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ABB PT003888 Operation Manual

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Turbocharging
Operation Manual / Power2 340-H44
PT003888
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
HZTL4053
F
English
Original Operation Manual
PT003888
1247664
2022-04-01
440
n
Mmax
n
Bmax
t
Mmax
t
Bmax
kg
678
1/s
678
1/s
620
°C
600
°C

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  • Page 1 Turbocharging Operation Manual / Power2 340-H44 PT003888 Document identification Document number HZTL4053 Revision Language English Original Operation Manual Product identification Serial number PT003888 Customer part number 1247664 Delivery date (yyyy-mm-dd) 2022-04-01 Weight Operating limits according to rating plate Speed limit in test rig operation only...

  • Page 3: Table Of Contents

    Commissioning after taking out of operation............39 Monitoring during operation................40 Lubricating oil pressure..................... 40 Lubricating oil temperature ..................41 Speeds........................... 42 Operation and service ..................45 Noise emission ......................45 © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...
  • Page 4 Fitting the cover plate....................94 10.4 Cover plate drawing ....................95 Mothballing the low-pressure stage ..............96 11.1 Taking the engine out of operation for up to 12 months ........96 © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...
  • Page 5 Commissioning and operating ................114 15.2 Periodic maintenance ....................115 15.3 Removal and installation ..................116 15.4 Storage and disposal ....................118 15.5 Spare parts........................118   Figures......................... 120   Tables ........................121 © Copyright 2022 ABB. All rights reserved. HZTL4053_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. HZTL4053_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. HZTL4053_EN Rev.F March 2022...
  • Page 8 Operation Manual / Power2 340-H / Low-pressure stage 1 Introduction / 1.3 Essential information © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 9: Power2 Layout And Function

    (26) into the compressor (21) of the high-pressure stage. Here the air or air/gas mixture is compressed further and leaves the two-stage turbocharging (Power2) in the direction of the charge air cooler. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F...

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

    Gas outlet flange 03 Diffuser Nozzle ring 04 Bearing casing Turbine casing 05 Thrust bearing Turbine-end bearing flange 06 Radial bearing Compressor-end bearing flange 07 Turbine Compressor wheel 08 Support © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 11: Fig. 3

    As the air or air/gas mixture flows through the diffuser (03), the com- pressor casing (02) and the intercooler (26), it is compressed further, cooled and then guided into the HP compressor (21). © Copyright 2022 ABB. All rights reserved. HZTL4053_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. HZTL4053_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. HZTL4053_EN Rev.F March 2022...

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

    Old VCI corrosion protection emitters must be disposed of in an environmentally compat- ible, professional way and in compliance with locally applicable regulations. Close the package. The more tightly the package is sealed, the longer the protection will last. © Copyright 2022 ABB. All rights reserved. HZTL4053_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. HZTL4053_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. HZTL4053_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. HZTL4053_EN Rev.F March 2022...

  • Page 18: Intended Use

    The Operation Manual ¡ The instructions of the enginebuilder State of the art The Power2 is designed and built according to the state of the art and is safe to operate. © Copyright 2022 ABB. All rights reserved. HZTL4053_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. HZTL4053_EN Rev.F...

  • Page 20: Warning Plates On The Low-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. HZTL4053_EN Rev.F March 2022...

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

    Year of construction of the low or high-pressure stage Weight of the low or high-pressure stage Part number of the customer of the low or high-pressure stage Table 7: Further data © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 22: Fig. 8: Locations Of The Rating Plates

    Locations of the rating plates on the low-pressure stage Fig. 8: Locations of the rating plates One rating plate each is attached on the left and the right side of the bearing casing. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F...

  • Page 23: 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. HZTL4053_EN Rev.F March 2022...

  • Page 24: 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. HZTL4053_EN Rev.F March 2022...

  • Page 25: 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. HZTL4053_EN Rev.F March 2022...

  • Page 26: 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. HZTL4053_EN Rev.F March 2022...
  • Page 27 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. HZTL4053_EN Rev.F March 2022...

  • Page 28: 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. HZTL4053_EN Rev.F March 2022...

  • Page 29: 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. HZTL4053_EN Rev.F March 2022...
  • Page 30 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. HZTL4053_EN Rev.F...
  • Page 31 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. HZTL4053_EN Rev.F March 2022...
  • Page 32 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. HZTL4053_EN Rev.F March 2022...

  • Page 33: Removal And Installation

    For transport and storage of the low-pressure stage, drain the cooling water from the bearing casing via one of the two bottom openings of the water connections. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 34: Fig. 12: Removing The Low-Pressure Stage

    2. Loosen and remove the fixing screws (01) and the fixing screws (05) on the sup- port (61300). 3. Remove the low-pressure stage vertically. 4. Cover the oil connections (02) in the bracket (04) to protect them from dirt. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 35: Installing The Low-Pressure Stage

    A pin can be installed in the support as an installation safety device to prevent inadvertent incorrect fitting. This pin fits into the respective slot on the foot of the bearing casing. In- structions of the enginebuilder must be observed. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F...

  • Page 36: Fig. 14: Placing The Low-Pressure Stage On The Bracket

    Once the support can be turned, the three fixing screws (05) can be fitted. Observe the steps for fastening the low-pressure stage (see following section). © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F...

  • Page 37: Fig. 15: Low-Pressure Stage, Tightening The Fixing Screws

    →34). Connect all gas pipes and air lines. Version with water-cooled bearing casing Fit the water pipes according to the instructions of the enginebuilder. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 38: Commissioning

    With an oil inlet pressure of more than 3 bar (when engine under load) before the low-pres- sure or high-pressure stage, the bearing casings are equipped as standard with an orifice at the oil inlet. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F...

  • Page 39: Inspection Procedures

    Any prolonged failure of the water cooling will negatively affect the oil tight- ness of the low-pressure or high-pressure stage and increase their thermo- mechanical fatigue. Ensure the correct assembly of the water pipes and the cooling water supply. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...
  • Page 40 Lubricants and pastes used during assembly can liquefy or vaporise and escape as oily fluids during the initial hours of operation. Continual escape of an oily fluid indicates an oil leak. In the event of a leak, contact a Turbo Systems service station. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F...

  • Page 41: 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. HZTL4053_EN Rev.F March 2022...

  • Page 42: Monitoring During Operation

    Warning signal: (n ≥ 0.5 x n 0.5 < p ≤ 1.25 Bmax Alarm signal: Not admissible. Stop the engine immedi- 0.0 < p ≤ 0.5 ately. Table 12: Lubricating oil pressure at oil inlet upstream of the turbocharger © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 43: 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. HZTL4053_EN Rev.F...

  • Page 44: Speeds

    42188 Screw plug 86515 Cable connector 42189 Gasket 86526 F/I converter Plug with integrated voltage limiter 86528 Tachometer Alternative mounting position for speed sensor 32109 Sealing disc with cams © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...
  • Page 45 If the engine can be stopped temporarily: Inspect air lines, exhaust gas pipes and the low-pressure and high-pressure stages and remedy any malfunctions. In any case, contacting the nearest Turbo Systems service station is recommended. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...
  • Page 46 Switch on lubricating oil supply to the low-pressure or high-pressure stage. 5.3.5 Malfunction of the speed measurement system In the case of malfunctions of the speed measurement system, refer to the chapter entitled Troubleshooting/Speed measurement system →65. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 47: Operation And Service

    Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7: A-weighted emission sound pressure level The enginebuilder must provide acoustically equivalent measures in case of deviating in- sulation versions © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 48: Fig. 18: Noise Insulation, Bellows

    Suggestion for noise insulation, bellows Fig. 18: Noise insulation, bellows Compressor casing Bellows Charge air duct / scavenging air duct Insulation cushion Insulation mat (at least 15 mm) Sheet metal cover © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 49: Service Work

    Service work at 100 hours after commissioning 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. HZTL4053_EN Rev.F March 2022...
  • Page 50 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. HZTL4053_EN Rev.F March 2022...

  • Page 51: Expected Replacement Intervals

    12000 … 24000 Other casings 50000 Table 15: Expected replacement intervals [h] = Gas = Marine Diesel Oil The specified values are guideline values and are not guaranteed, see influence parameters. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...
  • Page 52 ¡ Lubricating oil quality (oil filtering, oil condition, oil monitoring) ¡ Load profile (speed, pressure conditions, temperature) ¡ Number of starts/stops ¡ Unbalance of the rotor (degree of contamination). © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 53: Stopping The Engine

    If the residual heat in the low-pressure stage is not sufficiently dissipated by the circulating cooling water, machine damage could occur. Allow water cooling to continue for 20 … 30 minutes after stopping the engine. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 54: Periodic Maintenance

    LP compressors as well as the parallel clean- ing of the HP compressors. This cleaning process is faster and reduces the risk of surging of the low-pressure and high- pressure stages. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 55: Cleaning The Compressor During Operation

    Cleaning process The compressor is cleaned during operation using the wet cleaning method. This cleaning method is tested and approved by Turbo Systems. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...
  • Page 56 Corrosion and deposits when cleaning Salt water and cooling water treatment substances damage and adversely affect parts of the low-pressure and high-pressure stage. Never use salt water, but only pure water for cleaning. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 57: Table 18: Parameters For Wet Cleaning Of Compressor

    If the cleaning is still unsuccessful after three processes and the engine values are unsatis- factory, it is recommended to have the low-pressure and / or high-pressure stage checked and cleaned by a service station. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F...

  • Page 58: Cleaning The Filter Silencer

    Rinse in cold water. Avoid high mechanical loads (water jet). Let the filter ring dry completely before assembling. Dirty water and mild detergent must be disposed of in compliance with locally applicable regulations. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 59: Cleaning Turbine And Nozzle Ring During Operation

    Any tension bands that have become damaged must be replaced. Fit the filter ring (81265), if present. Cleaning turbine and nozzle ring during operation Power2 340-H is carried out without turbine cleaning function. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 60: 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 21: Malfunctions when starting – Rubbing of rotating parts © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 61: 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 25: Malfunctions during operation – Power2 LP speed increases © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 62: Table 26: 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 27: Malfunctions during operation – Exhaust gas temperature too high © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 63: Table 28: 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 29: Malfunctions during operation – Charge air pressure too high © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 64: Table 30: Malfunctions During Operation - Compressor 1 Contamination

    Contact a Turbo Systems service sta- tion Table 32: Malfunctions during operation – Blow-by too high © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 65: Surging Of The Low-Pressure Or High-Pressure Stage

    A surge blow is accompanied by a loud bang and escape of hot air or air/gas mixture from the filter silencer of the low-pressure stage. There is no escape of air or air/gas mixture from the high-pressure stage. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F...

  • Page 66: Malfunctions When Stopping

    Clean Bearing damaged Contact a Turbo Systems service sta- high-pressure tion Rotor rubbing stage Foreign object in the pressure stage Table 35: Malfunctions when stopping – Runout time too short © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 67: Speed Measurement System

    Table 38: Speed measurement – speed too low Other causes of malfunction If none of the measures described above remedy the malfunction, have the speed measure- ment system checked by a Turbo Systems service station. © Copyright 2022 ABB. All rights reserved. HZTL4053_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. HZTL4053_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. HZTL4053_EN Rev.F March 2022...

  • Page 70: Fig. 20: Swivel Lifting Eye (Example)

    Swivel lifting eyes are required for the safe lifting of loads, which are not supplied by Turbo Systems. Fig. 20: Swivel lifting eye (example) Thread M Length L Minimum load limit Quantity 21 mm 250 kg Table 39: Swivel lifting eyes © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 71: Weights Of Assemblies

    Wall insert Diffuser Cartridge group Nozzle ring Burst ring Turbine casing * (1 inlet) Gas outlet flange Gas outlet casing Support Table 40: Weights of the assemblies * including burst protection © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 72: Removing The Gas Outlet Casing And Gas Outlet Flange

    7. Press off the gas outlet flange (57002) with screws (S) according to the following table. Press-off screws to be used (strength 8.8)* 6x M10 Table 41: Press-off screws to be used *not included in the Turbo Systems. scope of delivery. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 73: Removing The Air Inlets

    2. Loosen and remove V-clamp (72020). 3. Remove filter silencer (81000) or air suction branch (82000), set it down properly in an appropriate place and secure it. 4. Remove and dispose of the O-ring (81010 / 82010). © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 74: Measuring Radial Clearances N And R

    Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by a Turbo Systems service station. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 75: Removing The Compressor Casing

    Dispose of counter-sunk screws (79041). If the compressor casing cannot be loosened, it can be pressed off against the turbine cas- ing using the press-off tool (90042) (see chapter Pressing off the casing →75). © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 76: Wall Insert

    1. Knock the wall insert (77000) out of the compressor casing (72000) with a plastic tip hammer. 2. Attach swivel lifting eye (S) to the compressor casing (72000) and the lifting gear. 3. Lift up the compressor casing (72000). 4. Remove and dispose of the O-ring (77005). © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 77: Pressing Off The Casing

    If the casing is pressed off with too much force on one side, the rotor can be damaged. Use the tool on both sides in alternation and make sure not to press off too hard on either side. Fig. 27: Press off the casing © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 78: Removing The Cartridge Group

    If an oil orifice is fitted in the oil inlet of the bearing casing, it must not be removed. Fig. 28: Oil orifice 01 Bearing casing 02 Oil orifice 03 Circlip © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 79: Fig. 29: Removing Cartridge Group 1

    7. Turn the cartridge group into the horizontal rotor axis. If the cartridge group cannot be loosened, the press-off tool (90042) can be used (see chapter Pressing off the casing →75). © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 80: Removing The Nozzle Ring

    2. Position the fastening strips (51002) in place. 3. Pull out the nozzle ring (56001) with the two extraction devices (90070) and the service support base (90012). 4. Remove the lamellar sealing ring (56005). 5. Remove the burst ring (57210). © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 81: Installing The Cartridge Group On The Service Support

    Fig. 32: Installing the cartridge group on the service support 1. Remove ring nuts (VRM). 2. Remove service support screws. 3. Fit service support (90012) according to the illustration. 4. Insert the cartridge group. 5. Fit the nuts. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 82: Measuring Clearance A And B

    Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by a Turbo Systems service station. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 83: Nozzle Ring Compression Pd

    1. Measure dimensions A, B and S on cleaned surfaces. 2. Calculate compression (PD). If the calculated value (PD) lies outside the specified range, contact a Turbo Systems ser- vice station. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 84: Installing The Nozzle Ring

    Align the cams on the nozzle ring with the recesses of the turbine cas- ing (51000). Do not remove the adhesive tape (01). 5. If present: Fit the metal C-ring (51105). © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F...

  • Page 85: Installing The Cartridge Group

    3. Insert the screws of the service support from above and fit ring nuts (VRM) with washers. 4. Attach lifting gear to the ring nuts (VRM). 5. Lift cartridge group at the side of the ring nuts (VRM) and turn it into a vertical position. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F...

  • Page 86: Fig. 37: Installing The Cartridge Group

    3. Lower the cartridge group into the turbine casing. 4. Remove ring nuts and screws. 5. Fit fastening strips (51002) with Verbus Ripp® washers (51003) and hexagon nuts (51007). 6. Tighten the hexagon nuts (51007). © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 87: Installing The Compressor Casing

    Table 46: Tightening torque (79041) 1. Fit new O-ring (77005) (see Spare parts →100). 2. Install the wall insert (77000) into the compressor casing. 3. Secure the diffuser (79000) with fixing discs (79040) and new screws (79041). © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 88: Fig. 39: Installing The Compressor Casing

    2. Thoroughly clean the fastening strips (72012) before assembly. 3. Attach swivel lifting eyes (01) to the compressor casing (72000) and lifting gear. 4. Install the compressor casing (72000). 5. Fit the fastening strips (72012) with screws (72011). © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 89: Measuring Radial Clearances N And R

    Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by a Turbo Systems service station. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 90: Installing The Air Inlets

    2. Fit a new O-ring (81010) to the filter silencer (81000) or a new O-ring (82010) to the air suction branch (82000). 3. Fit the filter silencer (81000) or air suction branch (82000) with the V-clamp (72020). 4. Observe tightening torque. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 91: Installing The Gas Outlet Flange

    1. If present: Insert the metal C-ring (57003) into the turbine casing (51000) and secure with high-vacuum grease. 2. Install the gas outlet flange (57002) in the turbine casing. 3. Measure radial clearance (R) (see chapter Radial clearances N and R). © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 92: Installing The Gas Outlet Casing

    3. Attach the lifting gear to the gas outlet casing (61001) and position the gas outlet casing in the correct position on the turbine casing (51000). 4. Fit the washers (51004) and hexagon nuts (51009). Observe tightening torque. 5. Fit support (61300) with washer (61004) and screw (61003). 6. Tighten screw (61003). © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 93: Table Of Tightening Torques

    Part number Tightening torque [Nm] 82005, 82007 M18x1.5 72020 79041 72011 51007 51101 / 51103 / 51104 51009 61005 M18x1.5 61003 86505 M12x1.5 42188 M12x1.5 Table 51: Tightening torques [Nm] © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 94: Taking Out Of Operation At Short Notice

    If a replacement cartridge group is not available: Fit the cover plate and contact a Turbo Systems service station. Observe the following sections in connection with the emergency repairs mentioned. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 95: Installing A Replacement Cartridge Group

    For information on how to remove and install the cartridge group, see chapter Disas- sembly and assembly. Send the defective cartridge group to a Turbo Systems service station for inspection and repair. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 96: Fitting The Cover Plate

    4. Fasten the cover plate on the turbine casing (51000) with fastening strips (51002), Ver- bus Ripp® washers (51003) and nuts (51007), and screw it onto the bracket. Part number Tightening torque [Nm] 51007 Table 52: Tightening torques (51007) © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 97: Cover Plate Drawing

    Material: General structural steel, in accordance with DIN EN 10025-2. Fig. 46: Cover plate drawing ØD1 ØD2 ± 0.5 ± 0.2 ± 0.2 98.2 17.2 48.2 332.5 ≤ 153 Table 53: Cover plate dimensions [mm] © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 98: Mothballing The Low-Pressure Stage

    The rotor and bearing parts must be dismantled and subsequently refitted by a Turbo Systems service station. Clean all parts. Coat plain surfaces of steel and cast parts with anticorrosive oil. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 99: Taking The Engine Out Of Operation For More Than 12 Months

    State of the mothballed low-pressure and high-pressure stage Check the low-pressure and high-pressure stage parts annually for corrosion If there are signs of rust: Thoroughly clean parts and renew corrosion protection. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F...

  • Page 100: 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. HZTL4053_EN Rev.F...

  • Page 101: Disposing Of Low-Pressure And High-Pressure Stage Components

    Wear safety gloves. Wear safety goggles. Wear a respiratory mask to protect against dusts. Wear safety gloves to protect against mechanical hazards. Dispose of thermal insulation as hazardous waste. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 102: Spare Parts

    These parts are only available in the complete set. 97070 Designation Quantity 42012 O-ring 81010 / O-ring 82010 77005 O-ring 61002 Gasket 79041 Counter-sunk screw Table 54: Customer spare part set (97070) © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 103: Spare Part - Illustrations

    * = Available within the spare part set HZTL443580 Mod. A Part no. Designation 10900 Cartridge oil cooled 42012* O-ring 42188 Hexagon-head screw 42189 Gasket 42196** Orifice oil inlet 42197** Safety ring Table 55 © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 104: Table 56

    * = Available within the spare part set HZTL443581 Mod. A Part no. Designation 10900 Cartridge water cooled 42012* O-ring 42188 Hexagon-head screw 42189 Gasket 42196** Orifice oil inlet 42197** Safety ring Table 56 © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 105: Table 57

    Radial bearing 32103* Thrust ring 32104* Thrust bearing 32109 Sealing disc 32110 Bearing flange 32111* Auxiliary bearing 32112 Bearing flange 32113* Socket screw 32114* Socket screw 42002 Socket screw Table 57 © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 106: Table 58

    HZTL443367 Mod. A Part no. Designation 42001 Bearing casing 42008* Socket screw 42196** Orifice oil inlet 42197** Safety ring 42301 Bearing cover 42302* Piston ring 42305* O-ring 42400 Heat shield Table 58 © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 107: Table 59

    Core hole cover 42142* Socket screw 42188 Hexagon-head screw 42189 Gasket 42196** Orifice oil inlet 42197** Safety ring 42301 Bearing cover 42302* Piston ring 42305* O-ring 42400 Heat shield Table 59 © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 108: Nozzle Ring

    51027(p) Screw plug 51101 Hexagon-head screw 51102 Tension washer 51103 Hexagon-head screw 51500 Burst protection 56001 Nozzle ring 56005 Lamellar sealing ring 57002 Gas-outlet flange 57210 Burst ring Table 60 © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 109: Gas Outlet Casing

    * = Available within the spare part set HZTL443298 Mod. A Part no. Designation 61001 Gas outlet casing 61002* Gasket 61003 Hexagon-head screw 61004 Verbusripp washer 61005 Screw plug 61300 Support Table 61 © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 110: Table 62

    Compressor casing 72005 Screw plug 72011 Hexagon-head screw 72012 Fastening strip 72020 V-clamp 72080 Warning plate 77000 Wall insert 77005* O-ring 79000 Diffuser 79040 Fixing washer 79041* Counter-sunk screw Table 62 © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 111: Table 63

    * = Available within the spare part set HZTL443013 Mod. D Part no. Designation 82000 Air suction branch 82005 Screw plug 82006 Gasket 82007 Screw plug 82008 Gasket 82010* O-ring Table 63 © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 112: Table 64

    * = Available within the spare part set HZTL443012 Mod. D Part no. Designation 82000 Air suction branch 82005 Screw plug 82006 Gasket 82007 Screw plug 82008 Gasket 82010* O-ring Table 64 © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 113: Table 65

    Silencer body 81136 Absorption segment 81137 Cover sheet-metal 81170 Screw plug 81171 Gasket 81265 Filter ring 81266 Cover grid 81270 Tension band 81271 Lock 82005 Screw plug 82006 Gasket Table 65 © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 114: Table 66

    13 Spare parts / 13.2 Spare part – Illustrations Speed measurement system 86526** 86505** 86528** 86517** ** = if provided HZTL443427 Mod. A Part no. Designation 86505** Speed sensor 86517** Adapter cable 86526** F/I-converter 86528** Tachometer Table 66 © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 115: Tools

    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. HZTL4053_EN Rev.F March 2022...

  • Page 116: Gas Piping (Option)

    If such new and unusual signs are found, their cause must be determined. Noise emission See chapter Noise emission →45. Expected replacement interval Product Replacement interval [h] Gas piping 60000 Table 68: Expected replacement interval © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 117: Periodic Maintenance

    Perform a visual inspection of the sealing points (flange connection to the gas inlet cas- ing and gas outlet casing). Always replace bellows with damaged sealing locations with a new bellows. Always replace dismantled gaskets with new gaskets. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 118: Removal And Installation

    Only use textile lifting gear to lift the bellows. Fig. 47: Removing the bellows Loosen nuts (85004) and remove with Verbus Ripp® washers (85005) and screws (85003). Remove bellows (85001) with metal C-rings (85002/61007). © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 119: Fig. 48: Installing The Bellows

    Table 71: Tightening torque (85003 / 85004) The tightening torques specified in the table refer to the part which is turned during tight- ening. The other part must be locked in place with a wrench. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F...

  • Page 120: Storage And Disposal

    Carefully clean any rusted parts and grease them. Dispose of replaced parts and parts that are not reusable in a professional and environ- mentally compatible manner. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 121: Fig. 49: Gas Piping With Part Numbers (Power2 340-H)

    Operation Manual / Power2 340-H / Low-pressure stage 15 Gas piping (option) / 15.5 Spare parts 15.5.2 View of gas piping with part numbers Fig. 49: Gas piping with part numbers (Power2 340-H) © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...

  • Page 122: Figures

    Fig. 27: Press off the casing ........75 Fig. 28: Oil orifice............76 Fig. 29: Removing cartridge group 1 ......77 Fig. 30: Removing cartridge group 2 ......77 Fig. 31: Removing the nozzle ring......78 © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Revision F March 2022...

  • Page 123: Tables

    HP speed reductions ........... 59 Table 51: Tightening torques [Nm] ......91 Table 25: Malfunctions during operation – Power2 LP speed increases ............59 Table 52: Tightening torques (51007) ....... 94 © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Revision F March 2022...
  • Page 124 Table 67: Customer tool set 90000 ......113 Table 68: Expected replacement interval ....114 Table 69: Maintenance interval......... 115 Table 70: Weight ............116 Table 71: Tightening torque (85003 / 85004) ..117 © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Revision F March 2022...

This manual is also suitable for:

Power2 340-h44

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