ABB Power2 340-H44, Operation Manual

Page 1: ...fication Serial number PT003888 Customer part number 1247664 Delivery date yyyy mm dd 2022 04 01 Weight 440 kg Operating limits according to rating plate Speed limit in test rig operation only nMmax 678 1 s Speed limit during operation nBmax 678 1 s Gas inlet temperature limit in test rig operation only tMmax 620 C Gas inlet temperature limit during operation tBmax 600 C ...

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Page 3: ...tions 15 2 5 Intended use 16 2 6 Deflagration on gas engines 17 2 7 Warning plates on the low pressure stage 18 2 8 Rating plate of the low pressure stage 19 2 9 Periodic check of the pressure vessels 21 2 10 Lifting of loads 22 2 11 Prerequisites for operation and maintenance 23 2 12 Hazards during operation and maintenance 24 2 13 Safe operation 26 2 14 Safe maintenance 27 3 Removal and installa...

Page 4: ...and gas outlet flange 70 9 5 Removing the air inlets 71 9 6 Measuring radial clearances N and R 72 9 7 Removing the compressor casing 73 9 8 Pressing off the casing 75 9 9 Removing the cartridge group 76 9 10 Removing the nozzle ring 78 9 11 Installing the cartridge group on the service support 79 9 12 Measuring clearance A and B 80 9 13 Nozzle ring compression PD 81 9 14 Installing the nozzle rin...

Page 5: ... 98 12 1 REACH and RoHS Compliance Declaration For Products 98 12 2 Disposing of low pressure and high pressure stage components 99 13 Spare parts 100 13 1 Ordering spare parts 100 13 2 Spare part Illustrations 101 14 Tools 113 15 Gas piping option 114 15 1 Commissioning and operating 114 15 2 Periodic maintenance 115 15 3 Removal and installation 116 15 4 Storage and disposal 118 15 5 Spare parts...

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

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

Page 8: ...Operation Manual Power2 340 H Low pressure stage 1 Introduction 1 3 Essential information Copyright 2022 ABB All rights reserved HZTL4053_EN Rev F March 2022 Page 6 122 ...

Page 9: ...2 LP and high pressure stage Power2 HP within two stage turbocharging Power2 The low pressure stage is always op erated in combination with a high pressure stage connected in series The two stage tur bocharging Power2 supplies the engine with the air volume and associated charging pres sure required for operation Here the exhaust gases of the internal combustion engine flow through the turbine 22 ...

Page 10: ... 2022 1 5 Layout and function of the low pressure stage Fig 2 01 Air suction branch filter silencer 09 Gas outlet casing 02 Compressor casing 10 Gas outlet flange 03 Diffuser 11 Nozzle ring 04 Bearing casing 12 Turbine casing 05 Thrust bearing 13 Turbine end bearing flange 06 Radial bearing 14 Compressor end bearing flange 07 Turbine 15 Compressor wheel 08 Support Page 8 122 ...

Page 11: ...casing 12 and the nozzle ring 11 and then reaches the turbine 07 The turbine uses the energy contained in the exhaust gas to drive the rotor The exhaust gases then reach the atmosphere through the gas outlet flange 10 the gas outlet casing 09 and the exhaust gas pipe connected to it The rotor runs in two radial plain bearings 06 which are located in the bearing casing 04 between the compressor and...

Page 12: ...pment to be worn for a task The mandatory signs are described in chapter Safety and must be complied with Definition of Caution Warning Caution and warning signs are described in chapter Safety Terms used The following terms are used in this document Two stage turbocharging Power2 Low pressure stage Power2 LP High pressure stage Power2 HP Low pressure and high pressure stage Turbo Systems Turbo Sy...

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

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

Page 15: ...e group must be checked and repack aged by a Turbo Systems service station u Inspect the package for damage If the package is damaged the low pressure or high pressure stage or the cartridge group must be checked and repackaged by a Turbo Sys tems service station After every 3 years the following work steps must be performed by a Turbo Systems service station Inspect the component Replace the desi...

Page 16: ... or supplies and materials Are a consequence of insufficient compliance with safety instructions Are a consequence of insufficient or inappropriate performance of maintenance and in spection work The 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 fre...

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

Page 18: ...erating limits of Power2 were determined on the basis of information from the enginebuilder about the intended use This data is given on the rating plate and is gener ally different for the low pressure stage and high pressure stage The use of Power2 is limited to the specific application released at the time of delivery Turbo Systems accepts no liability and rejects all warranty claims for any no...

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

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

Page 21: ...ion Table 5 Operating limits Recommended inspection and replacement intervals 3 Inspection interval of plain bearings in 1000 h 4 Replacement interval of compressor in 1000 h 5 Replacement interval of turbine in 1000 h Table 6 Recommended inspection and replacement intervals Further data 6 Power2 designation 7 Power2 serial number 8 Power2 stage 9 Serial number of the low or high pressure stage 10...

Page 22: ...cated values nBmax tBmax can considerably shorten the recommended replacement intervals In such cases Turbo Systems recommends contacting the nearest Turbo Systems service station nMmax tMmax normally only apply 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 ...

Page 23: ...els 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 prom...

Page 24: ...ty helmet Fig 9 Attachment of loads on the crane hook Fig 10 Attachment angle If there are two or more suspension points the attachment angle of 45 must not be ex ceeded This prevents excessive loading due to diagonal pull u Before looping around the components of the low pressure and high pressure stage al low them to cool down maximum 80 C u Attach components of the low pressure and high pressur...

Page 25: ...ust be checked periodically Suitable working materials and personal protective equipment must be kept in a perfect condition Only authorised personnel may remain in the vicinity of the Power2 when the 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 Mod...

Page 26: ...ar ear protection if the sound pressure level exceeds 85 dB A Wear ear protection Hazards due to hot surfaces Surfaces of the low pressure and high pressure stage attached parts and operating fluids 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 Touc...

Page 27: ... sulation and for providing protection against contact with hot surfaces u Compliance with the instructions and specifications given by the en ginebuilder to protect against contact with hot surfaces on the low pres sure and high pressure stage is compulsory Wear safety gloves to protect against thermal hazards Hazards due to rotating parts WARNING Physical hazards due to rotating parts Contact wi...

Page 28: ...g commissioning and operation u Visually inspect your working environment before starting work u Remove any obstacles and objects littering the workplace u Check all pipes to and from the Power2 for damage and leaks before commissioning u Check Power2 for recognisable damage or defects every 12 hours of operation or at least once a day u Report any damage and any alterations of operational charact...

Page 29: ...ootwear to protect against mechanical hazard and risk of fall ing Wear protective clothing WARNING Risk of falling When work is performed on the low pressure or high pressure stage there is a risk of falling u Do not climb onto the low pressure or high pressure stage or onto at tached parts and do not use them as climbing aids u Use suitable climbing aids and working platforms for work above body ...

Page 30: ...g work Safety during disassembly assembly maintenance and repair u Observe the procedures for set up service and inspection work and the inspection inter vals u Inform the operating staff before starting any service or repair work Make sure the en gine is not started while work is being conducted on the Power2 u Before taking off any cover or removing any guard from the low pressure or high pres s...

Page 31: ...aling vapours of operating materials and supplies or con tact with them may be harmful to health u Do not breathe in these substances and avoid contact with the skin u Ensure proper ventilation u 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...

Page 32: ...ibres from insulation materials can have adverse effects on the health or cause irritations Unsuitable and combustible insulation materials are a fire hazard u Only use suitable and non combustible 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 w...

Page 33: ...e Fig 11 Transport Weight 440 kg Table 8 Weight of the low pressure stage complete 3 2 Removing the low pressure stage u Disconnect all pipes according to the instructions of the enginebuilder Version with water cooled bearing casing u Disconnect the water connections according to the instructions of the enginebuilder Close the openings of the water connections with locking screws CAUTION Freezing...

Page 34: ...e version of the bracket 04 a pin 03 may have been inserted to ensure the safe assembly of the low pressure stage Therefore always remove the low pressure stage from and install it on the bracket vertically Fig 12 Removing the low pressure stage 1 Attach the lifting gear to the suspension eye and additionally loop it around the gas out let casing 61001 2 Loosen and remove the fixing screws 01 and ...

Page 35: ...bracket 01 The necessary sealing is provided by O rings The O rings are not included in the Turbo Sys tems scope of delivery Fig 13 Inserting gaskets into the bracket 01 Bracket 04 Slot for gasket 02 Oil supply 05 O rings 03 Oil drain 06 Pin optional The low pressure stage can have an oil inlet either on its right or left side and this can be different for the low pressure stage fitted on the left...

Page 36: ...ing gear to the suspension eye and additionally loop it around the gas out let casing 61001 3 Clean the contact surfaces of the fixing screws 01 in the bearing casing 4 Place the low pressure stage on the bracket 04 and align it The oil inlet of the low pres sure stage must fit the oil supply of the bracket A positioning pin 03 may have been fit ted in the bracket to ensure correct positioning 5 F...

Page 37: ...ightening torque 01 u If a support is present tighten the fixing screws 05 according to the following table Power2 Fixing screws 05 mm Tightening torques Nm 340 LP M16 180 Table 10 Fixing screw tightening torque 05 u Then tighten the hexagon head screw 61003 Power2 Hexagon head screws 61003 mm Tightening torques Nm 340 LP M20 320 Table 11 Tightening torque 61003 u Remove lifting gear u Connect the...

Page 38: ...lly driven oil pump u Switch on the oil pump u Build up oil pressure Lubricating oil pressure 40 u Do not exceed a pre lubrication time of 2 minutes u Start the engine u Let the oil pump run until the pump driven by the engine generates sufficient pressure Turbo Systems recommends integrating the entire pre lubrication cycle into the engine con trol 4 1 3 Oil filtering Lubricating oil filtering wi...

Page 39: ...itial 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 Ch...

Page 40: ...enginebuilder s instruc tions Wear safety gloves to protect against thermal hazards 4 2 4 Checks when starting up the engine u Measure speed oil pressure and charging pressure at various engine performances u Measure the exhaust gas temperature before and after the turbine u Measure the air temperature before and after the compressor u Compare the measured values with the values of the acceptance ...

Page 41: ...k 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 repla...

Page 42: ...ues Fig 16 Oil monitoring 01 Contact surface of the low pressure stage 02 Oil inlet 03 Oil outlet M Oil pressure measuring point T Oil temperature measuring point If the drain pipe is vented the oil temperature measuring point can be installed at the out let in the vent tank Otherwise the measurement should be taken in the drain pipe as close to the low pressure and high pressure stage as possible...

Page 43: ...re at the outlet The oil temperature at the outlet is mainly dependant on Lubricating oil temperature and pressure at the oil inlet Engine load and speeds of the low pressure and the high pressure stages Exhaust gas temperature The maximum admissible oil temperature at the outlet is listed in the following table The specified oil outlet temperature is to be considered as alarm value for the operat...

Page 44: ...tems enable the constant monitoring of the speeds of the low pres sure and the high pressure stage 5 3 2 Layout and overview Fig 17 Low pressure stage speed measurement system 86505 Speed sensor 42188 Screw plug 86515 Cable connector 42189 Gasket 86526 F I converter 01 Plug with integrated voltage limiter 86528 Tachometer Alternative mounting position for speed sensor 32109 Sealing disc with cams ...

Page 45: ... difference is exceeded the following steps must be carried out u Reduce the engine performance immediately until the maximum speed of all low and high pressure stages no longer exceeds 70 of nBmax u If the engine cannot be stopped it can continue to be driven with this reduced engine performance or at this low pressure and high pressure stage speed u If a low pressure or high pressure stage surge...

Page 46: ...tor from the speed sensor u Unscrew the defective speed sensor u Screw in new speed sensor to the stop u For the tightening torque of the low pressure stage speed sensor see document Operation Manual Power2 Low pressure stage Disassembly and assembly Table of tightening torques u For the tightening torque of the high pressure stage speed sensor see document Operation Manual Power2 High pressure st...

Page 47: ...hes a maximum of 105 dB A near the compressor end compressor casing filter silencer air suction branch The following prerequisites must be fulfilled with regard to the low pressure and high pres sure stage to observe this limit value Air inlet system and piping fitted All standard noise reducing measures2 have been fitted Bellows at the air outlet has been properly acoustically insulated by the en...

Page 48: ...pyright 2022 ABB All rights reserved HZTL4053_EN Rev F March 2022 Suggestion for noise insulation bellows Fig 18 Noise insulation bellows 01 Compressor casing 02 Bellows 03 Charge air duct scavenging air duct 04 Insulation cushion 05 Insulation mat at least 15 mm 06 Sheet metal cover Page 46 122 ...

Page 49: ...nvir onmental 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 specific service interval with Turbo Systems To prevent machine damage caused by ageing and downtime we recommend having an in spection carried out by a Turbo Systems service station no later than 5 years after the last service...

Page 50: ...n nozzle ring turbine casing and compressor casing and check for cracks and erosion corrosion 6 2 5 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 e...

Page 51: ...n 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 necess...

Page 52: ...ality 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...

Page 53: ...ion Duration of post lub rication min Oil pressure during post lubrication en gine stopped poil bar 550 imperative 15 20 0 5 poil 1 0 550 necessary until the ro tor comes to a stand still 10 recommended 0 5 poil 1 0 Table 16 Water cooled bearing casing variant u Post lubricate as long as the rotor is turning u Observe the oil pressure while performing post lubrication 1 0 poil 0 5 u Switch off pos...

Page 54: ... be maintained Recommended cleaning inter val Operating state LP HP compressor 24 72 h Engine load 50 85 LP filter silencer 500 h Engine stopped HP bellows At every disassembly Engine stopped Table 17 If the recommended cleaning intervals are incompatible with operation of the engine con tact Turbo Systems If present If compressor cleaning present Compressor cleaning We recommend cleaning the HP c...

Page 55: ...f 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 th...

Page 56: ...rocess is particularly suitable as long as the fouling is not too ad vanced 7 2 3 Prerequisites for wet cleaning of compressor Engine load of 50 85 CAUTION Volume of water Uncontrolled volumes of water can damage the pressure stages and the en gine u Never connect injection tubes directly to a water pipe or a larger meter ing container other than that specified by Turbo Systems CAUTION Corrosion a...

Page 57: ...cleaning of compressor Executing wet cleaning u Remove sealing plug 27005 u Fill container with 0 4 dm3 pure water u Screw in sealing plug 27005 again u Push the valve activator 03 against the spring and hold for 10 15 seconds until the whole volume of water is injected u Continue to operate the engine for at least five more minutes to dry the compressor stage The cleaning process can be repeated ...

Page 58: ...ilter ring 81265 u Remove the filter ring u Clean the filter ring as required or every 500 hours of operation and replace it after the fifth cleaning process at the latest Contamination of the filter ring depends on the degree of purity of the sucked in air u Rinse the filter ring with water and mild detergent or in the case of heavy contamination soak and carefully push through Rinse in cold wate...

Page 59: ...ion segments may only be cleaned lightly with pres surized air a soft brush or a moist cleaning cloth u Have any heavily contaminated absorption segment replaced by a Turbo Systems service station Fitting the filter silencer u Insert the absorption segments 81136 into the sheet metal coverings 81137 u Bend the sheet metal coverings 81137 back to their original shape and insert into the slotted gui...

Page 60: ...essure stage Rotor unbalance Contact a Turbo Systems service sta tion Turbine or compressor damaged Bearing damaged Table 20 Malfunctions when starting Vibrations Rubbing of rotating parts Normal behaviour not a malfunction Low pressure or high pressure stage A minimal and uniform wear at the circumference of the rotor components caused by slight local rubbing against adjacent components is permit...

Page 61: ...a Turbo Systems service sta tion Change of operating state of high pressure stage Check the operating point of the high pressure stage Pipes Defects such as leaks in the ex haust gas pipes or charge air ducts Repair Table 23 Malfunctions during operation Power2 LP speed reductions Drop in high pressure stage speed Possible causes Remedy Engine Defects on the connected cylinders Contact enginebuild...

Page 62: ...ture too high Engine performance and engine speed unchanged Possible causes Remedy Engine Malfunction in the injection system Repair or contact manufacturer Low pressure or high pressure stage Insufficient air for example because filter silencer is blocked by contam ination Clean Compressor turbine contaminated Exhaust gas back pressure too high Clean or repair boiler or exhaust gas si lencer Turb...

Page 63: ...ter silencer contaminated there fore pressure drop too high Clean Compressor turbine contaminated Compressor turbine damaged Contact a Turbo Systems service sta tion Exhaust gas back pressure too high Clean or repair boiler or exhaust gas si lencer Table 28 Malfunctions during operation Charge air pressure too low Charge air pressure too high Engine performance and engine speed unchanged suction c...

Page 64: ...the compressor wheel compressor blade breakage Possible causes Remedy Low pressure or high pressure stage Material of the compressor wheel corroded due to the influx of ventila tion gases containing corrosive com ponents Correct the influx of ventilation gases in accordance with the enginebuilder s in structions Material of the compressor wheel corroded due to intake air containing exhaust gases o...

Page 65: ...ing If the low pressure or high pressure stages surge continuously or periodic ally their components may be damaged u Gradually reduce the engine load u Have the cause clarified and remedied immediately by a Turbo Systems service station u Have parts assessed for damage and if necessary replaced by a Turbo Systems service station Sporadic surge blows Surging of the low pressure stage can occur dur...

Page 66: ...re stage contaminated Clean Bearing damaged Contact a Turbo Systems service sta tion Rotor rubbing Foreign object in the pressure stage Table 34 Malfunctions when stopping Runout noises Runout time too short Possible causes Remedy Low pressure or high pressure stage Pressure stage contaminated Clean Bearing damaged Contact a Turbo Systems service sta tion Rotor rubbing Foreign object in the pressu...

Page 67: ...sensor 86505 refer to chapter Ordering spare parts Replace the speed sensor Table 36 Speed measurement poor signal amplitude Measured speed too high Possible causes Remedy Low pres sure or high pres sure stage Sensor tip contaminated since it is magnetic and can attract metallic particles This reduces the distance to the signal emitting sealing disc which can lead to ampli fication of the noise co...

Page 68: ...ried out only by trained personnel from a Turbo Sys tems service station u Mark the casing position for assembly Tightening torques for components The specified bolted connection tightening torques must be observed see Table of tighten ing torques 91 Tightening torques for assembly devices Unless otherwise described the screws and nuts of the assembly devices supplied by Turbo Systems must be tigh...

Page 69: ...ion 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 pl...

Page 70: ...l rights reserved HZTL4053_EN Rev F March 2022 Swivel lifting eyes to be used Swivel lifting eyes are required for the safe lifting of loads which are not supplied by Turbo Systems Fig 20 Swivel lifting eye example Thread M Length L Minimum load limit Quantity M12 21 mm 250 kg 2 Table 39 Swivel lifting eyes Page 68 122 ...

Page 71: ...lies are rounded up standard values Fig 21 Weights of the assemblies Designation Weight kg 01 Filter silencer 40 02 Radial air suction branch 13 03 Axial air suction branch 6 04 Compressor casing 65 05 Wall insert 15 06 Diffuser 7 07 Cartridge group 110 08 Nozzle ring 4 09 Burst ring 5 10 Turbine casing 1 inlet 120 11 Gas outlet flange 20 12 Gas outlet casing 65 13 Support 11 Table 40 Weights of t...

Page 72: ...let casing 61001 with lifting gear 2 Remove screw 61003 with Verbus Ripp washer 61004 and support 61300 3 Loosen nuts 51009 and remove with Verbus Ripp washers 51004 4 Remove the gas outlet casing 61001 5 Remove the gasket 61002 6 Measure radial clearance R see chapter Measuring radial clearances N and R 72 7 Press off the gas outlet flange 57002 with screws S according to the following table Pres...

Page 73: ...oving the air inlets u Mark the casing position for assembly Fig 23 Removing the air inlets 1 Attach lifting gear to the filter silencer 81000 or air suction branch 82000 2 Loosen and remove V clamp 72020 3 Remove filter silencer 81000 or air suction branch 82000 set it down properly in an appropriate place and secure it 4 Remove and dispose of the O ring 81010 82010 Page 71 122 ...

Page 74: ...learance and measure simultaneously at the top N1 and the bottom N2 2 Calculate clearance N and compare it with the permissible values in the table 3 Push the feeler gauges 01 into the gap without clearance and measure simultaneously at the top R2 and the bottom R1 4 Calculate clearance R and compare it with the permissible values in the table CAUTION Clearances outside the tolerance Serious damag...

Page 75: ... remove together with fastening strips 72012 2 Attach swivel lifting eye S to the compressor casing and the lifting gear 3 Remove the compressor casing 72000 and turn it 180 4 Remove and dispose of the O ring 42012 5 Loosen counter sunk screws 79041 and remove from the compressor casing 72000 with fixing discs 79040 and diffuser 79000 Dispose of counter sunk screws 79041 If the compressor casing c...

Page 76: ...TL4053_EN Rev F March 2022 Dismantling the wall insert Fig 26 Dismantling the wall insert 1 Knock the wall insert 77000 out of the compressor casing 72000 with a plastic tip hammer 2 Attach swivel lifting eye S to the compressor casing 72000 and the lifting gear 3 Lift up the compressor casing 72000 4 Remove and dispose of the O ring 77005 Page 74 122 ...

Page 77: ...2 9 8 Pressing off the casing CAUTION Axial force of the press off tool Using the press off tool 90042 a high level of axial force can be generated If the casing is pressed off with too much force on one side the rotor can be damaged u Use the tool on both sides in alternation and make sure not to press off too hard on either side Fig 27 Press off the casing Page 75 122 ...

Page 78: ...r 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 28 Oil orifice 01 Bearing cas...

Page 79: ...us Ripp washers 51003 together with fastening strips 51002 Fig 30 Removing cartridge group 2 3 Insert screws from service support into cartridge group 4 Secure ring nuts VRM onto the screws with washers 5 Secure the lifting gear to the ring nuts and suspension eye as shown 6 Remove the cartridge group vertically from the turbine casing 7 Turn the cartridge group into the horizontal rotor axis If t...

Page 80: ... Rev F March 2022 9 10 Removing the nozzle ring Fig 31 Removing the nozzle ring 1 If present Remove the metal C ring 51105 2 Position the fastening strips 51002 in place 3 Pull out the nozzle ring 56001 with the two extraction devices 90070 and the service support base 90012 4 Remove the lamellar sealing ring 56005 5 Remove the burst ring 57210 Page 78 122 ...

Page 81: ...2022 ABB All rights reserved HZTL4053_EN Rev F March 2022 9 11 Installing the cartridge group on the service support Fig 32 Installing the cartridge group on the service support 1 Remove ring nuts VRM 2 Remove service support screws 3 Fit service support 90012 according to the illustration 4 Insert the cartridge group 5 Fit the nuts Page 79 122 ...

Page 82: ... Table 43 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 i...

Page 83: ...ust be clamped between the heat shield 42400 and the turbine casing 51000 Fig 34 Nozzle ring compression PD 42001 Bearing casing 51000 Turbine casing 42400 Heat shield 56001 Nozzle ring Product Nozzle ring compression PD mm Power2 340 H LP 0 16 0 16 Table 44 Nozzle ring compression PD 1 Measure dimensions A B and S on cleaned surfaces 2 Calculate compression PD u If the calculated value PD lies ou...

Page 84: ...ing 56005 in the correct slot see detail A1 A2 When doing this pay attention to correct winding of the lamellar sealing ring see detail B 2 Secure the lamellar sealing ring 56005 with adhesive tape 01 3 Place the burst ring 57210 in the turbine casing 4 Insert the nozzle ring 56001 with the cams facing downwards into the turbine casing as far as it will go Align the cams on the nozzle ring with th...

Page 85: ...ng the cartridge group and rotating it by 90 Fig 36 Lifting the cartridge group and rotating it by 90 1 Loosen and remove nuts 2 Lift the cartridge group out of the service support 90012 3 Insert the screws of the service support from above and fit ring nuts VRM with washers 4 Attach lifting gear to the ring nuts VRM 5 Lift cartridge group at the side of the ring nuts VRM and turn it into a vertic...

Page 86: ...ge group Product Size Tightening torque Nm Power2 340 H LP M12 75 Table 45 Tightening torque 51007 1 Coat the threads of the studs 51006 with high temperature grease 2 Align the casing position of the cartridge group to the marking 3 Lower the cartridge group into the turbine casing 4 Remove ring nuts and screws 5 Fit fastening strips 51002 with Verbus Ripp washers 51003 and hexagon nuts 51007 6 T...

Page 87: ...alling the compressor casing Fitting the wall insert and the diffuser Fig 38 Fitting the wall insert and the diffuser Product Size Tightening torque Nm Power2 340 H LP M6 8 Table 46 Tightening torque 79041 1 Fit new O ring 77005 see Spare parts 100 2 Install the wall insert 77000 into the compressor casing 3 Secure the diffuser 79000 with fixing discs 79040 and new screws 79041 Page 85 122 ...

Page 88: ...l graphite cord sealing 42126 is fitted instead of the O ring 42012 see Spare parts 100 Product Size Tightening torque Nm Power2 340 H LP M12 105 Table 47 Tightening torque 72011 1 Fit a new high temperature resisting O ring 42012 red or green 2 Thoroughly clean the fastening strips 72012 before assembly 3 Attach swivel lifting eyes 01 to the compressor casing 72000 and lifting gear 4 Install the ...

Page 89: ...clearance and measure simultaneously at the top N1 and the bottom N2 2 Calculate clearance N and compare it with the permissible values in the table 3 Push the feeler gauges 01 into the gap without clearance and measure simultaneously at the top R2 and the bottom R1 4 Calculate clearance R and compare it with the permissible values in the table CAUTION Clearances outside the tolerance Serious dama...

Page 90: ...ets Fig 41 Installing the air inlets Product Size Tightening torque Nm Power2 340 H LP M12 60 Table 49 Tightening torque 72020 1 Secure lifting gear to filter silencer 81000 2 Fit a new O ring 81010 to the filter silencer 81000 or a new O ring 82010 to the air suction branch 82000 3 Fit the filter silencer 81000 or air suction branch 82000 with the V clamp 72020 4 Observe tightening torque Page 88...

Page 91: ... HZTL4053_EN Rev F March 2022 9 19 Installing the gas outlet flange Fig 42 Installing the gas outlet flange 1 If present Insert the metal C ring 57003 into the turbine casing 51000 and secure with high vacuum grease 2 Install the gas outlet flange 57002 in the turbine casing 3 Measure radial clearance R see chapter Radial clearances N and R Page 89 122 ...

Page 92: ...0 LP 51009 M12 65 Nm Power2 340 LP 61003 M20 320 Nm Table 50 Tightening torques 51009 61003 1 Insert a new gasket 61002 into the gas outlet casing 61001 2 Coat thread of studs with high temperature grease 3 Attach the lifting gear to the gas outlet casing 61001 and position the gas outlet casing in the correct position on the turbine casing 51000 4 Fit the washers 51004 and hexagon nuts 51009 Obse...

Page 93: ...g 44 Tightening torque overview The following tightening torques Nm must be observed for the designated screw fittings Position Part number Tightening torque Nm 01 82005 82007 M18x1 5 60 02 72020 M12 60 03 79041 M6 8 04 72011 M12 105 05 51007 M12 75 06 51101 51103 51104 M12 65 07 51009 M12 65 08 61005 M18x1 5 60 09 61003 M20 320 10 86505 M12x1 5 15 11 42188 M12x1 5 35 Table 51 Tightening torques N...

Page 94: ... in an environmentally compatible manner Wear safety gloves to protect against thermal hazards CAUTION Directives for taking out of operation Serious damage to engine or property can be caused by non compliance with the directives for blanking off the low pressure or high pressure stage on the engine u Follow the directives of the enginebuilder If the engine has to be brought back into operation a...

Page 95: ...ays have repairs to the cartridge group carried out by a Turbo Sys tems service station NOTICE Quick recommissioning To enable you to put a defective low pressure or high pressure stage back into operation quickly Turbo Systems recommends having a replacement cartridge group available in stock A replacement cartridge group can be in stalled within a short period of time and the low pressure or hig...

Page 96: ...e turbine casing into the gas pipe and on the gas outlet casing again u Attach cover plate Fig 45 Fitting the cover plate u Make sure that the oil connections in the bracket are equipped with gaskets 1 Close the opening in the turbine casing 51000 with the cover plate 01 2 Thoroughly clean the fastening strips 51002 before assembly 3 Coat the threads of the studs 51006 with high temperature grease...

Page 97: ...te drawing The cover plate is not included in the Turbo Systems scope of delivery and must be manufac tured by the operating company according to the following drawing Material General structural steel in accordance with DIN EN 10025 2 Fig 46 Cover plate drawing B1 0 5 B2 B3 B4 0 2 B5 B6 B7 ØD1 0 2 ØD2 R1 M 98 2 102 190 17 2 2 220 48 2 332 5 25 153 M10 Table 53 Cover plate dimensions mm Page 95 12...

Page 98: ...re largely protected against corrosion Preparations for mothballing WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or con tact 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 ope...

Page 99: ...w pressure and high pressure stage are completely removed either as whole units or in single parts For the measures always necessary for preparing the low pressure and high pressure stage for mothballing see section Taking the engine out of operation for up to 12 months subsec tion Preparations for mothballing If the low pressure and the high pressure stage remain attached to the engine see sectio...

Page 100: ...rm the customer of the presence of such substance s with sufficient information available to the supplier RoHS2 Directive 2011 65 EC in English only The EU Directive 2011 65 EC recast restricts the use of certain hazardous substances in electrical and electronic equipment RoHS2 Products and related accessories manufac tured by Turbo Systems Switzerland Ltd do not fall within the Scope of RoHS2 due...

Page 101: ...engine oil electronic parts speed sensor and associated components and thermal insulation u Dispose of metals as scrap metal for recycling u Dispose of non metallic materials as waste u Dispose of residues of lubricants as waste oil u Dispose of electronic components as electronic waste WARNING Handling damaged thermal insulation Damaged thermal insulation can lead to dust exposure The glass fibre...

Page 102: ...arts can be ordered from an Turbo Systems Service Station u If different model variants are not taken into account in this document contact an Turbo Systems Service Station u Dispose of placed and unusable parts in an 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 mann...

Page 103: ...are part Illustrations The spare parts lists shown below are only available in English Cartridge oil cooled 42196 42197 10900 42189 42188 42012 HZTL443580 Mod A Available within the spare part set if provided Part no Designation 10900 Cartridge oil cooled 42012 O ring 42188 Hexagon head screw 42189 Gasket 42196 Orifice oil inlet 42197 Safety ring Table 55 Page 101 122 ...

Page 104: ...reserved HZTL4053_EN Rev F March 2022 Cartridge water cooled 42196 42197 10900 42189 42188 42012 HZTL443581 Mod A Available within the spare part set if provided Part no Designation 10900 Cartridge water cooled 42012 O ring 42188 Hexagon head screw 42189 Gasket 42196 Orifice oil inlet 42197 Safety ring Table 56 Page 102 122 ...

Page 105: ...2 32103 32104 32111 32110 32101 32109 32113 42002 HZTL443579 Mod A Available within the spare part set Part no Designation 21000 Turbine 21002 Piston ring 25000 Compressor wheel 32101 Radial bearing 32102 Radial bearing 32103 Thrust ring 32104 Thrust bearing 32109 Sealing disc 32110 Bearing flange 32111 Auxiliary bearing 32112 Bearing flange 32113 Socket screw 32114 Socket screw 42002 Socket screw...

Page 106: ...ev F March 2022 Bearing casing oil cooled 42196 42197 42400 42001 42305 42008 42301 42302 HZTL443367 Mod A if provided Available within the spare part set Part no Designation 42001 Bearing casing 42008 Socket screw 42196 Orifice oil inlet 42197 Safety ring 42301 Bearing cover 42302 Piston ring 42305 O ring 42400 Heat shield Table 58 Page 104 122 ...

Page 107: ...42001 42189 42140 42188 42141 42305 42142 42008 42301 42302 HZTL443296 Mod B if provided Available within the spare part set Part no Designation 42001 Bearing casing 42008 Socket screw 42140 Gasket 42141 Core hole cover 42142 Socket screw 42188 Hexagon head screw 42189 Gasket 42196 Orifice oil inlet 42197 Safety ring 42301 Bearing cover 42302 Piston ring 42305 O ring 42400 Heat shield Table 59 Pag...

Page 108: ...51003 51007 56005 56001 51102 51101 51102 51101 HZTL443297 Mod A p pre assembled Part no Designation 51000 Turbine casing 51002 Fastening strip 51003 Verbusripp washer 51006 Stud 51007 Hexagon nut 51008 Stud 51009 Hexagon nut 51027 p Screw plug 51101 Hexagon head screw 51102 Tension washer 51103 Hexagon head screw 51500 Burst protection 56001 Nozzle ring 56005 Lamellar sealing ring 57002 Gas outle...

Page 109: ...All rights reserved HZTL4053_EN Rev F March 2022 Gas outlet casing 61004 61003 61005 61300 61001 61002 HZTL443298 Mod A Available within the spare part set Part no Designation 61001 Gas outlet casing 61002 Gasket 61003 Hexagon head screw 61004 Verbusripp washer 61005 Screw plug 61300 Support Table 61 Page 107 122 ...

Page 110: ... 77005 72011 72012 79000 72005 79041 79040 77000 72000 72080 72020 72080 HZTL443299 Mod A Available within the spare part set Part no Designation 72000 Compressor casing 72005 Screw plug 72011 Hexagon head screw 72012 Fastening strip 72020 V clamp 72080 Warning plate 77000 Wall insert 77005 O ring 79000 Diffuser 79040 Fixing washer 79041 Counter sunk screw Table 62 Page 108 122 ...

Page 111: ...2 ABB All rights reserved HZTL4053_EN Rev F March 2022 Air suction branch axial 82000 82007 82008 82010 82006 82005 HZTL443013 Mod D Available within the spare part set Part no Designation 82000 Air suction branch 82005 Screw plug 82006 Gasket 82007 Screw plug 82008 Gasket 82010 O ring Table 63 Page 109 122 ...

Page 112: ...2 ABB All rights reserved HZTL4053_EN Rev F March 2022 Air suction branch radial 82005 82006 82010 82000 82008 82007 HZTL443012 Mod D Available within the spare part set Part no Designation 82000 Air suction branch 82005 Screw plug 82006 Gasket 82007 Screw plug 82008 Gasket 82010 O ring Table 64 Page 110 122 ...

Page 113: ...36 81270 81000 82006 81137 82005 81135 81171 81170 81271 81266 HZTL443011 Mod E Available within the spare part set Part no Designation 81000 Filter silencer complete 81010 O ring 81135 Silencer body 81136 Absorption segment 81137 Cover sheet metal 81170 Screw plug 81171 Gasket 81265 Filter ring 81266 Cover grid 81270 Tension band 81271 Lock 82005 Screw plug 82006 Gasket Table 65 Page 111 122 ...

Page 114: ...t Illustrations Copyright 2022 ABB All rights reserved HZTL4053_EN Rev F March 2022 Speed measurement system 86526 86505 86528 86517 HZTL443427 Mod A if provided Part no Designation 86505 Speed sensor 86517 Adapter cable 86526 F I converter 86528 Tachometer Table 66 Page 112 122 ...

Page 115: ...mer tool set 90000 is required Part number Designation Quantity 90012 Service support 1 90013 Plastic insert 1 90042 Press off tool 1 90070 Extraction device 2 Table 67 Customer tool set 90000 This tool set can be ordered from any Turbo Systems Service Station The following specific ations must be included in the order Equipment type Designation and part number of the tool set Page 113 122 ...

Page 116: ...e 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 unus...

Page 117: ...erval 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 A...

Page 118: ...h 2022 15 3 Removal and installation 15 3 1 Weight Product Weight kg Gas piping Power2 340 H 11 Table 70 Weight 15 3 2 Removing gas piping Only use textile lifting gear to lift the bellows Fig 47 Removing the bellows u Loosen nuts 85004 and remove with Verbus Ripp washers 85005 and screws 85003 u Remove bellows 85001 with metal C rings 85002 61007 Page 116 122 ...

Page 119: ...ear to lift the bellows Fig 48 Installing the bellows u Coat threads of all screws with high temperature grease u Position bellows 85001 with metal C rings 61007 85002 u Fit screws 85003 and nuts 85004 with Verbus Ripp washers 85005 and tighten to the tightening torque specified in the table Part number Maximum tightening torque Nm 85004 nut with Verbus Ripp washer 325 85003 screw 230 Table 71 Tig...

Page 120: ...terial and Disposal 98 15 5 Spare parts 15 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 a Turbo Systems service station u If different model variants are not taken into account in this document contact a T...

Page 121: ... Low pressure stage 15 Gas piping option 15 5 Spare parts Copyright 2022 ABB All rights reserved HZTL4053_EN Rev F March 2022 15 5 2 View of gas piping with part numbers Fig 49 Gas piping with part numbers Power2 340 H Page 119 122 ...

Page 122: ...as out let flange 70 Fig 23 Removing the air inlets 71 Fig 24 Measuring clearances N and R 72 Fig 25 Removing the compressor casing 73 Fig 26 Dismantling the wall insert 74 Fig 27 Press off the casing 75 Fig 28 Oil orifice 76 Fig 29 Removing cartridge group 1 77 Fig 30 Removing cartridge group 2 77 Fig 31 Removing the nozzle ring 78 Fig 32 Installing the cartridge group on the service support 79 F...

Page 123: ...n Power2 HP speed reductions 59 Table 25 Malfunctions during operation Power2 LP speed increases 59 Table 26 Malfunctions during operation Power2 HP speed increases 60 Table 27 Malfunctions during operation Exhaust gas temperature too high 60 Table 28 Malfunctions during operation Charge air pressure too low 61 Table 29 Malfunctions during operation Charge air pressure too high 61 Table 30 Malfunc...

Page 124: ...r spare part set 97070 100 Table 55 101 Table 56 102 Table 57 103 Table 58 104 Table 59 105 Table 60 106 Table 61 107 Table 62 108 Table 63 109 Table 64 110 Table 65 111 Table 66 112 Table 67 Customer tool set 90000 113 Table 68 Expected replacement interval 114 Table 69 Maintenance interval 115 Table 70 Weight 116 Table 71 Tightening torque 85003 85004 117 Page 122 122 Page 122 122 ...