ABB Power2 650-M46, Operation Manual

Page 1: ...nual Chapter Document ID 1 Introduction HZTL4003_EN_D 2 Safety HZTL4021_EN_G 3 Safety data sheets 505998_1249752_B 4 Product description HZTL4064_EN_E 4 1 Low pressure stage 1251915 HZTL4065_EN_C 1251916 HZTL4065_EN_C 4 2 High pressure stage 1251917 HZTL4066_EN_A 1251918 HZTL4066_EN_A 4 3 Gas piping HZTL4067_EN_ ...

Page 2: ...als and the corresponding operating limits in chapter 3 are jointly defined with the enginebuilder This information is specific to the product Non observance of the recommended replacement intervals and the operating limits increases the risk of unpre dictable component failures ...

Page 3: ...l rights reserved HZTL4003_EN Revision D June 2017 Introduction 1 Introduction 2 1 1 Purpose of the manual 2 1 2 Symbols definitions 2 1 3 Registered trademarks 4 1 4 Power2 layout and function 5 1 5 Storage of new low pressure and high pressure stages 6 1 6 Contact information 8 ...

Page 4: ...or the proper operation of the engine and for the Power2 connected to it Availability of the Operation Manual The Operation Manual must be available where the Power2 is used All persons operating or working on the Power2 must have read and fully understood the Operation Manual 1 2 Symbols definitions Symbols The following symbols are used in this document u Indicates an action step 1 Indicates a n...

Page 5: ...is document Two stage turbocharging Power2 Low pressure stage Power2 LP High pressure stage Power2 HP Low pressure and high pressure stage ABB Turbo Systems ABB Turbo Systems Ltd is identified as ABB Turbo Systems in this document Official service stations of ABB Turbo Systems Official service stations are identified in this document as ABB Turbocharging Service Sta tions They are regularly audite...

Page 6: ... Affix Tighten over specified tighten ing angle Measure Hand tight tighten without tools Note Oil Visually inspect Apply screw locking paste e g Loctite Please note text for numbered work step Apply high temperature grease See document Apply other paste in accord ance with specifications Dispose of in an environmentally compatible professional way and in compliance with locally applic able regulat...

Page 7: ...ower2 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...

Page 8: ...dge groups for more than 6 months VCI WARNING Health protection when handling VCI VCI products are not hazardous in terms of the Ordinance on Hazardous Substances Nevertheless the following points must be observed when handling VCI u Ensure proper space ventilation u Do not eat drink or store food at the workplace while working with VCI u Wear safety gloves u Clean hands and face after working wit...

Page 9: ...s changed colour the maximum admissible atmospheric humidity has been exceeded In this case the low pressure or high pressure stage or the cartridge group must be checked and repackaged by an ABB Turbocharging Service Station u Check the package for damage If the package is damaged the low or high pressure stage or the cartridge group must be checked and repackaged by an ABB Turbocharging Service ...

Page 10: ...l rights reserved HZTL4003_EN Revision D June 2017 1 6 Contact information Contact information for the ABB Turbocharging Service Stations is available online u Scan the QR code to access our website ABB Turbo Systems Ltd Bruggerstrasse 71a CH 5401 Baden Switzerland www abb com turbocharging Page 8 8 ...

Page 11: ...ion of safety instructions 3 1 5 Intended use 4 1 6 Deflagration on gas engines 5 1 7 Warning plates on the low pressure and high pressure stage 6 1 8 Rating plate of the high pressure and low pressure stage 7 1 9 Periodic check of the pressure vessels 9 1 10 Lifting of loads 10 1 11 Prerequisites for operation and maintenance 11 1 12 Hazards during operation and maintenance 12 1 13 Safe operation...

Page 12: ...upplies 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 ope...

Page 13: ...iratory mask to protect against Dusts Gases Safety helmet Ear protection Table 2 Personal protective equipment to be worn specific to the respective task 1 4 Definition of safety instructions WARNING Definition of Warning Non compliance or inaccurate compliance with working or operating in structions indicated by this symbol and the word WARNING can lead to seri ous injuries to personnel and even ...

Page 14: ...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 mus...

Page 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 t...

Page 16: ...he 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 i...

Page 17: ...unless otherwise agreed with the enginebuilder 2 Operating limits during operation Table 3 Recommended replacement intervals 3 Replacement interval of plain bearings in 1000 h 4 Replacement interval of compressor in 1000 h 5 Replacement interval of turbine in 1000 h Table 4 Further data 6 Power2 designation 7 Power2 serial number 8 Power2 stage 9 Serial number of the low or high pressure stage 10 ...

Page 18: ...nebuilder 2 Operating limits during operation Table 6 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 7 Further data 6 Power2 designation 7 Power2 serial number 8 Power2 stage 9 Serial number of the low or high pressure stage 10 Year of construction of...

Page 19: ...ng 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 ...

Page 20: ...met 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...

Page 21: ...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 t...

Page 22: ... 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 h...

Page 23: ...tion 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 r...

Page 24: ...ation 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 o...

Page 25: ...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 platfor...

Page 26: ...ctric 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 an...

Page 27: ...ion 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 cont...

Page 28: ...n 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 combu...

Page 29: ... Page 1 5 Safety data sheets Copyright 2020 ABB All rights reserved 505998_1249752_B December 2020 Power2 650 M46 1249752 Name Hardware ID Page Low pressure stage 1251915 2 Low pressure stage 1251916 3 High pressure stage 1251917 4 High pressure stage 1251918 5 ...

Page 30: ...46 1249752 Low pressure stage 1251915 Power2 650 M46 see rating plate Low pressure stage see rating plate 420 420 80 2020 1900 80 1251915 Additional Safety Data Maximum permissible temperatures Exhaust gas inlet temperature At engine overload 110 in test rig operation only unless otherwise agreed with the enginebuilder tMmax C 550 During operation tBmax C 520 ...

Page 31: ...46 1249752 Low pressure stage 1251916 Power2 650 M46 see rating plate Low pressure stage see rating plate 420 420 80 2020 1900 80 1251916 Additional Safety Data Maximum permissible temperatures Exhaust gas inlet temperature At engine overload 110 in test rig operation only unless otherwise agreed with the enginebuilder tMmax C 550 During operation tBmax C 520 ...

Page 32: ...Power2 650 M46 see rating plate High pressure stage see rating plate 20 559 538 80 2020 750 80 1251917 Additional Safety Data Maximum permissible temperatures Exhaust gas inlet temperature At engine overload 110 in test rig operation only unless otherwise agreed with the enginebuilder tMmax C 650 During operation tBmax C 620 Compressor inlet temperature after intercooler During operation tCmax C 5...

Page 33: ...Power2 650 M46 see rating plate High pressure stage see rating plate 20 559 538 80 2020 750 80 1251918 Additional Safety Data Maximum permissible temperatures Exhaust gas inlet temperature At engine overload 110 in test rig operation only unless otherwise agreed with the enginebuilder tMmax C 650 During operation tBmax C 620 Compressor inlet temperature after intercooler During operation tCmax C 5...

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Page 35: ... out of operation 17 4 Monitoring during operation 18 4 1 Lubricating oil pressure 18 4 2 Lubricating oil temperature 19 4 3 Speed measurement 20 5 Operation and service 26 5 1 Noise emission 26 5 2 Service work 27 5 3 Expected replacement intervals 29 5 4 Stopping the engine 29 6 Periodic maintenance 30 6 1 Foreword to maintenance 30 6 2 Cleaning the compressor during operation 31 6 3 Cleaning tu...

Page 36: ...B All rights reserved HZTL4064_EN Rev E March 2020 10 Taking out of operation for a long period 47 10 1 General 47 10 2 Lubricating oil 47 10 3 Process for taking out of operation 47 11 Disposing of low pressure and high pressure stage components 48 12 Spare parts 49 Figures 50 Tables 51 ...

Page 37: ...ed HZTL4064_EN Rev E March 2020 1 Introduction 1 1 Related documents Chapter Document number Operation Manual 1 Introduction HZTL4003 Operation Manual 2 Safety HZTL4021 Operation Manual 3 Safety data sheet Serial number of Power2 Table 1 Related documents This chapter is only present in serialised operation manuals Page 3 51 ...

Page 38: ...Operation Manual Power2 650 M 4 Product description 1 Introduction 1 1 Related documents Copyright 2020 ABB All rights reserved HZTL4064_EN Rev E March 2020 Page 4 51 ...

Page 39: ... 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 turbi...

Page 40: ... E March 2020 1 3 Layout and function of the low pressure stage Fig 2 Layout and function of the low pressure stage 01 Air suction branch 07 Gas inlet casing 02 Injection ring for air 08 Nozzle ring 03 Compressor wheel 09 Turbine 04 Diffuser 10 Bearing casing 05 Bearing bush with heat shield 11 Compressor casing 06 Gas outlet casing 12 Injection ring for blowby Page 6 51 ...

Page 41: ...er2 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 ax...

Page 42: ... ABB All rights reserved HZTL4064_EN Rev E March 2020 1 4 Layout and function of the high pressure stage Fig 4 Layout of the high pressure stage 01 Air suction branch 06 Turbine 02 Bellows 07 Gas piping 03 Compressor casing 08 Nozzle ring 04 Diffuser 09 Compressor wheel 05 Bearing casing 10 Gas inlet casing turbine casing Page 8 51 ...

Page 43: ...high pressure stage 8 In the high pressure stage Power2 HP shown in the sectional view see Fig 4 Layout of the high pressure stage 8 the exhaust gas flows through the gas inlet casing 09 and the 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...

Page 44: ...er2 HP warning plates If warning plates are not present in the designated locations or not readable proceed as fol lows u Order new warning plates from ABB Turbocharging Service Stations u Remove any warning plates that have become unreadable u Clean and degrease the areas designated for the warning plates u Fit new warning plates and remove protective sheets Non insulated high and low pressure st...

Page 45: ...f 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 Page 11 51 ...

Page 46: ...formation 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 Page 12 51 ...

Page 47: ...ngine 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 swi...

Page 48: ...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 engin...

Page 49: ...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 o...

Page 50: ...struc tions Wear safety gloves to protect against thermal hazards 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 di...

Page 51: ... after the turbine for combustion residues or wa ter residues and clean it Remove any foreign objects that may be present u Check and clean filter silencer or air supply line and remove any foreign objects that may be present u With the high pressure stage check the bellows located between the radial air suction branch and the compressor casing for damage and replace if necessary u Put engine side...

Page 52: ...uf 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...

Page 53: ... 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 the inlet Toil inlet C Oil temperature at the outlet Toil inlet C 650 Admissible 90 150 Temporar...

Page 54: ... 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...

Page 55: ...rement Copyright 2020 ABB All rights reserved HZTL4064_EN Rev E March 2020 4 3 2 2 Replacing the speed measurement system 4 3 2 2 1 Low pressure stage Removing the speed measurement system Fig 11 Dimension X u Measure and note down dimension X Fig 12 Removing the speed measurement system Page 21 51 ...

Page 56: ... Copyright 2020 ABB All rights reserved HZTL4064_EN Rev E March 2020 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 Page 22 51 ...

Page 57: ... HZTL4064_EN Rev E March 2020 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 Page 23 51 ...

Page 58: ... sensor 86505 06 Connecting cable 86515 07 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 put the speed measurement cables under strain by pulling them If you pull the s...

Page 59: ...eded 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 l...

Page 60: ...stance 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 sta...

Page 61: ...rsh envir 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 ABB Turbocharging 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 th...

Page 62: ...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 ...

Page 63: ...u For information on the expected replacement intervals of the components of the high pressure stage see document Operation Manual Power2 4 2 High pressure stage 5 4 Stopping the engine CAUTION Residual heat in the low pressure and high pressure stage If the residual heat in the low pressure and high pressure stage is not suffi ciently dissipated by the circulating lubricating oil machine damage c...

Page 64: ...to be main tained Recommended cleaning interval1 Operating state LP compressor3 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 2 If present 3 If compressor cleaning present Compressor cleaning if present We recommend cleaning the HP c...

Page 65: ...l The contamination of the compressor stage compressor wheel and diffuser depends on the degree of purity of the sucked in air Deposits can form in the flow channels if salt oil mist or dust are sucked in with the air Consequences of contamination Impaired compressor efficiency Higher exhaust gas temperatures Increased fuel consumption Increased rotor unbalance Periodic cleaning of the compressor ...

Page 66: ... water but only pure water for cleaning CAUTION Volume of water Uncontrolled volumes of water can damage the pressure stages and the en gine u Never connect the water line without the orifice specified for the low pressure and high pressure stages Surging of the compressor Should repeated surging of the compressor stage occur during compressor cleaning first the cleaning parameters water flow rate...

Page 67: ...rigger 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 unsucce...

Page 68: ...onnecting rods Fig 16 Cleaning the filter silencer 81135 Filter silencer body 81266 Cover grid 81136 Absorption segment 81269 Connecting rods 81137 Sheet metal covering 81272 Screw 81265 Filter ring if present 81273 Lock nut E Insert unit absorption segment sheet metal covering Cleaning the filter ring if present u Remove filter ring 81265 u Clean filter ring 81265 as required or every 500 hours o...

Page 69: ...ption segments 81136 must only be cleaned lightly with pressurized air with a soft brush or a moist cleaning cloth u Have any heavily contaminated absorption segments and filter rings as well as damaged connecting rods replaced by an ABB Turbocharging Service Station Fitting the filter silencer u Assemble the insert units E by inserting the absorption segments 81136 into the sheet metal coverings ...

Page 70: ...nnecting rods 81269 with the screws 81272 While tightening the screws 81272 make sure that the connecting rods 81269 lie correctly in the slots on the filter silencer body 81135 Now alternately tighten the screws 81272 up to the maximum tightening torque shown above u Fit lock nuts 81273 to screws 81272 and tighten with the tightening torque shown above u Fit the filter ring 81265 if present 6 4 2...

Page 71: ...n compliance with locally applicable regulations Cleaning the absorption segments see Fig 18 Cleaning the filter silencer 36 u Loosen the tension bands 81270 u Remove the cover grid 81266 u Pull out and bend up the sheet metal coverings 81137 and remove the absorption seg ments 81136 u Clean the absorption segments 81136 When cleaning note that the absorption segments 81136 must only be cleaned li...

Page 72: ...ure stage Rotor unbalance Contact ABB Turbocharging Service Station Turbine or compressor damaged Bearing damaged Table 12 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 permitte...

Page 73: ... ABB Turbocharging Service Station 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 15 Malfunctions during operation Power2 LP speed reductions Drop in high pressure stage speed Possible causes Remedy Engine Defects on the connected cylinders Contact enginebui...

Page 74: ...erature 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 T...

Page 75: ...lter 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 20 Malfunctions during operation Charge air pressure too low Charge air pressure too high Engine performance and engine speed unchanged suction...

Page 76: ...ation gases Correct the influx of ventilation gases in accordance with the enginebuilder s in structions Table 22 Malfunctions during operation Compressor 1 contamination Reduced fatigue strength of the compressor wheel compressor blade breakage Possible causes Remedy Low pressure or high pressure stage Material of the compressor wheel corroded due to the influx of ventila tion gases containing co...

Page 77: ...nuously or periodic ally their components may be damaged u Gradually reduce the engine load u Have the cause clarified and remedied immediately by an ABB Turbochar ging Service Station u Have parts assessed for damage and if necessary replaced by an ABB Turbocharging Service Station Sporadic surge blows Surging of the low pressure stage can occur during certain operating states such as when reduci...

Page 78: ...bing Foreign object in the pressure stage Table 25 Malfunctions when stopping Runout noises Runout time too short Possible causes Remedy Low pressure or high pressure stage Pressure stage contaminated Clean Bearing damaged Contact ABB Turbocharging Service Station Rotor rubbing Foreign object in the pressure stage Table 26 Malfunctions when stopping Runout time too short 7 5 Speed measurement syst...

Page 79: ... 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 Page 45 51 ...

Page 80: ...E March 2020 9 Taking out of operation at short notice u For more information on briefly taking the low pressure stage out of operation see docu ment Operation Manual Power2 4 1 Low pressure stage u For more information on briefly taking the high pressure stage out of operation see doc ument Operation Manual Power2 4 2 High pressure stage Page 46 51 ...

Page 81: ...ludes cleaning and applying preservative oil to the relevant compon ents 10 3 Process for taking out of operation Different measures are required depending on the process used to take the low pressure and high pressure stage out of operation The low pressure and high pressure stage remains on the engine Take countermeasures if there is a risk that the rotor will turn due to the stack draught One o...

Page 82: ...d 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 da...

Page 83: ... 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 Page 49 51 ...

Page 84: ... the high pressure stage 9 Fig 6 Location of Power2 LP warning plates 10 Fig 7 Location of Power2 HP warning plates 10 Fig 8 Location of Power2 LP rating plate 11 Fig 9 Location of Power2 HP rating plate 11 Fig 10 Functional principle 20 Fig 11 Dimension X 21 Fig 12 Removing the speed measurement system 21 Fig 13 Setting dimension X 22 Fig 14 Control dimension S 23 Fig 15 Layout and overview 24 Fi...

Page 85: ...bricat ing oil pressure too low 39 Table 15 Malfunctions during operation Power2 LP speed reductions 39 Table 16 Malfunctions during operation Power2 HP speed reductions 39 Table 17 Malfunctions during operation Power2 LP speed increases 39 Table 18 Malfunctions during operation Power2 HP speed increases 40 Table 19 Malfunctions during operation Exhaust gas temperature too high 40 Table 20 Malfunc...

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Page 87: ...earance A prior to disassembly 13 4 6 Removing the wall insert 14 4 7 Removing the compressor casing 15 4 8 Removing the cartridge group 16 4 9 Removing turbine diffuser and nozzle ring 18 4 10 Installing turbine diffuser and nozzle ring 20 4 11 Installing the cartridge group 22 4 12 Installing the compressor casing 24 4 13 Installing the wall insert 25 4 14 Axial clearance A after assembly 27 4 1...

Page 88: ...r applicable documents Chapter Document number Operation Manual Power2 1 Introduction HZTL4004 Operation Manual Power2 2 Safety HZTL4021 Operation Manual Power2 3 Safety data sheet Power2 serial number HT Operation Manual Power2 650 M 4 Product description HZTL4064 Table 1 Related documents This chapter is only present in serialised operation manuals Page 2 42 ...

Page 89: ...le 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 650 LP M24 30 mm 40 mm 1900 kg Table 2 Swivel lifting eyes to be used Lifting gear with a sufficient load limit must be used for removing and installing the low pressure stage The following weight specification is ...

Page 90: ...a suitable location u Secure with lifting gear wherever possible 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 s...

Page 91: ... the orifices specified for the low pressure stage have been installed in both oil supply lines u Check that the gaskets have been correctly fitted at the oil inlet and the oil outlet 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 water and oil pipes in accordance with th...

Page 92: ...g the non rotating components exposed to hot gas A decisive role is played by various influencing parameters which in extreme cases can drastically reduce the replacement interval of these parts During the prescribed periodic service work the individual parts are examined for wear and replaced if necessary Expected replacement intervals h GAS MDO HFO Gas inlet casing 50000 100000 35000 50000 Gas o...

Page 93: ...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 pre...

Page 94: ...tarting work make sure the required tool set is available see chapter Tools 40 Not all tools are marked with a part number Identification is guaranteed by the tool list This list is enclosed with the tool set WARNING 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...

Page 95: ...le 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 commercially available products Use assembly devices only for the described applications Lifting gear Equipment for the lifting and transporting of loads lifting slings ...

Page 96: ...fied weights of the individual parts or assemblies are rounded up standard values Fig 3 Overview of assemblies Designation Weight kg 01 Filter silencer 190 02 Air suction branch 60 03 Injection ring for air 70 04 Injection ring for blow by 70 05 Wall insert 190 06 Diffuser 25 07 Compressor casing 210 08 Cartridge group 330 09 Turbine diffuser 40 10 Nozzle ring 15 Table 5 Weights of the assemblies ...

Page 97: ...ction 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...

Page 98: ...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...

Page 99: ...e 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 A...

Page 100: ...sor 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 Fig 8 Removing wall insert 2 4 Unplug cable connector 86515 and fix speed measurement ...

Page 101: ... 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 4 7 Removing the compressor casing Fig 10 Removing the compressor casing 1 1 Loosen two studs 72002 and screw 72021 in the upper area 2 Fit bracket 90030 with four screws 9...

Page 102: ... 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 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 ...

Page 103: ...tridge group to crane 6 Evenly press off cartridge group by screwing three press off screws 90920 into the des ignated holes 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 Pu...

Page 104: ...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...

Page 105: ...th bolt 90033 9 Secure lifting gear to swivel lifting eye 90231 10 Fit four plates 90031 and secure with plate 90032 screw 90656 and nut 90432 11 Press off turbine diffuser evenly using the press off screws 90902 Fig 18 Removing turbine diffuser and nozzle ring 4 12 Carefully move out turbine diffuser 63000 13 Put down turbine diffuser Remove plate 90032 screw 90656 nut 90432 and plates 90031 Remo...

Page 106: ... 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 tight ening 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 Removing turbine diffuser and nozzle ring 1...

Page 107: ...erved HZTL4065_EN Rev C March 2020 Part number Thread and tightening torque 61056 M10x90 50 Nm Table 8 Tightening torque 61056 1 Remove plates and brackets 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 tightening torque Page 21 42 ...

Page 108: ...he 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 the cartridge group 1 1 Screw bracket to cartridge group with two screws 90955 2 Fit swivel lifting eye 90231 to bracket 90030 and secure lifting gear to swivel l...

Page 109: ...e 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 tightening torque 7 Fit a new O ring 42012 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...

Page 110: ...r installing the cartridge group the control dimension X must be measured Control dimension X mm 63 0 0 1 Table 10 Control dimension X 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 Pre tightening torque 60 Nm Tightening angle 90 5 72021 M10x20 70 Nm Table 11 Tightening ...

Page 111: ...talling 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 the wall insert 1 Part number Thread and tightening torque ...

Page 112: ...ft the wall insert and remove the support angle 90480 6 Carefully insert the wall insert Fig 27 Installing the 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 stu...

Page 113: ...ance Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts u Have the components assessed and if necessary replaced by an ABB Tur bocharging Service Station Fig 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 c...

Page 114: ... 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 l...

Page 115: ...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 9023...

Page 116: ...s Nm must be observed for the designated bolted connec tions 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 ...

Page 117: ...Operation Manual Power2 650 M 4 1 Low pressure stage 4 Disassembly and assembly 4 17 Table of tightening torques Copyright 2020 ABB All rights reserved HZTL4065_EN Rev C March 2020 Page 31 42 ...

Page 118: ...e 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 th...

Page 119: ...ery of ABB and must be manufactured by the operator on the basis of the drawing see Fig 32 Cover plate gasket sleeves and screws 33 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...

Page 120: ...g 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...

Page 121: ...wing 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 enviro...

Page 122: ...e Operation Manual the customer spare part set 97070 is required These parts are only available in the complete set Part number Designation Quantity 42012 79020 O ring 2 42017 O ring 1 42018 O ring 2 42087 Hexagon head screw 1 56017 Hexalobular head screw 3 56018 Clamp 3 61037 Hexagon nut 3 61056 Hexagon head screw 8 72003 Washer 3 72004 Hexagon nut 4 77016 Hexagon head screw 5 77040 O ring 1 7902...

Page 123: ...Operation Manual Power2 650 M 4 1 Low pressure stage 6 Spare parts 6 1 Ordering spare parts Copyright 2020 ABB All rights reserved HZTL4065_EN Rev C March 2020 Page 37 42 ...

Page 124: ...6 2 View of low pressure stage with part numbers Copyright 2020 ABB All rights reserved HZTL4065_EN Rev C March 2020 6 2 View of low pressure stage with part numbers Fig 35 Low pressure stage with part numbers only available in customer spare part set 97070 Page 38 42 ...

Page 125: ...er spare part set Clamp 61001 Gas outlet casing 61009 Hexagon head screw 61037 in customer spare part set Hexagon nut 61050 Spiral wound gasket 61056 in customer spare part set Hexagon head screw 63000 Turbine diffuser 68002 Foot turbine end 72000 Compressor casing 72002 Stud 72003 in customer spare part set Washer 72004 in customer spare part set Hexagon nut 72021 Socket screw 73000 Injection rin...

Page 126: ...le 1 90920 Press off screw 3 90924 Press off screw 3 90902 Press off screw 3 90320 Guide stud 2 90321 Guide stud 2 90316 Guide stud 2 90955 Hexagon head screw 6 90959 Hexagon head screw 4 90950 Hexagon head screw 3 90961 Hexagon head screw 3 90656 Hexagon head screw 1 90415 Hexagon nut 6 90431 Hexagon nut 3 90432 Hexagon nut 1 90430 Nut 1 90161 Protective bag 1 90250 Special key 1 90251 Special ke...

Page 127: ...ine diffuser and nozzle ring 1 18 Fig 16 Removing turbine diffuser and nozzle ring 2 18 Fig 17 Removing turbine diffuser and nozzle ring 3 19 Fig 18 Removing turbine diffuser and nozzle ring 4 19 Fig 19 Installing the nozzle ring and turbine diffuser 1 20 Fig 20 Installing the nozzle ring and turbine dif fuser 2 20 Fig 21 Installing O rings 22 Fig 22 Installing the cartridge group 1 22 Fig 23 Inse...

Page 128: ...g torque 56017 20 Table 8 Tightening torque 61056 21 Table 9 Tightening torque 42087 23 Table 10 Control dimension X 24 Table 11 Tightening torque 61037 72021 24 Table 12 Tightening torque 77016 25 Table 13 Tightening torque 72002 26 Table 14 Axial clearance A 27 Table 15 Tightening torque 72004 28 Table 16 Tightening torque 72004 77022 29 Table 17 Tightening torques 30 Table 18 Cover plate gasket...

Page 129: ...ction 15 4 2 Weights of assemblies 17 4 3 Removing the compressor casing 18 4 4 Removing the cartridge group 19 4 5 Installing the cartridge group 22 4 6 Installing the compressor casing 25 4 7 Radial clearances N and R 26 4 8 Axial clearance A and radial clearance B 27 4 9 Table of tightening torques 28 5 Taking out of operation at short notice 29 5 1 Possible emergency repairs 29 5 2 Installing ...

Page 130: ...ther applicable documents Chapter Document number Operation Manual Power2 1 Introduction HZTL4004 Operation Manual Power2 2 Safety HZTL4021 Operation Manual Power2 3 Safety data sheet Power2 serial number HT Operation Manual Power2 600 M 4 Product description HZTL4064 Table 1 Related documents This chapter is only present in serialised operation manuals Page 2 39 ...

Page 131: ...le The operating instructions provided by the swivel lifting eye manufacturer should be observed Swivel lifting eye S Power2 Thread Length Minimum load limit Lmin Lmax 650 HP M16 20 mm 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 heavies...

Page 132: ... 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 threa...

Page 133: ...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 Wor...

Page 134: ...ntre 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 th...

Page 135: ...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 Bearing casing 42198 O ring 42199 O ring 01 Oil supply 02 Oil drains The oil is supplied 01 and drained 02 through the bracket u Insert the O rings 42198 and 421...

Page 136: ...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 cent...

Page 137: ...d 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 revolution this will loosen the centering bush which may have jammed the rod Then ...

Page 138: ...ABB All rights reserved HZTL4066_EN Revision A March 2019 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 Page 10 39 ...

Page 139: ...hat 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 p...

Page 140: ... 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 th...

Page 141: ...s and replacing the non rotating components exposed to hot gas A decisive role is played by various influencing parameters which in extreme cases can drastically reduce the replacement interval of these parts During the prescribed periodic service work the individual parts are examined for wear and replaced if necessary Expected replacement intervals h GAS MDO HFO Turbine casing 25000 50000 25000 ...

Page 142: ... 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 monitori...

Page 143: ...ce 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 Dam...

Page 144: ...vices 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 n...

Page 145: ...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 01 Radial air suction branch 95 02 Bellows 60 03 Compressor casing 160 04 Wall insert 30 05 Diffuser 12 06 Cartridge group 160 07 Nozzle ring 6 08 Turbine casing 220 Table 7 Weights of the assemblies Page 17 39 ...

Page 146: ...moving the compressor casing 72000 see chapter Radial clearances N and R 26 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 Loo...

Page 147: ...mbly 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 casin...

Page 148: ...e group 1 Treat threads of studs 51006 with penetrating oil and leave to take effect 2 Loosen nuts 51007 and remove Verbus Ripp washers 51003 together with fastening strips 51002 3 Attach swivel lifting eyes 01 to the cartridge group 10900 4 Secure lifting gear to swivel lifting eye and loop around the cartridge group 10900 see illustration above 5 Remove the cartridge group and turn it 90 6 Place...

Page 149: ...group Copyright 2019 ABB All rights reserved HZTL4066_EN Revision A March 2019 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 Page 21 39 ...

Page 150: ...01 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 Bearing casing 43001 Heat shield 51000 Turbine casing 56001 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 out...

Page 151: ...ng 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 ...

Page 152: ...al 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 cart...

Page 153: ...005 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...

Page 154: ...e 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 C...

Page 155: ...clearance B 0 24 0 44 mm 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 tim...

Page 156: ...s 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 72005 82005 82007 M18x1 5 60 02 82022 M12 85 03 72013 M12 85 04 77022 M10 75 05 42007 M10 50 06 72011 M12 130 07 42009 M20 65 08 51007 M12 75 09 61072 V clamp M12 60 10 86505 M12x1 5 15 11 42188 M12x1 5 35 Table 13 Tightening torq...

Page 157: ...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...

Page 158: ... 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 ...

Page 159: ...e 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 contact surface of the cover plate see Fig 24 Figure for cover plate slots for O rings 33 2 Close the opening in the turbine casing 51000 with the...

Page 160: ...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 B2 B3 B4 0 2 B5 B6 B7 ØD1 0 2 ØD2 R1 M 120 5 100 230 29 3 2 310 70 4 367 31 173 M10 Table 15 Cover plate dimensions mm Page ...

Page 161: ...er plate drawing Copyright 2019 ABB All rights reserved HZTL4066_EN Revision A March 2019 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 Page 33 39 ...

Page 162: ...peration Manual Power2 650 M 4 2 High pressure stage 5 Taking out of operation at short notice 5 4 Cover plate drawing Copyright 2019 ABB All rights reserved HZTL4066_EN Revision A March 2019 Page 34 39 ...

Page 163: ...ion 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 Designation Quantity 42010 O ring 1 42012 O ring 1 42198 O ring 1 42199 O ring 1 51005 Socket screw 3 51105 Metal C ring 1 56005 Lamellar sealing ring 1 77005 O ring 1 T...

Page 164: ... View of high pressure stage with part numbers Copyright 2019 ABB All rights reserved HZTL4066_EN Revision A March 2019 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 Page 36 39 ...

Page 165: ...ce oil inlet 42197 Locking ring 42198 in customer spare part set O ring 42199 in customer spare part set O ring 42201 Clamping nut 51000 Turbine casing 51002 Fastening strip 51005 Socket screw 51105 in customer spare part set Metal C ring 56001 Nozzle ring 56005 in customer spare part set Lamellar sealing ring 61003 Hexagon head screw 61300 Support 72000 Compressor casing 72012 Fastening strip 770...

Page 166: ...or the tightening procedure 11 Fig 9 Tightening pressure screws 12 Fig 10Weights of the assemblies 17 Fig 11 Removing the compressor casing 18 Fig 12 Oil orifice in the bearing casing 19 Fig 13 Removing the cartridge group 20 Fig 14 Removing the nozzle ring 21 Fig 15 Nozzle ring compression PD 22 Fig 16 Installing the nozzle ring 23 Fig 17 Installing the cartridge group 24 Fig 18 Installing the co...

Page 167: ...ting eyes to be used 16 Table 7 Weights of the assemblies 17 Table 8 Nozzle ring compression PD 22 Table 9 Tightening torque 51007 24 Table 10 Tightening torques 42007 72011 77022 25 Table 11 Permissible clearances N and R 26 Table 12 Permissible clearances A and B 27 Table 13 Tightening torques Nm 28 Table 14 Tightening torque 51007 31 Table 15 Cover plate dimensions mm 32 Table 16 Dimensions of ...

Page 168: ......

Page 169: ...7_EN Revision July 2017 Gas piping 1 Commissioning and operating 2 2 Periodic maintenance 3 3 Removal and installation 4 3 1 Weight 4 3 2 Removing gas piping 4 3 3 Installing gas piping 5 4 Storage and disposal 6 5 Spare parts 7 5 1 Ordering spare parts 7 5 2 View of gas piping with part numbers 8 Figures 9 Tables 10 ...

Page 170: ...d 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 det...

Page 171: ...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 repl...

Page 172: ...stallation 3 1 Weight Product Weight kg Gas piping GEJ920 30 Table 3 Weight 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 Page 4 10 ...

Page 173: ... 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 51013 nut with Verbus Rip...

Page 174: ... 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 Pa...

Page 175: ...ce 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 Designation Quantity 51011 Hexagon head screw 3 51012 Verbus Ripp Washer 3 51013 Hexagon nut 3 61007 Metal C ring 1 61050 Gasket 1 85002 Metal C ring 1 Table 5 Cu...

Page 176: ... part numbers only available in customer spare part set 97150 Part number Designation 51011 in customer spare part set Hexagon head screw 51012 in customer spare part set Verbus Ripp Washer 51013 in customer spare part set Hexagon nut 61007 in customer spare part set Metal C ring 61050 in customer spare part set Gasket 61072 V clamp 85001 Bellows 85002 in customer spare part set Metal C ring Table...

Page 177: ...50 M 4 3 Gas piping GEJ920 Figures Copyright 2017 ABB All rights reserved HZTL4067_EN Revision July 2017 Figures Fig 1 Removing gas piping 4 Fig 2 Installing gas piping 5 Fig 3 Gas piping with part numbers 8 Page 9 10 Page 9 10 ...

Page 178: ...ghts reserved HZTL4067_EN Revision July 2017 Tables Table 1 Expected replacement interval 2 Table 2 Maintenance interval 3 Table 3 Weight 4 Table 4 Tightening torque 51011 51013 61072 5 Table 5 Customer spare part set 97150 7 Table 6 Gas piping with part numbers 8 Page 10 10 Page 10 10 ...