
Axial clearance of the rotor excessive Contact ABB Turbocharging Service
Station
high-pressure
stage
Table 13: Malfunctions during operation – Lubricating oil pressure too low
Drop in low-pressure stage speed
Possible causes
Remedy
Engine
Defects on the connected cylinders Contact enginebuilder
Low-pressure
Heavy contamination of the tur-
Clean
stage
bine
Damaged rotor components or
bearing
Contact ABB Turbocharging Service
Station
Change of operating state of high- Check the operating point of the high-
pressure stage
pressure stage.
Repair
Pipes
Defects, such as leaks, in the ex-
haust gas pipes or charge air ducts
Table 14: Malfunctions during operation – Power2 LP speed reductions
Drop in high-pressure stage speed
Possible causes
Remedy
Engine
Defects on the connected cylinders
Contact enginebuilder
High-pressure Heavy contamination of the turbine Clean
stage
Damaged rotor components or bear- Contact ABB Turbocharging Service
ing
Change of operating state of low-
pressure stage
Station
Check the operating point of the low-
pressure stage.
Pipes
Defects, such as leaks, in the exhaust Repair
gas pipes or charge air ducts
Table 15: Malfunctions during operation – Power2 HP speed reductions
Increase in low-pressure stage speed
Possible causes
Remedy
Low-pressure
Heavy contamination of the nozzle Contact ABB Turbocharging Service
stage
ring
Station
Table 16: Malfunctions during operation – Power2 LP speed increases
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
7 Troubleshooting / 7.2 Malfunctions during operation
Increase in high-pressure stage speed
Possible causes
Remedy
High-pressure Heavy contamination of the nozzle
Contact ABB Turbocharging Service
stage
ring
Station
Low-pressure stage defective
Contact ABB Turbocharging Service
Station
Pipes
Leak in exhaust gas pipe before the Repair
low-pressure stage
Table 17: Malfunctions during operation – Power2 HP speed increases
Exhaust gas temperature too high
Engine performance and engine speed unchanged
Possible causes
Engine
Remedy
Repair or contact manufacturer
Malfunction in the injection system
Low-pressure
Insufficient air, for example, because Clean
filter silencer is blocked by contam-
ination
or
high-pressure
stage
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
Station
Charge air
cooler/inter-
cooler
Cooler contaminated
Cooling water volume too low
Clean
Fill
Inlet temperature of cooling water
Check/clean cooling system
too high
Insufficient ventilation
Improve ventilation
Table 18: Malfunctions during operation – Exhaust gas temperature too high
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
7 Troubleshooting / 7.2 Malfunctions during operation
Charge air pressure too low
Engine performance and engine speed unchanged, suction condition normal
Possible causes
Remedy
Engine
Air receiver not sealed
Repair
Gas piping between engine and tur-
bine not sealed
Injection mistimed
Set correctly
Valve control misadjusted
Manometer display not correct
Low-pressure
or
Replace manometer
Repair leak
Supply pipe to manometer not
high-pressure
stage
sealed
Filter silencer contaminated, there-
fore pressure drop too high
Clean
Compressor/turbine contaminated
Compressor/turbine damaged
Contact ABB Turbocharging Service
Station
Exhaust gas back pressure too high Clean or repair boiler or exhaust gas si-
lencer
Table 19: Malfunctions during operation – Charge air pressure too low
Charge air pressure too high
Engine performance and engine speed unchanged, suction condition normal
Possible causes
Remedy
Engine
Malfunction in the injection system
Injection mistimed
Repair or contact manufacturer
Set correctly
Engine performance higher than ex- Check engine performance
pected
Low-pressure
or
Manometer display not correct
Replace manometer
high-pressure
stage
Table 20: Malfunctions during operation – Charge air pressure too high
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
7 Troubleshooting / 7.2 Malfunctions during operation
Contamination of the compressor
Reduced compressor performance/efficiency and therefore engine performance losses
Possible causes
Remedy
Low-pressure
or
Heavy contamination of the com-
pressor components due to the in-
flux of ventilation gases
Increased vibration, compressor
blade damage due to the influx of
ventilation gases
Clean the compressor
Optimize oil separation
high-pressure
stage
Correct the influx of ventilation gases in
accordance with the enginebuilder's in-
structions.
Table 21: Malfunctions during operation – Compressor 1 contamination
Reduced fatigue strength of the compressor wheel, compressor blade breakage.
Possible causes
Remedy
Low-pressure
or
Material of the compressor wheel
Correct the influx of ventilation gases in
corroded due to the influx of ventila- accordance with the enginebuilder's in-
tion gases containing corrosive com- structions.
ponents
high-pressure
stage
Material of the compressor wheel
Prevent exhaust gas leakages in the en-
corroded due to intake air containing gine space
exhaust gases or salt
Clean the compressor
Table 22: Malfunctions during operation – Compressor 2 contamination
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
7 Troubleshooting / 7.3 Surging of the low-pressure or high-pressure
stage
7.3
Surging of the low-pressure or high-pressure
stage
Possible causes
Remedy
Low-pressure
or
Filter silencer or diffuser contamin-
ated
Clean
high-pressure
stage
Charge air
cooler/inter-
cooler
Cooler contaminated
Charge air duct blocked
Clean
Table 23: Surging of the low-pressure or high-pressure stage
CAUTION
Continuous 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 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
reducing the engine performance quickly when manoeuvring. When this happens, the flow
direction in the compressor is momentarily reversed. Such sporadic surge blows do not im-
pair the safe operation of the low-pressure stage.
¡
A surge blow is accompanied by a loud bang and the escape of hot air from the filter si-
lencer of the low-pressure stage.
No air escapes from the high-pressure stage.
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
7 Troubleshooting / 7.4 Malfunctions when stopping
7.4
Malfunctions when stopping
Runout noises
Possible causes
Remedy
Low-pressure
or
Pressure stage contaminated
Bearing damaged
Rotor rubbing
Clean
Contact ABB Turbocharging Service
high-pressure
stage
Station
Foreign object in the pressure stage
Table 24: Malfunctions when stopping – Runout noises
Runout time too short
Possible causes
Remedy
Low-pressure
or
Pressure stage contaminated
Bearing damaged
Rotor rubbing
Clean
Contact ABB Turbocharging Service
high-pressure
stage
Station
Foreign object in the pressure stage
Table 25: Malfunctions when stopping – Runout time too short
7.5
Speed measurement system
Measured speed incorrect
Possible causes
Remedy
Contact ABB Turbocharging Service Station
Low-pres-
sure or
- -
high-pres-
sure stage
Table 26: Measured speed incorrect
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
8 Disassembly and assembly /
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.
u For more information on the disassembly and assembly of the gas piping, see document
Operation Manual / Power2 … / 4.3 Gas piping.
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
9 Taking out of operation at short notice /
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.
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
10 Taking out of operation for a long period / 10.1 General
10
Taking out of operation for a long
period
10.1
General
When taking the low-pressure and high-pressure stage out of operation, mothballing meas-
ures must be taken in order to minimise the risk of corrosion on components. The necessary
measures depend on the condition of the lubricating oil and the process used to take the
low-pressure and high-pressure stage out of operation.
10.2
Lubricating oil
No measures must be taken with regard to the lubricating oil if:
¡
The directives of the enginebuilder on lubricating oil selection and on the oil change in-
tervals are followed.
Or:
¡
The engine lubricating oil is replaced by a preservative oil and circulated with the pre-lub-
rication pump before the engine is taken out of operation.
If neither of the criteria above are met, mothballing by an ABB Turbocharging Service Station
is necessary. This includes 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 option is to install a blind flange on the outlet flange of the gas outlet
casing or the compressor casing.
– If the engine is being taken out of operation for a long period in a corrosive environ-
ment, all components through which air flows must be provided with corrosion pro-
tection. Contact an ABB Turbocharging Service Station for this purpose.
¡
Disassembly of the low-pressure and high-pressure stage as a whole unit or in individual
parts
– Seal all openings of the low-pressure and high-pressure stage with paraffin paper and
wooden lids.
– Store the disassembled parts in a dry room with 40-70% atmospheric humidity in
which no condensation can form.
– Check all low-pressure and high-pressure stage parts for corrosion annually.
– If there are signs of rust, thoroughly clean the parts and renew the corrosion protec-
tion.
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
11 Disposing of low-pressure and high-pressure stage components /
11
Disposing of low-pressure and high-
pressure stage components
Disposal must be environmentally compatible, professional, and in compliance with locally
applicable regulations.
The low-pressure and high-pressure stages mainly consist of metal (cast iron materials,
steel, nickel-steel alloys, aluminium and bearing brass).
Further components are: Non-metallic materials (filter components of felt and polyethylene),
lubricants (engine oil), electronic parts (speed sensor and associated components).
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 fibres can
cause mechanical irritation of the eyes, skin, and respiratory tracts.
u The enginebuilder's instructions must be followed for the handling and
disposal of the thermal insulation.
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4 Product description
12 Spare parts /
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.
u For more information on spare parts for the gas piping, see document
Operation Manual / Power2 … / 4.3 Gas piping.
© Copyright 2019 ABB. All rights reserved.
HZTL4064_EN
Rev.D
December 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
Table of contents
Low-pressure stage
Further applicable documents ............................................................................. 2
Removal and installation ...................................................................................... 3
Removing the low-pressure stage............................................................................. 4
Installing the low-pressure stage............................................................................... 5
Expected replacement intervals .......................................................................... 6
Disassembly and assembly................................................................................... 8
Introduction ................................................................................................................... 8
Removing the filter silencer and injection ring...................................................... 11
Removing the compressor casing............................................................................ 16
Removing the cartridge group.................................................................................. 17
Installing the compressor casing ............................................................................ 26
Axial clearance A after assembly.............................................................................. 29
Installing injection ring and air suction branch .................................................... 30
Taking out of operation at short notice........................................................... 34
Possible emergency repairs...................................................................................... 34
Spare parts ........................................................................................................... 37
Tables .................................................................................................................... 43
© Copyright 2019 ABB. All rights reserved.
HZTL4065_EN
Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
1 Further applicable documents /
1
Further applicable documents
Chapter
Document number
HZTL4004
HZTL4021
Operation Manual / Power2 / 1 Introduction
Operation Manual / Power2 / 2 Safety
Operation Manual / Power2 / 3 Safety data sheet *)
Operation Manual / Power2 650-M / 4 Product description
Table 1: Related documents
Power2 serial number (HT……)
HZTL4064
*) This chapter is only present in serialised operation manuals.
© Copyright 2019 ABB. All rights reserved.
HZTL4065_EN
Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
2 Removal and installation / 2.1 Transport / weight
2
Removal and installation
2.1
Transport / weight
Swivel lifting eyes to be used
Two swivel lifting eyes (S) are required for the safe lifting of loads. These are not included in
the ABB Turbo Systems scope of delivery.
The requirements of the swivel lifting eyes are listed in the table. The operating instructions
provided by the swivel lifting eye manufacturer must be observed for the application.
Swivel lifting eye (S)
Power2 Thread
650 LP M24
Length
Minimum load
limit
Lmin
30 mm
Lmax
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 the rating plate depending on the specifica-
tion.
Complete low-pressure stage
Suspension
Weight [kg]
1900
Table 3: Transporting the low-pressure stage
© Copyright 2019 ABB. All rights reserved.
HZTL4065_EN
Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
2 Removal and installation / 2.2 Removing the low-pressure stage
2.2
Removing the low-pressure stage
WARNING
Risk of tipping
If the turbocharger is not sufficiently supported or not supported at all dur-
ing removal and installation, it may tip over and cause severe injury to per-
sonnel or accidents resulting in fatalities.
u Support the turbocharger at a suitable 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 bearing casing suspension points.
u Loosen the fixing elements on the foot.
u Lift the low-pressure stage from the engine.
u Put down the low-pressure stage so that all contact surfaces of the feet make contact.
u Also place a support made from hard wood beneath the compressor casing.
© Copyright 2019 ABB. All rights reserved.
HZTL4065_EN
Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
2 Removal and installation / 2.3 Installing the low-pressure stage
2.3
Installing the low-pressure stage
Fig. 2: Suspension of complete low-pressure stage
u Attach one lifting gear to each of the two bearing casing suspension points.
u Check that 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 the instructions of the engineb-
uilder.
u Connect the cable connector to the speed sensor.
u Fit insulation according to the instructions of the enginebuilder.
© Copyright 2019 ABB. All rights reserved.
HZTL4065_EN
Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
3 Expected replacement intervals /
3
Expected replacement intervals
Rotating components
The recommended replacement intervals for compressor and turbine wheels are specified
based on the safety concept for rotating parts (SIKO) and dependant on the operating con-
ditions. These intervals are shown on the rating plate of the low-pressure and high-pressure
stage.
Non-rotating components
Depending on the system-specific operating conditions, a differentiation must be made
between the intervals to be 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 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
50000 … 100000
50000 … 100000
35000 … 50000
35000 … 50000
100000
HFO
Gas inlet casing
Gas outlet casing
Nozzle ring
Turbine diffuser / cover ring
Other casings
35000 … 50000
50000 … 100000
25000 … 50000
25000 … 50000
100000
Rotor components
Bearing parts
See rating plate information
See rating plate information
- - ≥ 12000
Turbine blades
(due to wear)
Table 4: Expected replacement intervals [h]
GAS
MDO = Marine Diesel Oil
HFO = Heavy Fuel Oil
= Gas
The specified values are guideline values and are not guaranteed, see influencing paramet-
ers.
© Copyright 2019 ABB. All rights reserved.
HZTL4065_EN
Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
3 Expected replacement intervals /
Influencing parameters
The actual values can deviate considerably from the guideline values, for example, due to the
following influences:
¡
¡
¡
¡
¡
¡
Fuel quality and fuel treatment
Load profile (thermal cycling, also number of starts/stops, emergency shutdowns)
Gas inlet temperature
Frequency and execution of turbine and compressor cleaning
Specification of the low-pressure stage
System-specific operating conditions (combustion quality, exhaust gas composition)
For bearing parts
¡
¡
¡
¡
Lubricating oil quality (oil filtering, oil condition, oil monitoring)
Load profile (speed, pressure conditions, temperature)
Number of starts/stops
Unbalance of the rotor (degree of contamination).
© Copyright 2019 ABB. All rights reserved.
HZTL4065_EN
Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
4 Disassembly and assembly / 4.1 Introduction
4
Disassembly and assembly
4.1
Introduction
CAUTION
Further operations
This Operation Manual may be used to carry out only those operations that
are described in it. Further operations that are executed in an incorrect way
can lead to serious damage to the machine.
u ABB Turbo Systems recommends having further operations carried out
only by trained personnel from an ABB Turbocharging Service Station.
u Mark the casing position for assembly.
Identification of the assembly devices
Not all assembly devices are marked with a part number. Identification is guaranteed by the
tool list. This list is enclosed 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 spare part set is available (see
Tightening torques for components
The specified bolted connection tightening torques must be observed (see chapter Table of
Tightening torques for assembly devices
Unless described otherwise, the screws and nuts of the assembly devices supplied by ABB
must be tightened so they rest firmly against the surface.
Definition of terms
¡
Suspension point
Defined loading point on a component or an assembly (blind hole thread, eyelet, lug).
© Copyright 2019 ABB. All rights reserved.
HZTL4065_EN
Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
4 Disassembly and assembly / 4.1 Introduction
¡
¡
Assembly device
Devices that are fitted on the low-pressure or high-pressure stage in order to obtain a
suspension point. Assembly devices are specially constructed and designed for the
defined use; they are not trading goods. Use assembly devices only for the described 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.
© Copyright 2019 ABB. All rights reserved.
HZTL4065_EN
Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
4 Disassembly and assembly / 4.2 Weights of assemblies
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 Filter silencer
190
60
70
70
190
25
02 Air suction branch
03 Injection ring for air
04 Injection ring for blowby
05 Wall insert
06 Diffuser
07 Compressor casing
08 Cartridge group
09 Turbine diffuser
10 Nozzle ring
210
330
40
15
Table 5: Weights of the assemblies
© Copyright 2019 ABB. All rights reserved.
HZTL4065_EN
Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
4 Disassembly and assembly / 4.3 Removing the filter silencer and in-
jection ring
4.3
Removing the filter silencer and injection ring
u Dismantle insulation as far as necessary.
u If present: Disconnect supply line for compressor cleaning from filter silencer.
Fig. 4: Removing the filter silencer and injection ring
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 silen-
cer (81000).
2. Loosen nuts (72004) and remove with washers (72003).
3. Remove and put down filter silencer.
4. Loosen and remove nuts (77022). Remove sleeves (77023).
5. Secure injection ring (73000) for air to lifting gear with swivel lifting eye (90231).
6. Remove and put down injection ring (73000) for air.
7. Secure injection ring (73000) for blowby to lifting gear with swivel lifting eye (90231).
8. Remove and put down injection ring (73000) for blowby.
© Copyright 2019 ABB. All rights reserved.
HZTL4065_EN
Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
4 Disassembly and assembly / 4.4 Removing air suction branch and in-
jection ring
4.4
Removing air suction branch and injection ring
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. 5: Removing air suction branch and injection ring
1. Loop around air suction branch (82000) with lifting gear.
2. Loosen nuts (72004) and remove with washers (72003).
3. Remove and put down the air suction branch (82000).
4. Secure injection ring (73000) for air to lifting gear with swivel lifting eye (90231).
5. Remove and put down injection ring (73000) for air.
6. Secure injection ring (73000) for blowby to lifting gear with swivel lifting eye (90231).
7. Remove and put down injection ring (73000) for blowby.
© Copyright 2019 ABB. All rights reserved.
HZTL4065_EN
Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
4 Disassembly and assembly / 4.5 Axial clearance A prior to disas-
sembly
4.5
Axial clearance A prior to disassembly
CAUTION
Clearances outside 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).
Axial clearance A
[mm]
0.32 ... 0.53
Table 6: Axial clearance A
© Copyright 2019 ABB. All rights reserved.
HZTL4065_EN
Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
4 Disassembly and assembly / 4.6 Removing wall insert
4.6
Removing wall insert
CAUTION
Clearance between compressor wheel and wall insert
Serious damage to machinery or 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. Use three press-off screws (90920) to press off the wall insert (77000) until the lifting
device can be fitted.
2. Remove the press-off screws (90920).
3. Remove two studs (72002) in the upper area.
© Copyright 2019 ABB. All rights reserved.
HZTL4065_EN
Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
4 Disassembly and assembly / 4.6 Removing wall insert
Fig. 8: Removing wall insert 2
4. Unplug cable connector (86515) and fix speed measurement cable in wall insert.
5. Fit bracket (90030) with screws (90955) and nuts (90415).
Fit two plates (90031) and secure with plate (90032), screw (90656) and nut (90432).
6. Secure lifting gear to swivel lifting eye (90231).
7. Carefully move out wall insert.
Fig. 9: Removing wall insert 3
8. Fit support angle (90480) with screws (90955) and nut (90415).
9. Put down the wall insert (77000).
10. Remove plate (90032), screw (90656), nut (90432) and plates (90031).
Remove lifting gear and bracket (90030).
11. Remove O-rings (77040 / 79020 / 79021).
12. Loosen screws (77016) and remove diffuser (79000).
© Copyright 2019 ABB. All rights reserved.
HZTL4065_EN
Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
4 Disassembly and assembly / 4.7 Removing the compressor casing
4.7
Removing the compressor casing
Fig. 10: Removing the compressor casing 1
1. Remove 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 screws (90924).
7. Move out compressor casing (72000) and put down.
© Copyright 2019 ABB. All rights reserved.
HZTL4065_EN
Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
4 Disassembly and assembly / 4.8 Removing the cartridge group
4.8
Removing the cartridge group
CAUTION
Clearance between blade tip and casing
Serious damage to machinery or property can result from 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. 12: Moving out cartridge group 1
1. Remove the O-ring (42012).
2. Loosen and remove the screws (42087).
3. Fit swivel lifting eye (90231) to bracket (90030) and screw bracket to cartridge group
with two screws (90955).
4. Fit five plates (90031) and secure with plate (90032), screw (90656) and nut (90432).
5. Secure lifting gear to swivel lifting eye (90231) and secure cartridge group to crane.
6. Evenly press off cartridge group by screwing three press-off screws (90920) into the des-
ignated holes.
© Copyright 2019 ABB. All rights reserved.
HZTL4065_EN
Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
4 Disassembly and assembly / 4.8 Removing the cartridge group
Fig. 13: Moving out cartridge group 2
7. Carefully move out cartridge group.
8. Put cartridge group 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 transport the cartridge group.
Fig. 14: Putting down cartridge group onto cover
© Copyright 2019 ABB. All rights reserved.
HZTL4065_EN
Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
4 Disassembly and assembly / 4.9 Removing turbine diffuser and
nozzle ring
4.9
Removing turbine diffuser and nozzle ring
Fig. 15: Removing turbine diffuser and nozzle 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 bracket (90030) with screws (90955) and nuts (90415).
6. Do not fit front bolt (90033) yet.
© Copyright 2019 ABB. All rights reserved.
HZTL4065_EN
Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
4 Disassembly and assembly / 4.9 Removing turbine diffuser and
nozzle ring
Fig. 17: Removing turbine diffuser and nozzle ring 3
1. Insert bracket with guide tube into connecting flange.
2. Secure guide tube with bolt (90033).
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 screws (90902).
8. Loosen screws (56017) with box spanner insert (90770) and remove together with clamps
(56018).
9. Remove nozzle ring (56001).
© Copyright 2019 ABB. All rights reserved.
HZTL4065_EN
Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
4 Disassembly and assembly / 4.10 Installing the nozzle ring and tur-
bine diffuser
4.10
Installing the nozzle ring and turbine diffuser
Fig. 19: Installing the nozzle ring and turbine diffuser 1
Part number
Thread and tightening torque
56017
M8 Tx40
25 Nm
Table 7: Tightening torque (56017)
1. Fit nozzle ring (56001).
2. Coat thread of screws (56017) with high-temperature grease. Fit clamps (56018) and
screws (56017).
3. Tighten screws with torque spanner using the box spanner insert (90770). 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: Removing turbine diffuser and nozzle ring 3
6. Insert turbine diffuser (63000) via the guide studs.
7. Coat a screw (61056) with high-temperature grease and screw in to secure the turbine
diffuser.
© Copyright 2019 ABB. All rights reserved.
HZTL4065_EN
Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
4 Disassembly and assembly / 4.10 Installing the nozzle ring and tur-
bine diffuser
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.
© Copyright 2019 ABB. All rights reserved.
HZTL4065_EN
Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
4 Disassembly and assembly / 4.11 Installing the cartridge group
4.11
Installing the cartridge group
CAUTION
Clearance between blade tip and casing
Serious damage to machinery or property can result from 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 lifting
eye.
3. Fit five plates (90031) and secure with plate (90032), screw (90656) and nut (90432).
4. Lift the cartridge group.
© Copyright 2019 ABB. All rights reserved.
HZTL4065_EN
Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
4 Disassembly and assembly / 4.11 Installing the cartridge group
Fig. 23: Inserting the cartridge group
Part number
Thread and tightening torque
42087
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 screws.
Observe the tightening torque.
7. Fit a new O-ring (42012).
© Copyright 2019 ABB. All rights reserved.
HZTL4065_EN
Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
4 Disassembly and assembly / 4.11 Installing the cartridge group
Control dimension after installing cartridge group
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 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 cartridge group, the control dimension (X) must be measured.
Control dimension X
[mm]
63.0 ±0.1
Table 10: Control dimension X
© Copyright 2019 ABB. All rights reserved.
HZTL4065_EN
Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
4 Disassembly and assembly / 4.12 Installing the compressor casing
4.12
Installing the compressor casing
Fig. 25: Installing the compressor casing
Part number
Thread and tightening torque
61037
M16
250 Nm
61037 (nuts that are difficult to access)
72021
Pre-tightening torque 60 Nm
Tightening torque angle 90° ±5°
M10x20
70 Nm
Table 11: Tightening torque (61037 / 72021)
1. Secure lifting gear to swivel lifting eye (90231) and insert compressor casing.
2. Fit nuts (61037). Observe the tightening torque.
3. Remove plates (90031) and bracket (90030).
4. Fit screw (72021). Observe the tightening torque.
© Copyright 2019 ABB. All rights reserved.
HZTL4065_EN
Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
4 Disassembly and assembly / 4.13 Installing the wall insert
4.13
Installing the wall insert
CAUTION
Clearance between compressor wheel and wall insert
Serious damage to machinery or 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. 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. Fit two plates (90031) and secure with plate (90032), screw (90656) and nut (90432).
5. Lift the wall insert and remove the support angle (90480).
6. Carefully insert the wall insert.
© Copyright 2019 ABB. All rights reserved.
HZTL4065_EN
Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
4 Disassembly and assembly / 4.13 Installing the wall insert
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.
© Copyright 2019 ABB. All rights reserved.
HZTL4065_EN
Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
4 Disassembly and assembly / 4.14 Axial clearance A after assembly
4.14
Axial clearance A after assembly
CAUTION
Clearances outside 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. 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).
Axial clearance A
[mm]
0.32 ... 0.53
Table 14: Axial clearance A
© Copyright 2019 ABB. All rights reserved.
HZTL4065_EN
Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
4 Disassembly and assembly / 4.15 Installing injection ring and air suc-
tion branch
4.15
Installing injection ring and air suction branch
Fig. 29: Installing the air suction branch
Part number
Thread and tightening torque
72004
M16
200 Nm
Table 15: Tightening torque (72004)
1. Secure injection ring (73000) for blowby to lifting gear with swivel lifting eye (90231).
2. Fit injection ring (73000) for blowby and remove lifting gear.
3. Secure injection ring (73000) for air to lifting gear with swivel lifting eye (90231).
4. Fit injection ring (73000) for air and remove lifting gear.
5. Loop around air suction branch (82000) and secure to lifting gear.
6. Fit air suction branch (82000) and remove lifting gear.
7. Fit nuts (72004) with washer (72003). Observe the tightening torque.
u Reinstall dismantled insulation.
u Reinstall all air lines according to the instructions of the enginebuilder.
© Copyright 2019 ABB. All rights reserved.
HZTL4065_EN
Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
4 Disassembly and assembly / 4.16 Installing the injection ring and fil-
ter silencer
4.16
Installing the injection ring and filter silencer
Fig. 30: Installing the injection ring and filter silencer
Part number
Thread and tightening torque
72004
M16
200 Nm
72004 (nuts that are difficult to access)
Pre-tightening torque 60 Nm
Tightening angle 60° ±5°
77022
150 Nm
Table 16: Tightening torque (72004 / 77022)
1. Secure injection ring (73000) for blowby to lifting gear with swivel lifting eye (90231).
2. Fit injection ring (73000) for blowby and remove lifting gear.
3. Secure injection ring (73000) for air to lifting gear with swivel lifting eye (90231).
4. Fit injection ring (73000) for air and remove lifting gear.
5. Fit sleeves (77023) and nuts (77022) in accordance with position of filter silencer and
tighten nuts (77022).
6. 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 silen-
cer (81000).
7. Fit the filter silencer.
8. Fit nuts (72004) and washers (72003) and tighten nuts (72004).
u If present: Fit supply line for compressor cleaning to filter silencer.
u Reinstall dismantled insulation.
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HZTL4065_EN
Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
4 Disassembly and assembly / 4.17 Table of tightening torques
The following tightening torques [Nm] must be observed for the designated 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
M16x334
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
M16
150 Nm
Table 17: Tightening torques
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Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
5 Taking out of operation at short notice / 5.1 Possible emergency re-
pairs
5
Taking out of operation at short notice
5.1
Possible emergency repairs
WARNING
Danger of fire and explosion due to lubricating oil leaks
Leaking oil may ignite on hot surfaces. This can result in serious injuries to
personnel or fatal accidents.
u Cordon off danger area.
u 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
on the engine.
u Follow the directives of the enginebuilder.
If damage has occurred to the low-pressure stage and the engine has to be brought back
into operation again as quickly as possible, the following emergency repair option is avail-
able:
¡
Attaching the cover plate
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HZTL4065_EN
Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
5 Taking out of operation at short notice / 5.1 Possible emergency re-
pairs
5.1.1
Manufacturing the cover plate
The cover plate and the other parts that 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
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 (gasket), sleeves and screws, dimensions [mm]
Ø1
Ø2
Ø3
Ø4
Ø5
B1
B2
L1
M1
655
600
14
14
20
10
32
60
M12
Table 18: Cover plate / gasket
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Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
5 Taking out of operation at short notice / 5.1 Possible emergency re-
pairs
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
Complete sealing of the lubricating oil supply is not guaranteed with the
cover plate fitted.
u Shut off lubricating oil supply to low-pressure stage at engine side.
© Copyright 2019 ABB. All rights reserved.
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Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
6 Spare parts / 6.1 Ordering spare parts
6
Spare parts
6.1
Ordering spare parts
CAUTION
Spare part storage
All spare parts that were ordered together with the low-pressure and/or
high-pressure stage must be kept intact and ready for use.
u Carefully clean any rusted parts and grease them.
Please quote the following 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 environmentally-friendly and professional
manner in accordance with the local regulations.
u Dispose of the packaging of new parts in an environmentally-friendly and professional
manner in accordance with the local regulations.
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HZTL4065_EN
Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
6 Spare parts / 6.1 Ordering spare parts
Required customer spare part set (97070) for a low-pressure 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
42012 / 79020
42017
Designation
O-ring
O-ring
Quantity
2
1
42018
42087
56017
56018
61037
61056
72003
72004
O-ring
2
1
Hexagon-head screw
Hexalobular-head screw
Clamp
Hexagon nut
Hexagon-head screw
Washer
Hexagon nut
Hexagon-head screw
O-ring
3
3
3
8
3
4
5
1
77016
77040
79021
O-ring
1
Table 20: Customer spare part set (97070)
© Copyright 2019 ABB. All rights reserved.
HZTL4065_EN
Rev.B
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Operation Manual / Power2 650-M / 4.1 Low-pressure stage
6 Spare parts / 6.1 Ordering spare parts
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HZTL4065_EN
Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
6 Spare parts / 6.2 View of low-pressure stage with part numbers
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)
© Copyright 2019 ABB. All rights reserved.
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Rev.B
August 2019
Operation Manual / Power2 650-M / 4.1 Low-pressure stage
6 Spare parts / 6.2 View of low-pressure stage with part numbers
Part number
Designation
01
42001
Cartridge group
Bearing casing
O-ring
42012 (in customer spare part set)
42017 (in customer spare part set)
O-ring
42018 (in customer spare part set)
O-ring
42087 (in customer spare part set)
51001
51001
56001
Hexagon-head screw
Gas inlet casing, radial
Gas inlet casing, axial
Nozzle ring
56017 (in customer spare part set)
56018 (in customer spare part set)
Hexalobular-head screw
Clamp
61001
61009
Gas outlet casing
Hexagon-head screw
Hexagon nut
61037 (in customer spare part set)
61050
Spiral-wound gasket
Hexagon-head screw
Turbine diffuser
Foot, turbine end
Compressor casing
Stud
61056 (in customer spare part set)
63000
68002
72000
72002
72003 (in customer spare part set)
Washer
72004 (in customer spare part set)
Hexagon nut
72021
73000
73000
77000
Socket screw
Injection ring (Air)
Injection ring (Blowby)
Wall insert
77016 (in customer spare part set)
77023
Hexagon-head screw
Sleeve
77040 (in customer spare part set)
79000
O-ring
Diffuser
79020 (in customer spare part set)
79021 (in customer spare part set)
82000
O-ring
O-ring
Air suction branch
Speed sensor / connecting cable
86505 / 86515
Table 21: Low-pressure stage part numbers
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Rev.B
August 2019
Operation Manual / Power2 650-M / 4.2 High-pressure stage
Table of contents
High-pressure stage
Further applicable documents ............................................................................. 2
Removal and installation ...................................................................................... 3
Removing the high-pressure stage........................................................................... 4
Expected replacement intervals ........................................................................ 13
Disassembly and assembly................................................................................. 15
Introduction .................................................................................................................. 15
Removing the compressor casing............................................................................ 18
Removing the cartridge group.................................................................................. 19
Installing the cartridge group .................................................................................. 22
Installing the compressor casing ............................................................................ 25
Radial clearances N and R.......................................................................................... 26
Table of tightening torques...................................................................................... 28
Taking out of operation at short notice........................................................... 29
Possible emergency repairs...................................................................................... 29
Installing a replacement cartridge group .............................................................. 30
Spare parts ........................................................................................................... 35
Ordering spare parts.................................................................................................. 35
Tables .................................................................................................................... 39
© Copyright 2019 ABB. All rights reserved.
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Revision A
March 2019
Operation Manual / Power2 650-M / 4.2 High-pressure stage
1 Further applicable documents /
1
Further applicable documents
Chapter
Document number
HZTL4004
HZTL4021
Operation Manual / Power2 / 1 Introduction
Operation Manual / Power2 / 2 Safety
Operation Manual / Power2 / 3 Safety data sheet *)
Operation Manual / Power2 600-M / 4 Product description
Table 1: Related documents
Power2 serial number (HT……)
HZTL4064
*) This chapter is only present in serialised operation manuals.
© Copyright 2019 ABB. All rights reserved.
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Operation Manual / Power2 650-M / 4.2 High-pressure stage
2 Removal and installation / 2.1 Transport / weight
2
Removal and installation
2.1
Transport / weight
Swivel lifting eyes to be used
Two swivel lifting eyes (S) are required for the safe lifting of loads. These are not included in
the ABB Turbo Systems scope of delivery.
The requirements of the swivel lifting eyes are listed in the table. The operating instructions
provided by the swivel lifting eye manufacturer should be observed.
Swivel lifting eye (S)
Power2 Thread
650 HP M16
Length
Minimum load
limit
Lmin
20 mm
Lmax
30 mm
750 kg
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 specifications apply to the heaviest variant possible.
Depending on the specification, the weight specified on the rating plate may be lower than
the standard values specified here.
Complete high-pressure stage
Suspension
Weight
750 kg
Table 3: Transport / weight of high-pressure stage
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Operation Manual / Power2 650-M / 4.2 High-pressure stage
2 Removal and installation / 2.2 Removing the high-pressure stage
2.2
Removing the high-pressure stage
Preparing for removal
u Disconnect all pipes according to the instructions of the enginebuilder.
Fig. 1: Removing the high-pressure stage
1. Loosen screws (72013) between bellows (82300) and compressor casing (72000) and re-
move with washer (72014). The air suction branch (82000) with the bellows does not have
to be dismantled 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 (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) with penetrating oil and allow it to take
effect. Do not oil the pressure screws of the clamping nut (42201).
4. Secure lifting gear to high-pressure stage with two swivel lifting eyes (01).
u Loosen the clamping nuts (42201) in accordance with the following section.
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Operation Manual / Power2 650-M / 4.2 High-pressure stage
2 Removal and installation / 2.2 Removing the high-pressure stage
2.2.1
Loosening the clamping nut
CAUTION
Incorrect procedure can make loosening impossible
If individual pressure screws are fully relieved, the pressure screws can be-
come compressed, making it impossible to loosen them.
u Comply with the following steps for loosening the pressure screws.
CAUTION
Do 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 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. 2: 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 each pressure screw by 90° in 1...5 rounds until all of the pres-
sure screws have been relieved.
u Loosen clamping nut by hand.
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Operation Manual / Power2 650-M / 4.2 High-pressure stage
2 Removal and installation / 2.2 Removing the high-pressure stage
Removing the high-pressure stage
Fig. 3: Removing the high-pressure stage
1. Unscrew the threaded rods (42191) until they have been completely removed from the en-
gine support and the centre sleeve (42193).
2. Check whether the threaded rods (42191) can be moved.
3. Screw the threaded rods back into the centre sleeve by a few revolutions.
4. Manually lift threaded rods (42191) until the centring bushes (42193) are in the bearing
casing. If necessary, shake the threaded rods until the centre sleeves (42193) release
themselves from the engine support.
5. Screw down clamping nuts (42201) to the end of the expansion bush (42190). The
threaded rod remains in position.
6. Remove the high-pressure stage.
7. Cover the oil connections (01) in the bracket to protect them from dirt.
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Operation Manual / Power2 650-M / 4.2 High-pressure stage
2 Removal and installation / 2.3 Installing the high-pressure stage
2.3
Installing the high-pressure stage
2.3.1
Inserting gaskets
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. 4: Gaskets in the slots of the bearing casing
42001
42198
42199
01
Bearing casing
O-ring
O-ring
Oil supply
Oil drains
02
The oil is supplied (01) and drained (02) through the bracket.
u Insert the O-rings (42198 and 42199) into the slots of the bearing casing.
© Copyright 2019 ABB. All rights reserved.
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Operation Manual / Power2 650-M / 4.2 High-pressure stage
2 Removal and installation / 2.3 Installing the high-pressure stage
2.3.2
Placing the high-pressure stage on the bracket
Fig. 5: Preparing the fastening 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 centring bush (42193) flush onto the threaded rod from below.
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Operation Manual / Power2 650-M / 4.2 High-pressure stage
2 Removal and installation / 2.3 Installing the high-pressure stage
Fig. 6: Placing the high-pressure stage on the bracket
1. Lightly lubricate hole into which centering bush (42193) is inserted with screw grease.
2. Position threaded rod with centering bush into bracket and insert until stop.
3. Carefully lower high-pressure stage onto bracket and position using the centering
bushes (42193) located in 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 ½ revolution (this will loosen the centering bush
which may have jammed the rod). Then continue screwing in.
If value L is not reached, undo the screw connection, carefully take the high-pressure
stage off the bracket and repeat the procedure starting with Step 1.
u Observe the steps for fastening the high-pressure stage (see following section).
Value X
Value L
135 ±2 mm
70 mm
Table 4: Values X and L
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Operation Manual / Power2 650-M / 4.2 High-pressure stage
2 Removal and installation / 2.3 Installing the high-pressure stage
2.3.3
Steps for fastening the high-pressure stage
Fig. 7: 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.
u Connect all gas pipes and air lines.
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Operation Manual / Power2 650-M / 4.2 High-pressure stage
2 Removal and installation / 2.3 Installing the high-pressure stage
2.3.4
Tightening the clamping nut
Preparations for tightening the clamping nut
CAUTION
Do not clean pressure screws (04)
The pressure screws are equipped with a permanent sliding layer that must
not be removed.
Do neither clean nor lubricate the pressure screws. In case of non-compli-
ance, it cannot be ensured that the 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. 8: Preparing the clamping nut for the tightening procedure
1. Clean the thread of the bolt (01) and the contact surface.
2. Lightly oil the bolt thread.
3. Position the thrust washer (02) in place.
4. Tighten clamping nut (03) by hand.
5. Unscrew clamping nut (03) by ¼ of a turn (90°).
The distance between the thrust washer and the clamping nut is now about 1 mm.
© Copyright 2019 ABB. All rights reserved.
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Operation Manual / Power2 650-M / 4.2 High-pressure stage
2 Removal and installation / 2.3 Installing the high-pressure stage
Tightening pressure screws
Fig. 9: Tightening pressure screws
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 100 % in 5 … 7 rounds until the required residual tightening
angle of < 20° is achieved.
© Copyright 2019 ABB. All rights reserved.
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Revision A
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Operation Manual / Power2 650-M / 4.2 High-pressure stage
3 Expected replacement intervals /
3
Expected replacement intervals
Rotating components
The recommended replacement intervals for compressor and turbine wheels are specified
based on the safety concept for rotating parts (SIKO) and dependant on the operating con-
ditions. These intervals are shown on the rating plate of the low-pressure and high-pressure
stage.
Non-rotating components
Depending on the system-specific operating conditions, a differentiation must be made
between the intervals to be 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 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
25000 … 50000
25000 … 50000
25000 … 50000
25000 … 50000
25000 … 50000
20000
HFO
Turbine casing
Nozzle ring
Gas outlet flange
Heat shield
25000
25000
25000
25000
25000
20000
Heat sheet metal
Collecting grid in gas outlet casing
Rotor components
Bearing parts
See rating plate data
12000 … 24000
Other casings
50000
50000
Table 5: Expected replacement intervals [h]
GAS
MDO = Marine Diesel Oil
HFO = Heavy Fuel Oil
= Gas
The specified values are guideline values and are not guaranteed, see influence parameters.
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Operation Manual / Power2 650-M / 4.2 High-pressure stage
3 Expected replacement intervals /
Influencing parameters
The actual values can deviate considerably from the guideline values, for example, due to the
following influences:
¡
¡
¡
¡
¡
¡
¡
Fuel quality and fuel treatment
Load profile (thermal cycling, also number of starts/stops, emergency shutdowns)
Gas inlet temperature
Frequency and execution of turbine and compressor cleaning
Specification of the 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 monitoring)
Load profile (speed, pressure conditions, temperature)
Number of starts/stops
Imbalance of the rotor (degree of contamination).
© Copyright 2019 ABB. All rights reserved.
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Operation Manual / Power2 650-M / 4.2 High-pressure stage
4 Disassembly and assembly / 4.1 Introduction
4
Disassembly and assembly
4.1
Introduction
The precondition for the work described in the following is a high-pressure stage that has
CAUTION
Further operations
This Operation Manual may be used to carry out only those operations that
are described in it. Further operations that are executed in an incorrect way
can lead to serious damage to the machine.
u ABB Turbo Systems recommends having further operations carried out
only by trained personnel from an ABB Turbocharging Service Station.
u Mark the casing position for assembly.
Identification of the assembly devices
Not all assembly devices are marked with a part number. Identification is guaranteed by the
tool list. This list is enclosed 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 spare part set is available (see
Oil orifice
u When disassembling the high-pressure stage, an oil orifice fitted in the oil inlet must not
be removed (also see chapter Removing the cartridge group).
Tightening torques for components
The specified bolted connection tightening torques must be observed (see chapter Table of
© Copyright 2019 ABB. All rights reserved.
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Operation Manual / Power2 650-M / 4.2 High-pressure stage
4 Disassembly and assembly / 4.1 Introduction
Tightening torques for assembly devices
Unless described otherwise, the screws and nuts of the assembly devices supplied by ABB
must be tightened so they rest firmly against the surface.
Definition of terms
¡
Suspension point
Defined loading point on a component or an assembly (blind hole thread, eyelet, lug).
¡
Assembly device
Devices that are fitted on the low-pressure or high-pressure stage in order to obtain a
suspension point. Assembly devices are specially constructed and designed for the
defined use; they are not trading goods. Use assembly devices only for the described 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.
Swivel lifting eyes to be used
Two swivel lifting eyes (S) are required for the safe lifting of loads. These are not included in
the ABB Turbo Systems scope of delivery.
The requirements of the swivel lifting eyes are listed in the table. The operating instructions
provided by the swivel lifting eye manufacturer must be observed for the application.
Swivel lifting eye (S)
Power2 Thread
Length
Minimum load
limit
Lmin
Lmax
25 mm
30 mm
650 HP
M10
M16
15 mm
20 mm
400 kg
750 kg
Table 6: Swivel lifting eyes to be used
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Operation Manual / Power2 650-M / 4.2 High-pressure stage
4 Disassembly and assembly / 4.2 Weights of assemblies
4.2
Weights of assemblies
The specified weights of the individual parts or assemblies are rounded-up standard values.
Fig. 10Weights of the assemblies
Designation
Weight
[kg]
95
01
02
03
04
05
06
07
08
Radial air suction branch
Bellows
60
Compressor casing
Wall insert
Diffuser
Cartridge group
Nozzle ring
Turbine casing
160
30
12
160
6
220
Table 7: Weights of the assemblies
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Operation Manual / Power2 650-M / 4.2 High-pressure stage
4 Disassembly and assembly / 4.3 Removing the compressor casing
4.3
Removing the compressor casing
u Mark the casing position for assembly.
u Measure radial clearance N before removing the compressor casing (72000) (see chapter
u Remove expansion bushes and threaded rods from bearing casing.
Fig. 11: 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 nuts (77022) and remove with washer (77021). Wall insert (77000) is loose.
5. Remove O-ring (77005).
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Operation Manual / Power2 650-M / 4.2 High-pressure stage
4 Disassembly and assembly / 4.4 Removing the cartridge group
4.4
Removing the cartridge group
u Mark the casing position for assembly.
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.
Fig. 12: Oil orifice in the bearing casing
01 Bearing casing
02 Oil orifice
03 Circlip
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Operation Manual / Power2 650-M / 4.2 High-pressure stage
4 Disassembly and assembly / 4.4 Removing the cartridge group
WARNING
Looping the lifting gear around the cartridge group
The looped lifting gear can slip off and lead to serious injuries to persons or
even to fatal accidents.
u Make sure the surface for the loop on the cartridge group is free from oil.
Wear safety gloves to protect against mechanical hazards.
Wear safety helmet.
Fig. 13: Removing the cartridge 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 cartridge group with fitted expansion sleeves (42190) on service support (90012).
7. Hand-tighten the cartridge group with the threaded rod (42191) and the clamping nut
(42201) on the service support (90012).
8. Remove metal C-ring (51105).
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Operation Manual / Power2 650-M / 4.2 High-pressure stage
4 Disassembly and assembly / 4.4 Removing the cartridge group
Removing the nozzle ring
Fig. 14: Removing the nozzle ring
1. Pull out the nozzle ring (56001) by hand.
2. Remove the lamellar sealing ring (56005) from the nozzle ring and replace it with a new
one after cleaning the nozzle ring.
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Operation Manual / Power2 650-M / 4.2 High-pressure stage
4 Disassembly and assembly / 4.5 Installing the cartridge group
4.5
Installing the cartridge group
Nozzle ring compression
In order for the nozzle ring (56001) to be fixed during operation, it must be clamped
between the heat shield (43001) and the turbine casing (51000).
Fig. 15: Nozzle ring compression PD
42001
43001
51000
56001
Bearing casing
Heat shield
Turbine casing
Nozzle ring
1. Measure dimensions A, B, and S on cleaned surfaces.
2. Calculate compression (PD).
Compression PD
0.09 ... 0.37 mm
Table 8: Nozzle ring compression PD
u If the calculated value (PD) lies outside the specified range, contact an ABB Turbochar-
ging Service Station.
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Operation Manual / Power2 650-M / 4.2 High-pressure stage
4 Disassembly and assembly / 4.5 Installing the cartridge group
Installing the nozzle ring
NOTICE
Chamfering (02) on nozzle ring and turbine casing
The nozzle ring (56001) can only be fitted into the turbine casing (51000) if
both of the chamferings (02) on diameter D are aligned with one another.
Fig. 16: Installing the nozzle ring
1. Fit the lamellar sealing ring (56005) in the nozzle ring (56001). Make sure the lamellar
sealing ring is fitted correctly in the right slot (see above illustration).
2. Insert the nozzle ring into the turbine casing as far as it will go and check for correct pos-
itioning, chamfering (02).
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Operation Manual / Power2 650-M / 4.2 High-pressure stage
4 Disassembly and assembly / 4.5 Installing the cartridge group
Installing the cartridge group
WARNING
Looping the lifting gear around the cartridge group
The looped lifting gear can slip off and lead to serious injuries to persons or
even to fatal accidents.
u Make sure the surface for the loop on the cartridge group is free from oil.
Wear safety gloves to protect against mechanical hazards.
Wear safety helmet.
Fig. 17: Installing the cartridge group
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° and also loop lifting gear around cartridge group (10900)
as shown.
5. Move cartridge group into turbine casing. When doing this, ensure that the metal C-
ring (51105) is not crushed at one side.
6. Secure fastening strips (51002) together with nuts (51007) and secure and tighten the
Verbus Ripp® washers (51003).
Part number
Tightening torque [Nm]
51007
M12
75
Table 9: Tightening torque (51007)
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Operation Manual / Power2 650-M / 4.2 High-pressure stage
4 Disassembly and assembly / 4.6 Installing the compressor casing
4.6
Installing the compressor casing
Fig. 18: Installing the compressor casing
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 (79000) with screw (42007).
6. Insert new O-ring (42012).
7. Position compressor casing (72000) on cartridge group (10900).
8. Fit the fastening strips (72012) with screws (72011) and tighten.
Part number
Tightening torque [Nm]
42007
M10
50
72011
M12
130
77022
M10
75
Table 10: Tightening torques (42007, 72011, 77022)
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Operation Manual / Power2 650-M / 4.2 High-pressure stage
4 Disassembly and assembly / 4.7 Radial clearances N and R
4.7
Radial clearances N and R
4.7.1
Measuring radial clearances N and R
Fig. 19: Measuring clearances N and R
Clearance N
0.50 ... 0.80 mm
Clearance R
0.65 ... 1.00 mm
Table 11: Permissible clearances N and R
1. Push the feeler gauges (01) into the gap such that there is no clearance. The upper direc-
tion (N1) and lower direction (N2) must be covered simultaneously.
2. Calculate clearance N and compare it with the permissible values in the table.
3. Push the feeler gauges (01) into the gap such that there is no clearance. The upper direc-
tion (R2) and lower direction (R1) must be covered simultaneously.
4. Calculate clearance R and compare it with the permissible values in the table.
CAUTION
Clearances outside 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.
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Operation Manual / Power2 650-M / 4.2 High-pressure stage
4 Disassembly and assembly / 4.8 Axial clearance A and radial clear-
ance B
4.8
Axial clearance A and radial clearance B
4.8.1
Measuring clearance A and B
u Measure and record clearances A and B after the removal and before the installation of
the cartridge group.
u Attach the dial indicator and align it for the respective clearance as per the illustration.
Fig. 20: Measuring clearance A and B
Axial clearance A
0.24 ... 0.44 mm
Radial clearance B
0.91 ... 1.51 mm
Table 12: Permissible 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 permissible values in the table.
CAUTION
Clearances outside 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.
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Operation Manual / Power2 650-M / 4.2 High-pressure stage
4 Disassembly and assembly / 4.9 Table of tightening torques
4.9
Table of tightening torques
Fig. 21: Overview of tightening torques
The following tightening torques [Nm] must be observed for the designated screw fittings:
Part number
Thread / tightening torque [Nm]
01
02
03
04
05
06
07
08
09
10
11
72005, 82005, 82007
M18x1.5
60
82022
72013
77022
42007
72011
42009
51007
M12
85
M12
85
M10
75
M10
50
M12
130
M20
65
M12
75
61072
M12
(V-clamp)
60
86505
M12x1.5
15
42188
M12x1.5
35
Table 13: Tightening torques [Nm]
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Operation Manual / Power2 650-M / 4.2 High-pressure stage
5 Taking out of operation at short notice / 5.1 Possible emergency re-
pairs
5
Taking out of operation at short notice
5.1
Possible emergency repairs
WARNING
Danger of fire and explosion due to lubricating oil leaks
Leaking oil may ignite on hot surfaces. This can result in serious injuries to
personnel or fatal accidents.
u Cordon off danger area.
u 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
on the engine.
u Follow the directives of the enginebuilder.
If the engine has to be brought back into operation again as quickly as possible in the event
of a low-pressure or high-pressure stage defect, there are options for emergency repairs:
¡
¡
If present: Fit replacement cartridge group.
If a replacement cartridge group is not available: Fit cover plate and contact an ABB Tur-
bocharging Service Station.
u Observe the following sections in connection with the emergency repairs mentioned.
© Copyright 2019 ABB. All rights reserved.
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Operation Manual / Power2 650-M / 4.2 High-pressure stage
5 Taking out of operation at short notice / 5.2 Installing a replacement
cartridge group
5.2
Installing a replacement cartridge group
The repair of a cartridge group requires special tools and the expertise of an ABB Turbochar-
ging Service Station. The rotating parts rotate extremely fast, and are sensitive to unbal-
ance.
WARNING
Cartridge group
Incorrect handling of a cartridge group can damage the low-pressure or
high-pressure stage and cause injuries to persons.
u Always have repairs to the cartridge group carried out by an ABB Tur-
bocharging Service Station.
NOTICE
Quick recommissioning
To enable you to put a defective low-pressure or high-pressure stage back
into operation quickly, ABB Turbo Systems recommends having a replace-
ment cartridge group available in stock. A replacement cartridge group can
be installed within a short period of time, and the low-pressure or high-pres-
sure stage can be operated again.
A replacement cartridge group is ready for use immediately and includes the complete bear-
ing casing with bearing and a balanced rotor.
u For information on how to remove and install the cartridge group, see chapter Disas-
sembly and assembly.
u Send the defective cartridge group to an ABB Turbocharging Service Station for inspec-
tion and repair.
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Operation Manual / Power2 650-M / 4.2 High-pressure stage
5 Taking out of operation at short notice / 5.3 Fitting the cover plate
5.3
Fitting the cover plate
The cover plate has two functions. It seals the turbine casing from exhaust gas and the
bracket from oil leaks.
u Fit the turbine casing with the gas outlet casing into the gas pipe again.
u Attach the cover plate (see following section).
Fig. 22: Attaching the cover plate
1. With the high-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 into the
2. Close the opening in the turbine casing (51000) with the cover plate (01).
3. Thoroughly clean the fastening strips (51002) before assembly. Coat the threads of the
studs (51006) with high-temperature grease.
4. Fasten cover plate (01) to turbine casing (51000) with fastening strips (51002), Verbus
Ripp® washers (51003) and nuts (51007) and screw to bracket.
Part number
Tightening torque [Nm]
51007
M12
75
Table 14: Tightening torque (51007)
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Operation Manual / Power2 650-M / 4.2 High-pressure stage
5 Taking out of operation at short notice / 5.4 Cover plate drawing
5.4
Cover plate drawing
The cover plate is not included in the ABB Turbo Systems scope of delivery and must be
manufactured by the operating company according to the following drawing.
Material: General structural steel, in compliance with DIN EN 10025-2.
Fig. 23: Cover plate drawing
B1
± 0.5
120.5
B2
B3
B4
± 0.2
29.3
B5
B6
B7
ØD1
± 0.2
367
ØD2
R1
M
100
230
2
310
70.4
31
≤ 173
M10
Table 15: Cover plate dimensions [mm]
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Operation Manual / Power2 650-M / 4.2 High-pressure stage
5 Taking out of operation at short notice / 5.4 Cover plate drawing
Slots for O-rings in cover plate
Fig. 24: 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 16: Dimensions of cover plate, slots for O-rings [mm]
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Operation Manual / Power2 650-M / 4.2 High-pressure stage
5 Taking out of operation at short notice / 5.4 Cover plate drawing
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Operation Manual / Power2 650-M / 4.2 High-pressure stage
6 Spare parts / 6.1 Ordering spare parts
6
Spare parts
6.1
Ordering spare parts
Please quote the following 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.
Required customer spare part set (97070) for a high-pressure 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
42010
42012
42198
42199
51005
51105
56005
Designation
O-ring
O-ring
O-ring
O-ring
Socket screw
Metal C-ring
Lamellar sealing ring
O-ring
Quantity
1
1
1
1
3
1
1
1
77005
Table 17: Customer spare part set (97070)
CAUTION
Spare part storage
All spare parts that were ordered together with the low-pressure and/or
high-pressure stage must be kept intact and ready for use.
u Carefully clean any rusted parts and grease them.
u Dispose of replaced parts and parts that are not reusable in a professional and environ-
mentally compatible manner.
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Operation Manual / Power2 650-M / 4.2 High-pressure stage
6 Spare parts / 6.2 View of high-pressure stage with part numbers
6.2
View of high-pressure stage with part numbers
Fig. 25: High-pressure stage with part numbers
( . . . . . ) only available in customer spare part set (97070)
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Operation Manual / Power2 650-M / 4.2 High-pressure stage
6 Spare parts / 6.2 View of high-pressure stage with part numbers
Part number
42009
Designation
Screw plug
42010 (in customer spare part set)
O-ring
42012 (in customer spare part set)
O-ring
42190
42191
42193
42196
Expansion bush
Threaded rod
Centring bush
Orifice, oil inlet
Locking ring
O-ring
42197
42198 (in customer spare part set)
42199 (in customer spare part set)
O-ring
42201
51000
51002
51005
Clamping nut
Turbine casing
Fastening strip
Socket screw
Metal C-ring
Nozzle ring
51105 (in customer spare part set)
56001
56005 (in customer spare part set)
61003
61300
Lamellar sealing ring
Hexagon-head screw
Support
72000
72012
77000
Compressor casing
Fastening strip
Wall insert
77005 (in customer spare part set)
O-ring
79000
Diffuser
82000
82300
Air suction branch
Bellows
86505
Speed sensor
Table 18: High-pressure stage with part numbers
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Operation Manual / Power2 650-M / 4.3 Gas piping GEJ920
Table of contents
Gas piping
Commissioning and operating ............................................................................ 2
Periodic maintenance ........................................................................................... 3
Weight ............................................................................................................................. 4
Removing gas piping.................................................................................................... 4
Installing gas piping...................................................................................................... 5
Storage and disposal............................................................................................. 6
Spare parts ............................................................................................................. 7
View of gas piping with part numbers ..................................................................... 8
Tables .................................................................................................................... 10
© Copyright 2017 ABB. All rights reserved.
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Operation Manual / Power2 650-M / 4.3 Gas piping GEJ920
1 Commissioning and operating /
1
Commissioning and operating
Checks before commissioning
All components of the gas piping must be checked visually:
¡
¡
There must not be any damage to sealing surfaces (evenly fine surfaces)
There must not be any visible damage to the bellows (e.g. dents, cracks, scratches or
weld spatters).
¡
All criteria mentioned also apply to the C-ring gaskets. Moreover, they must not exhibit
any buckling.
Checks after commissioning (engine in idle mode)
u After starting the engine, check all gas pipes for leaks.
Discolourations on the insulation, the smell of exhaust gas and unusual noises (whistling,
hissing) can indicate small leaks. If such new and unusual signs are found, their cause must
be determined.
Noise emission
See main chapter 4 (Operation Manual / Power2 650-M / Product description)
Expected replacement interval
Product
Replacement interval [h]
Gas piping GEJ920
50000
Table 1: Expected replacement interval
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Operation Manual / Power2 650-M / 4.3 Gas piping GEJ920
2 Periodic maintenance /
2
Periodic maintenance
Component to be maintained
Gas piping
Recommended cleaning interval
Operating state
Engine stopped
At every disassembly
Table 2: Maintenance interval
The following maintenance work must be carried out on the gas piping:
u If present: Remove insulation.
u Perform a visual inspection for cracks and deposits.
Always replace bellows with cracks with a new bellows.
Remove any deposits found on the bellows mechanically (using brushes).
u Perform a visual inspection of the sealing points (flange connection to the gas inlet cas-
ing and gas outlet casing).
Always replace bellows with damaged sealing locations with a new bellows.
Always replace dismantled gaskets with new gaskets.
© Copyright 2017 ABB. All rights reserved.
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Operation Manual / Power2 650-M / 4.3 Gas piping GEJ920
3 Removal and installation / 3.1 Weight
3
Removal and installation
3.1
Weight
Product
Weight [kg]
Gas piping GEJ920
Table 3: Weight
30
3.2
Removing gas piping
Only use textile lifting gear to lift the gas piping.
Fig. 1: Removing gas piping
u Loosen nuts (51013) and remove with Verbus Ripp® washers (51012) and screws (51011).
u Loosen the V-clamp (61072) and slide at bellows side.
u Remove gas piping (85001) with metal C-rings (85002/61007).
© Copyright 2017 ABB. All rights reserved.
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Operation Manual / Power2 650-M / 4.3 Gas piping GEJ920
3 Removal and installation / 3.3 Installing gas piping
3.3
Installing gas piping
WARNING
Gas leakage
Gaskets that were installed incorrectly or are defective can lead to gas leaks.
u Dispose of used or defective gaskets.
u Always insert new gaskets.
Only use textile lifting gear to lift the gas piping.
Fig. 2: Installing gas piping
u Coat threads of all screws with high-temperature grease.
u Position gas piping (85001) with new metal C-rings (85002/61007).
u Fit V-clamp (61072) and tighten to the tightening torque specified in the table.
u Fit screws (51011) with Verbus Ripp® washers (51012) and nuts (51013) and tighten to the
tightening torque specified in the table.
Part number
Maximum tightening torque [Nm]
61072
60
325
230
51013 (nut with Verbus Ripp® washer)
51011 (screw)
Table 4: Tightening torque (51011 / 51013 / 61072)
The tightening torques for nut and screw specified in the table refer to the part which is
turned during tightening. The other part must be locked in place with a wrench.
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Operation Manual / Power2 650-M / 4.3 Gas piping GEJ920
4 Storage and disposal /
4
Storage and disposal
Storing gas piping
The bellows of the gas piping are made of rustproof chromium-nickel steel and can be
stored in their undamaged original packaging for an unlimited time.
They must be stored in such a way that mechanical damage to the parts can be excluded.
See also main chapter 4 (Operation Manual / Power2 650-M / Product description)
Disposing of gas piping components
See main chapter 4 (Operation Manual / Power2 650-M / Product description)
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Operation Manual / Power2 650-M / 4.3 Gas piping GEJ920
5 Spare parts / 5.1 Ordering spare parts
5
Spare parts
5.1
Ordering spare parts
Please quote the following 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.
Customer spare part set (97150) required to inspect the gas piping
For the operations described in the Operation Manual, the customer spare part set (97150)
is required. These parts are only available in the complete set.
Part number
51011
51012
51013
61007
61050
85002
Designation
Hexagon-head screw
Verbus Ripp® Washer
Hexagon nut
Metal C-ring
Gasket
Quantity
3
3
3
1
1
1
Metal C-ring
Table 5: Customer spare part set (97150)
CAUTION
Spare part storage
All spare parts that were ordered together with the low-pressure and/or
high-pressure stage must be kept intact and ready for use.
u Carefully clean any rusted parts and grease them.
u Dispose of replaced parts and parts that are not reusable in a professional and environ-
mentally compatible manner.
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HZTL4067_EN
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Operation Manual / Power2 650-M / 4.3 Gas piping GEJ920
5 Spare parts / 5.2 View of gas piping with part numbers
5.2
View of gas piping with part numbers
Fig. 3: Gas piping with part numbers
( . . . . . ) only available in customer spare part set (97150)
Part number
Designation
Hexagon-head screw
Verbus Ripp® Washer
Hexagon nut
Metal C-ring
Gasket
51011 (in customer spare part set)
51012 (in customer spare part set)
51013 (in customer spare part set)
61007 (in customer spare part set)
61050 (in customer spare part set)
61072
V-clamp
85001
Bellows
85002 (in customer spare part set)
Table 6: Gas piping with part numbers
Metal C-ring
© Copyright 2017 ABB. All rights reserved.
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Revision -
July 2017
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