ABB Power2 850-M16 Operation Manual
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ABB Power2 850-M16 Operation Manual

ABB Power2 850-M16 Operation Manual

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Turbo Systems Switzerland Ltd
Operation Manual / Power2 850-M16
High-pressure stage PT004135
Document identification
Document number
Revision
Language
Product identification
Serial number
Customer part number
Delivery date (yyyy-mm-dd)
Weight
Operating limits according to rating plate
Speed limit in test rig operation only
Speed limit during operation
Gas inlet temperature limit in test rig operation only
Gas inlet temperature limit during operation
Compressor inlet temperature after intercooler
HZTL4063
F
English
Original Operation Manual
PT004135
HZTL53396B
2022-08-08
700
n
Mmax
n
Bmax
t
Mmax
t
Bmax
t
Cmax
kg
612
1/s
612
1/s
650
°C
620
°C
60
°C

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Summary of Contents for ABB Power2 850-M16

  • Page 1 Turbo Systems Switzerland Ltd Operation Manual / Power2 850-M16 High-pressure stage PT004135 Document identification Document number HZTL4063 Revision Language English Original Operation Manual Product identification Serial number PT004135 Customer part number HZTL53396B Delivery date (yyyy-mm-dd) 2022-08-08 Weight Operating limits according to rating plate...

  • Page 3: Table Of Contents

    Commissioning after taking out of operation............37 Monitoring during operation................38 Lubricating oil pressure..................... 38 Lubricating oil temperature ..................39 Speed measurement ....................40 Operation and service ..................45 Noise emission ......................45 © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...
  • Page 4 REACH and RoHS Compliance Declaration For Products ........90 12.2 Disposing of low-pressure and high-pressure stage components ....91 Spare parts ......................92 13.1 Ordering spare parts....................92 13.2 Spare part – Illustrations ................... 93 © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...
  • Page 5 Operation Manual / Power2 850-M / High-pressure stage Table of contents Tools ........................101   Figures......................... 102   Tables ........................103 © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 6: Introduction

    Contact information for the Turbo Systems service stations is available online. Scan the QR code to access our website. Turbo Systems Switzerland Ltd. Bruggerstrasse 71a CH-5401 Baden Switzerland www.abb.com/turbocharging © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 7: Essential Information

    (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 understand- ing. Differences in detail are therefore possible. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...
  • Page 8 Operation Manual / Power2 850-M / High-pressure stage 1 Introduction / 1.3 Essential information © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 9: Power2 Layout And Function

    (21) of the high-pressure stage. Here the air or air/gas mixture is compressed fur- ther and leaves the two-stage turbocharging (Power2) in the direction of the charge air cooler. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 10: Layout And Function Of The High-Pressure Stage

    Radial plain bearing 02 Bellows Turbine 03 Compressor casing Support 04 Diffuser Gas inlet casing 05 Bearing casing Nozzle ring 06 Gas outlet casing Bearing bush 07 Axial bearing Compressor wheel © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 11: Fig. 3: Power2 Hp Diagram

    (25) through the air suction branch (01). The air is compressed further in the HP compressor (21) and the downstream diffuser (04) and sub- sequently supplied to the charge air cooler via the compressor casing (03). © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F...

  • Page 12: Symbols, Definitions

    Official service stations are identified in this document as Turbo Systems service stations. These Turbo Systems service stations are regularly audited and certified by Turbo Systems Switzerland Ltd. See also chapter Contact information →4. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 13: Registered Trademarks

    Dispose of in an environmentally compatible, professional way and in compliance with locally applicable regulations. Table 1: Definition of pictograms Registered trademarks The trademarks of outside companies are used in this document. These are marked with the ® symbol. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 14: Storage Of New Low-Pressure And High-Pressure Stages

    New VCI corrosion protection emitters can be obtained from www.branopac.com. Old VCI corrosion protection emitters must be disposed of in an environmentally compat- ible, professional way and in compliance with locally applicable regulations. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 15: Fig. 5: Package With Hygrometer

    The corrosion protection effect ends after the material is unpacked from the VCI package. To avoid the formation of condensation, the surroundings and the content of the package must have the same temperature during unpacking. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F...

  • Page 16: Safety

    (see section Definition of safety instructions) must also be observed. CE conformity Information Low-pressure and high-pressure stages from Turbo Systems comply with the machinery dir- ective 2006/42/EC and are partly completed machinery as defined by Article 2 g. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 17: Definition Of Mandatory Signs

    Non-compliance or inaccurate compliance with working or operating in- structions indicated by this symbol and the word CAUTION can lead to seri- ous damage to engine or property with grave consequences. Caution signs must always be observed. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 18: Intended Use

    The Power2 must be used in a technically perfect condition and in compliance with its inten- ded use. Turbo Systems excludes any liability for damage resulting from unauthorized modifications to the Power2 or improper operation. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 19: Deflagration On Gas Engines

    This inspection and evaluation must be carried out by a Turbo Systems service station. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F...

  • Page 20: Warning Plates On The High-Pressure Stage

    High and low-pressure stages supplied to the enginebuilder without insulation must be equipped later with warning plates to be attached to the insulation. This is the responsibility of the enginebuilder. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 21: Rating Plate Of The High-Pressure Stage

    Operation above the indicated values n can considerably shorten the recommended Bmax Bmax replacement intervals. In such cases, Turbo Systems recommends contacting the nearest Turbo Systems service station. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 22: Periodic Check Of The Pressure Vessels

    Necessary repair or maintenance work must be performed promptly, and the required safety measures must be taken. Pressure equipment must not be operated if defects are present. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 23: Lifting Of Loads

    The assembly devices must be completely screwed in and must not unscrew during use. Use assembly devices only for the described applications. Put down dismantled components of the low-pressure and high-pressure stage in such a way that they cannot tip over. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 24: Prerequisites For Operation And Maintenance

    Power2 and can cause serious damage to property and injury to personnel. Only use original parts from Turbo Systems. Turbo Systems accepts no liability for any damage resulting from the use of non-original parts and corresponding accessories. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 25: Hazards During Operation And Maintenance

    Wear heat-resistant safety gloves and protective clothing. Wait for the low-pressure and high-pressure stage to cool down before carrying out any work. Wear safety gloves to protect against thermal hazards. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...
  • Page 26 With the engine stopped, the rotor can rotate due to the stack draught alone. Operate the low-pressure and high-pressure stage in compliance with the specifications. Secure the rotor against unintentional rotation during maintenance. Wear safety gloves to protect against mechanical hazards. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 27: Safe Operation

    In case of damage, take the Power2 out of operation immediately and safeguard against accidental/unauthorised use. When switching on operating energy supplies (hydraulics, pneumatics, electricity), pay at- tention to the risks that may occur as a consequence of this energy input. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 28: Safe Maintenance

    Use of assembly devices 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. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...
  • Page 29 Safety when taking out of operation or preparing for mothballing Observe the material safety data sheet for the cleaning and mothballing agents. Wear personal protective equipment (PPE) according to the material safety data sheet. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F...
  • Page 30 Comply with local legislation. Do not allow any exposed flame or ignition source during cleaning work. Carry out cleaning in the open or provide sufficient ventilation. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...
  • Page 31 Dispose of insulation materials properly and in an environmentally com- patible manner in compliance with the legal regulations. Wear safety goggles. Wear a respiratory mask to protect against dusts. Wear safety gloves to protect against chemical hazards. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 32: Removal And Installation

    The following weight specification is the heaviest variant possible. This standard value may deviate from the data on the rating plate depending on the specifica- tion. Complete high-pressure stage Suspension Weight [kg] Table 8: Transporting the high-pressure stage © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 33: Removing The High-Pressure Stage

    Attach one lifting gear to the two suspension points of the bearing casing and one lifting gear to the support. Loosen fixing screws at foot and support. Lift the high-pressure stage from the engine and put it down. Cover the oil connection. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 34: Installing The High-Pressure Stage

    Install the air suction branch together with the bellows (see Fig. 41: Installing the air suc- →84). tion branch Attach all gas, air, water and oil pipes in accordance with the enginebuilder's instructions. Fit insulation. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 35: Commissioning

    An electrically driven oil pump is recommended for post-lubrication. Power2 Post-lubrication time 850 LP 30 min 850 HP 1.5 h or until turbine inlet temperature TTE <180 °C Table 10: Post-lubrication time © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 36: Table 11: Filter Mesh Width

    Monitoring during operation 4.1.7 Oil orifice Metering orifices are installed in the oil inlet of the low-pressure stage and the high-pressure stage in order to safeguard the oil pressures. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 37: Inspection Procedures

    Checks after commissioning (engine in idle mode) Lubricating system Check the oil pressure in the oil supply pipes. Check oil inlet temperature. The admissible values are specified in chapter Monitoring during operation →38. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...
  • Page 38 Con- tinual escape of an oily fluid indicates a possible oil leak. In the event of a leak, contact a Turbo Systems service station. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F...

  • Page 39: Commissioning After Taking Out Of Operation

    Put engine-side oil circulation to the low-pressure and high-pressure stage into opera- tion. Prepare the low-pressure and high-pressure stage for operation according to section Checks before commissioning. The low-pressure and high-pressure stage is now operational. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 40: Monitoring During Operation

    < 0.7 Table 12: Oil pressure range Metering orifices are installed in the oil inlet of the low-pressure stage and the high-pressure stage in order to safeguard the oil pressures. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 41: Lubricating Oil Temperature

    If the low-pressure or high-pressure stage has been operated outside of the admissible range for a long period of time, Turbo Systems recommends having the low-pressure or high-pressure stage inspected by an Turbo Systems service station. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F...

  • Page 42: Speed Measurement

    Do not put the speed measurement cables under strain by pulling them If you pull the speed measurement cables too hard, contacts can be pulled out. Do not strain the speed measurement cables by pulling. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...
  • Page 43 In any case, contacting the nearest Turbo Systems service station is recommended. 5.3.4 Malfunction of the speed measurement system The possible reasons for malfunction of the speed measuring system are described in →65. chapter Troubleshooting / Speed measurement system © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 44: Fig. 16: Dimension X

    5 Monitoring during operation / 5.3 Speed measurement 5.3.5 Replacing the speed measurement system Removing the speed measurement system Fig. 16: Dimension X Measure and note down dimension X. Fig. 17: Removing the speed measurement system © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 45: Fig. 18: Setting Dimension X

    Installing the speed measurement system Fig. 18: Setting dimension X 1. Set speed sensor (86505) in the plate (86507) to dimension X. 2. Secure speed sensor with wedge lock washer (86509) and clamping nut (86505). Observe tightening torque. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 46: Fig. 19: Control Dimension S

    4. Adjust dimension X until S = 0 mm is reached. 5. Position cable and secure it with rubber grommet (86516). 6. Screw in pressure nut (86505) secured with Loctite® 243. Observe tightening torque. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F...

  • Page 47: Operation And Service

    Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7: A-rated emission sound pressure level The enginebuilder must provide acoustically equivalent measures in case of deviating in- sulation versions © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 48: Service Work

    Service work according to instructions of enginebuilder Clean or replace the oil filter located in the supply pipe to the low-pressure and high-pres- sure stage while the engine is stopped. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...
  • Page 49 Air temperature before and after the compressor and after the charge air cooler ¡ Exhaust gas temperature before and after the turbine ¡ Atmospheric humidity of the suction air (before the low-pressure stage) © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 50: Expected Replacement Intervals

    Table 14: Expected replacement intervals [h] = Gas = Marine Diesel Oil = Heavy Fuel Oil The specified values are guideline values and are not guaranteed, see influencing paramet- ers. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 51: Stopping The Engine

    Observe the post-lubrication times and the oil pressure specified for post-lubrication (see chapter Monitoring during operation / Lubricating oil pressure). © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 52: Periodic Maintenance

    This cleaning process is faster and reduces the risk of surging of the low-pressure and high- pressure stages. Turbine stages cleaning We recommend cleaning the LP turbine stage after the HP turbine stage. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 53: Cleaning The Compressor During Operation

    Periodic cleaning of the compressor during operation prevents or delays any great increase in the contamination, but never replaces the regular service work where the low and high- pressure stages are completely dismantled and the compressors are mechanically cleaned. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F...
  • Page 54 Turbo Systems service station. The reduction of the en- gine load can lead to a reduction in the effectiveness of the compressor cleaning. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F...

  • Page 55: Table 16: Cleaning Parameters Power2 Lp

    Power2 Engine load Water pressure Water injection time [bar] 850 HP 50 … 100 % * + 3 Table 17: Cleaning parameters Power2 HP * Compressor inlet pressure depending on the operating point © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 56: Cleaning Turbine And Nozzle Ring During Operation

    Very heavily contaminated turbines can no longer be cleaned in this way. In this case, the contaminated components must be cleaned mechanically by a service station. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F...
  • Page 57 Comply with the cleaning parameters specified in the tables (see Table 19: Cleaning parameters HP →57) (see Table 20: Cleaning parameters LP →57). © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 58: Fig. 20: Load/Time Chart

    Due to the thermomechanical stress of the turbine casing, the gas inlet temperature should not exceed the specified maximum temperature before starting cleaning. If this is the case, the engine load is to be lowered until the permissible temperature is reached. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F...

  • Page 59: Table 19: Cleaning Parameters Hp

    The action of the cleaning water on the peripheral units (such as boiler) must be clarified by the operator. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 60: Table 22: Surface Of The Flow Channel

    Surface of the flow channel at the nozzle ring inlet of the HP turbine stage nozzle ring inlet of the LP turbine stage 0.031 0.068 Table 22: Surface of the flow channel © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 61: Troubleshooting

    If there is any doubt about the extent of the rubbing, contact a Turbo Systems service station. ¡ Have a dimension check carried out by a Turbo Systems service station. Table 25: Malfunctions when starting – Rubbing of rotating parts © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 62: Malfunctions During Operation

    Increase in low-pressure stage speed Possible causes Remedy Low-pressure Heavy contamination of the nozzle Contact a Turbo Systems service sta- stage ring tion Table 29: Malfunctions during operation – Power2 LP speed increases © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 63: Table 30: Malfunctions During Operation - Power2 Hp Speed Increases

    Cooling water volume too low Fill cooler Inlet temperature of cooling water Check/clean cooling system too high Insufficient ventilation Improve ventilation Table 31: Malfunctions during operation – Exhaust gas temperature too high © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 64: Table 32: Malfunctions During Operation - Charge Air Pressure Too Low

    Set correctly Engine performance higher than ex- Check engine performance pected Low-pressure Manometer display not correct Replace manometer high-pressure stage Table 33: Malfunctions during operation – Charge air pressure too high © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 65: Table 34: Malfunctions During Operation - Compressor 1 Contamination

    Prevent exhaust gas leakages in the en- corroded due to intake air containing gine space exhaust gases or salt Clean the compressor Table 35: Malfunctions during operation – Compressor 2 contamination © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 66: Surging Of The Low-Pressure Or High-Pressure Stage

    A surge blow is accompanied by a loud bang and the escape of hot air from the filter si- lencer of the low-pressure stage. No air escapes from the high-pressure stage. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F...

  • Page 67: Malfunctions When Stopping

    Table 38: Malfunctions when stopping – Runout time too short Speed measurement system Measured speed incorrect Possible causes Remedy Low-pres- Contact a Turbo Systems service station sure or high-pres- sure stage Table 39: Measured speed incorrect © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 68: Disassembly And Assembly

    Pay attention to the correct attachment of loads on the crane hook. People must not stand beneath suspended loads. Wear safety gloves to protect against mechanical hazards. Wear safety helmet. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 69: Material Required

    Use assembly devices only for the described applications. ¡ Lifting gear Equipment for the lifting and transporting of loads (lifting slings, chain block, crane). Lifting gear is not supplied by Turbo Systems. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 70: Weights Of Assemblies

    Designation Weight [kg] 01 Air suction branch 02 Bellows 03 Wall insert 04 Compressor casing 05 Cartridge group with hood diffuser and nozzle ring Table 40: Weights of the assemblies © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 71: Removing The Air Suction Branch Together With Bellows

    1. Loop around air suction branch and secure to lifting gear. 2. Loosen nuts (72004) and remove with washers (72003). 3. Remove and put down the air suction branch. 4. Fit a nut (72004) as a safeguard. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 72: Removing The Wall Insert

    5. Attach lifting gear to swivel lifting eye (90657). 6. Remove lock nut (72004). 7. Carefully move out wall insert (77000). When doing this, manually balance the wall insert at the bracket. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 73: Fig. 25: Removing Wall Insert 3

    9 Disassembly and assembly / 9.5 Removing the wall insert Fig. 25: Removing wall insert 3 8. Fit support angle (90450) with screws (90658), washers (72003) and nuts (72004). 9. Put down the wall insert (77000). 10. Remove the O-ring (77040). © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 74: Removing The Compressor Casing

    5. Move out compressor casing (72000) and put down. When doing this, do not roll com- pressor casing over the studs or put it down on them. 6. Remove the O-ring (42012). © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 75: Removing The Cartridge Group

    Fig. 28: Moving out cartridge group 2 7. Evenly press off cartridge group by screwing three press-off screws (90901) into the des- ignated holes. 8. Carefully move out cartridge group. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 76: Fig. 29: Moving Out Cartridge Group 3

    Pay attention to note concerning aligning the cover. 10. Remove plate (90032), screw (90656), nut (90415) and plates (90031). 11. Remove the lamellar rings (64001). Fig. 30: Moving out cartridge group 4 12. Remove O-rings (42017 / 42018). © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 77: Removing The Nozzle Ring

    9 Disassembly and assembly / 9.8 Removing the nozzle ring Removing the nozzle ring Fig. 31: Removing the nozzle ring 1. Loosen and remove screws (56017) with box spanner insert (90770). 2. Remove nozzle ring (56001). © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 78: Measuring Axial Clearance A

    The axial clearance (A) must be measured after removal and before installation of the cart- ridge group. Measure and note axial clearance (A). Axial clearance A [mm] 0.36 ... 0.48 Table 41: Axial clearance A © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 79: Installing The Nozzle Ring

    25 Nm Table 42: Tightening torque (56017) 1. Fit nozzle ring (56001). 2. Coat threads of screws (56017) with high-temperature grease and tighten the screws with the box spanner insert (90770). © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 80: Installing The Cartridge Group

    1. Clean slots for lamellar rings (64001) and fit new lamellar rings. Arrange joints so that they are offset by 180°. 2. Fit bracket (90030) and plates (90031). 3. Fit lifting gear to swivel lifting eye (90657). 4. Lift cartridge group and carefully move in. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 81: Fig. 36: Installing The Cartridge Group 2

    5. Fit a screw (42099) as a safeguard. 6. Remove screw (90656), nut (90415) and plates (90031). 7. Remove screws (90900) and bracket (90030). 8. Fit screws (42099). Observe tightening torque. 9. Fit a new O-ring (42010). © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 82: Fig. 37: Control Dimension X

    If the control dimension is still out of tolerance, contact a Turbo Systems service station. Fig. 37: Control dimension X After installing the cartridge group, the control dimension (X) must be measured. Control dimension X [mm] 49.0 ±0.2 Table 44: Control dimension X © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 83: Installing The Compressor Casing

    Attach the special key (90250 / 91250 / 90251 / 91251) to the torque spanner by using the adapter (90249 / 91249). Use the special key in an angle range between 30° and 90°. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F...

  • Page 84: Installing The Wall Insert

    2. Secure lifting gear to swivel lifting eye (90657) and lift wall insert (77000). 3. Remove support angle (90450). 4. Fit a new O-ring (77040). 5. Move in wall insert (77000) until bracket can be removed. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 85: Fig. 40: Installing The Wall Insert 2

    8. Slide in wall insert (77000) as far as it will go. 9. Detach speed measurement cable from provisional holder and insert cable connector (86515). 10. Fit three studs (72002) again in upper area and tighten. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 86: Installing The Air Suction Branch Together With Bellows

    Fit all air lines in accordance with the enginebuilder's instructions. If present: Connect supply line for compressor cleaning to air suction branch. Fit insulation, wherever it has been removed. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 87: Table Of Tightening Torques

    Pre-tightening torque 40 Nm Tightening angle 40° ±5° 90 Nm 72002 M12x95 50 Nm 72004 120 Nm 82022 M12x45 210 Nm Table 48: Tightening torques 1) Application with adapter 90249 and special key 90250 © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 88: Taking Out Of Operation At Short Notice

    If damage has occurred to the high-pressure stage and the engine has to be brought back into operation again as quickly as possible, the following emergency repair option is avail- able: ¡ Attaching the cover plate © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 89: Fig. 43: Cover Plate / Gasket And Sleeves

    1 gasket (02) (temperature resistant up to 550 °C) ¡ 8 sleeves (03) Fig. 43: Cover plate / gasket and sleeves Cover plate (gasket) and sleeves dimensions [mm] Ø1 Ø2 Ø3 Ø4 Ø5 Table 49: Cover plate / gasket © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 90: Fig. 44: Fitting The Cover Plate

    CAUTION Escaping lubricating oil Complete sealing of the lubricating oil supply is not guaranteed with the cover plate fitted. Close lubricating oil supply to high-pressure stage at engine side. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 91: Taking Out Of Operation For A Long Period

    – Check all low-pressure and high-pressure stage parts for corrosion annually. – If there are signs of rust, thoroughly clean the parts and renew the corrosion protec- tion. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 92: Material And Disposal

    6c) Copper alloy containing up to 4 % lead by weight. The maximum concentration of lead and lead compounds for our products is known to reach max. 0.8 % (mass % in homogeneous material). © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F...

  • Page 93: Disposing Of Low-Pressure And High-Pressure Stage Components

    Damaged thermal insulation can lead to dust exposure. The glass fibres can cause mechanical irritation of the eyes, skin, and respiratory tracts. The enginebuilder's instructions must be followed for the handling and disposal of the thermal insulation. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 94: Spare Parts

    O-ring 42018 O-ring 42099 Socket screw 56017 Hexalobular-head screw 61090 Press-off nut 64001 Lamelar labyrinth ring 72003 Washer 72004 Hexagon nut 77040 O-ring Table 51: Customer spare part set (97070) © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 95: Spare Part - Illustrations

    Radial bearing CE 32102* Radial bearing TE 32105* Floating disc 32106* Axial bearing 32118* Auxiliary bearing 32189* Locking ring 32190 Locking ring 42086* Socket screw 42302* Piston ring Table 52 © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 96: Table 53

    10900 42099* 42010* * = Available within the spare part set HZTL443552 Mod. A Part no. Designation 10900 Cartridge 42010* O-ring 42099* Socket screw 64001* Lamelar labyrinth ring Table 53 © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 97: Table 54

    Socket screw 42011* O-ring 42015 Sealing cover 42163 Sheet metal 42164* Hexalobular-head screw 42300 Partition wall 42305* O-ring 42306* O-ring 42700 Bearing bush 64000 Hood diffuser 64002* Hexalobular-head screw Table 54 © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 98: Table 55

    * = Available within the spare part set HZTL443387 Mod. A Part no. Designation 42001 Bearing casing 42009 Screw plug 42012* O-ring 42013 Gasket ring 42017* O-ring 42018* O-ring 42043 Orifice 42049 Locking ring Table 55 © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...

  • Page 99: Table 56

    Union nut 51258 Pressure plate 51259 Hexalobular-head screw 52208 Nozzle 56001 Nozzle ring 56017* Hexalobular-head screw 61003 Hexagon-head screw 61004 Verbusripp washer 61009 Hexagon-head screw 61050 Gasket 61300 Support Table 56 © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...
  • Page 100 * = Available within the spare part set HZTL443389 Mod. A Part no. Designation 61001 Gas-outlet casing 61036 Stud 61052 Screw plug 61073 Screw plug 61090* Press-off nut Hexagon nut Table 57 © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...
  • Page 101 Screw plug 77000 Wall insert 77012 Screw plug 77040* O-ring 86505 Speed sensor 86507 Plate 86508 Wedge lock washer 86509 Wedge lock washer 86510 Socket screw 86516 Grommet Table 58 © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...
  • Page 102 82300 82007 82000 82142 82140 HZTL443391 Mod. A Part no. Designation 82000 Air suction branch 82007 Screw plug 82022 Hexagon-head screw 82140 Cleaning nozzle 82142 Gasket 82300 Compensator Table 59 © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...
  • Page 103 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. © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Rev.F March 2022...
  • Page 104 Fig. 28: Moving out cartridge group 2....... 73 Fig. 29: Moving out cartridge group 3...... 74 Fig. 30: Moving out cartridge group 4 ..... 74 Fig. 31: Removing the nozzle ring....... 75 © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Revision F March 2022...
  • Page 105 Table 27: Malfunctions during operation – Power2 LP Table 53 ................94 speed reductions............60 Table 54 ................95 Table 28: Malfunctions during operation – Power2 HP speed reductions ........... 60 Table 55 ................96 Table 56 ................97 © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Revision F March 2022...
  • Page 106 Operation Manual / Power2 850-M / High-pressure stage Tables Table 57 ................98 Table 58 ................99 Table 59 ................ 100 Table 60: Customer tool set 90000......101 © Copyright 2022 ABB. All rights reserved. HZTL4063_EN Revision F March 2022...

This manual is also suitable for:

Power2 850-mPt004135

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