Page 1 Operation Manual Power2 850-M46 HT592742_A English Original Operation Manual Chapter Document-ID Introduction HZTL4004_EN_D Safety HZTL4025_EN_B Safety data sheets HT592742_A Product description HZTL4061_EN_B Low-pressure stage PT002745 HZTL4062_EN_A PT002746 HZTL4062_EN_A High-pressure stage PT002743 HZTL4063_EN_B PT002744 HZTL4063_EN_B ABB Turbocharging...
Page 2 Operating limits and replacement intervals The recommended replacement intervals 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 Purpose of the manual....................2 Symbols, definitions...................... 2 Registered trademarks ....................4 Power2 layout and function ..................5 Storage of new low-pressure and high-pressure stages........6 Contact information..................... 8 © Copyright 2017 ABB. All rights reserved. HZTL4004_EN Revision D June 2017...
Page 4 Introduction Purpose of the manual Operation Manual The Operation Manual explains the two-stage turbocharging (Power2) from ABB Turbo Sys- tems and contains instructions for safe operation. The Operation Manual is a complement to and expansion of existing national regulations for occupational safety, accident prevention and environmental protection.
Page 5 ABB Turbo Systems Ltd is identified as ABB Turbo Systems in this document. Official service stations of ABB Turbo Systems Official service stations are identified in this document as ABB Turbocharging Service Sta- tions. They are regularly audited and certified by ABB Turbo Systems. Also see chapter Con- tact information →8.
Page 6 Oil free, grease free and dry able 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 2017 ABB. All rights reserved. HZTL4004_EN Revision D June 2017...
Page 7 Air or air/gas mixture inlet Air or air/gas mixture outlet and supply - - - Not included in the ABB Turbo Sys- to the charge air cooler tems scope of delivery The diagram shows the position of the low-pressure (Power2 LP) and high-pressure stage (Power2 HP) within two-stage turbocharging (Power2).
Page 8 Storage of new low-pressure and high-pressure stages and cartridge groups for up to 6 months New low-pressure and high-pressure stages and cartridge groups from ABB Turbo Systems can be stored in their closed packages for 6 months from the date of delivery without addi- tional mothballing measures (indicated by VCI label on package).
Page 9 Check the package for damage. If the package is damaged, the low or high-pressure stage or the cartridge group must be checked and repackaged by an ABB Turbocharging Service Station. After every 3 years, the following steps must be carried out by an ABB Turbocharging Service Station: ¡...
Page 10 Operation Manual / Power2 / 1 Introduction 1 Introduction / 1.6 Contact information Contact information Contact information for the ABB Turbocharging Service Stations is available online. Scan the QR code to access our website. ABB Turbo Systems Ltd Bruggerstrasse 71a...
Page 11 Lifting of loads ......................9 1.11 Prerequisites for operation and maintenance............10 1.12 Hazards during operation and maintenance ............11 1.13 Safe operation ......................13 1.14 Safe maintenance ......................14 © Copyright 2019 ABB. All rights reserved. HZTL4025_EN Rev.B November 2019...
Page 12 Safety Introduction The two-stage turbocharging system (Power2) manufactured by ABB Turbo Systems is state of the art and complies with the respective health and safety standards in effect at the time the system was built. Thus Power2 is safe to operate. Nevertheless, there may be some re-...
Page 13 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 2019 ABB. All rights reserved. HZTL4025_EN Rev.B November 2019...
Page 14 This data is given on the rating plate and is gener- ally different for the low-pressure stage and high-pressure stage. ABB accepts no liability and rejects all warranty claims for any non-intended uses. [1]Euromot = The European Association of Internal Combustion Engine Manufacturers...
Page 15 1 Safety / 1.6 Deflagration on gas engines Deflagration on gas engines Low-pressure stages from ABB Turbo Systems can tolerate a deflagration with a transient pressure increase of 12 bar (guideline value). High-pressure stages from ABB Turbo Systems can tolerate a deflagration with a transient pressure increase of 15 bar (guideline value).
Page 16 Low-pressure and high-pressure stages supplied to the enginebuilder without insulation must be retrofitted with warning plates to be affixed to the insulation. This is the responsib- ility of the enginebuilder. © Copyright 2019 ABB. All rights reserved. HZTL4025_EN Rev.B November 2019...
Page 17 Serial number of the low or high-pressure stage Year of construction of the low or high-pressure stage Weight of the low or high-pressure stage Part number of the customer of the low or high-pressure stage Table 5 © Copyright 2019 ABB. All rights reserved. HZTL4025_EN Rev.B November 2019...
Page 18 The locations of the rating plates are defined in the Operation Manual, Chapter 4 Product description. Periodic check of the pressure vessels The pressure vessels used by ABB Turbocharging, such as those for wet or dry cleaning, are so-called "simple pressure vessels". ¡...
Page 19 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 2019 ABB. All rights reserved. HZTL4025_EN Rev.B November 2019...
Page 20 Power2 and can cause serious damage to property and injury to personnel. Only use original parts from ABB Turbo Systems. ABB Turbo Systems accepts no liability for any damage resulting from the use of non-ori- ginal parts and corresponding accessories.
Page 21 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 2019 ABB. All rights reserved. HZTL4025_EN Rev.B November 2019...
Page 22 Non-insulated low-pressure and high-pressure stages can cause serious in- juries to personnel (burns). ABB Turbo Systems supplies the low-pressure and high-pressure stage with or without insulation in accordance with the purchase order received from the enginebuilder. If supply is without insulation, the enginebuilder is re-...
Page 23 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 2019 ABB. All rights reserved. HZTL4025_EN Rev.B November 2019...
Page 24 Have oil binding agents ready and provide or keep oil pans at hand. Use of assembly devices Assembly devices are specially constructed and designed for the defined use; they are not commercially available products. © Copyright 2019 ABB. All rights reserved. HZTL4025_EN Rev.B November 2019...
Page 25 Only perform operations for which you have received instruction or train- ing. Safety when taking out of operation or preparing for mothballing Observe the material safety data sheet for the cleaning and mothballing agents. © Copyright 2019 ABB. All rights reserved. HZTL4025_EN Rev.B November 2019...
Page 26 Wear personal protective equipment (PPE) according to the material safety data sheet. Comply with local legislation. Wear safety goggles. Wear safety gloves to protect against chemical hazards. Wear a respiratory mask to protect against gases. © Copyright 2019 ABB. All rights reserved. HZTL4025_EN Rev.B November 2019...
Page 27 Dispose of insulation materials properly and in an environmentally com- patible manner in compliance with the legal regulations. Wear safety goggles. Wear a respiratory mask to protect against dusts. Wear safety gloves to protect against chemical hazards. © Copyright 2019 ABB. All rights reserved. HZTL4025_EN Rev.B November 2019...
Page 29 Operation Manual / Power2 850-M46 / Safety data sheets Contents Page 1 / 5 Safety data sheets Power2 850-M46 HT592742 Name Hardware ID Page Low-pressure stage PT002745 Low-pressure stage PT002746 High-pressure stage PT002743 High-pressure stage PT002744 © Copyright 2020 ABB. All rights reserved.
Page 30 Operation Manual / Power2 850-M46 / Safety data sheets Page 2 / 5 Safety data sheet Power2 850-M46 HT592742 Low-pressure stage PT002745 Power2 850-M46 HT592742 Low-pressure stage PT002745 2020 1900 HZTL53380M Additional Safety Data: Maximum permissible temperatures At engine overload (110 %) in test rig [°C]...
Page 31 Operation Manual / Power2 850-M46 / Safety data sheets Page 3 / 5 Safety data sheet Power2 850-M46 HT592742 Low-pressure stage PT002746 Power2 850-M46 HT592742 Low-pressure stage PT002746 2020 1900 HZTL53380M Additional Safety Data: Maximum permissible temperatures At engine overload (110 %) in test rig [°C]...
Page 32 Operation Manual / Power2 850-M46 / Safety data sheets Page 4 / 5 Safety data sheet Power2 850-M46 HT592742 High-pressure stage PT002743 Power2 850-M46 HT592742 High-pressure stage PT002743 2020 HZTL53380M Additional Safety Data: Maximum permissible temperatures At engine overload (110 %) in test rig [°C]...
Page 33 Operation Manual / Power2 850-M46 / Safety data sheets Page 5 / 5 Safety data sheet Power2 850-M46 HT592742 High-pressure stage PT002744 Power2 850-M46 HT592742 High-pressure stage PT002744 2020 HZTL53380M Additional Safety Data: Maximum permissible temperatures At engine overload (110 %) in test rig [°C]...
Page 35 Surging of the low-pressure or high-pressure stage .......... 43 Malfunctions when stopping..................44 Speed measurement system ..................44 Disassembly and assembly................. 45 Taking out of operation at short notice ............46 © Copyright 2019 ABB. All rights reserved. HZTL4061_EN Rev.B June 2019...
Page 36: Table Of Contents
Lubricating oil......................47 10.3 Process for taking out of operation................ 47 Disposing of low-pressure and high-pressure stage components ....48 Spare parts ......................49 Figures........................50 Tables ........................51 © Copyright 2019 ABB. All rights reserved. HZTL4061_EN Rev.B June 2019...
Page 37 Operation Manual / 2 Safety HZTL4025 Operation Manual / 3 Safety data sheet *) Serial number of Power2 Table 1: Related documents *) This chapter is only present in serialised operation manuals. © Copyright 2019 ABB. All rights reserved. HZTL4061_EN Rev.B June 2019...
Page 39 Air or air/gas mixture inlet Air or air/gas mixture outlet and supply - - - Not included in the ABB Turbo Sys- to the charge air cooler tems scope of delivery The diagram shows the position of the low-pressure (Power2 LP) and high-pressure stage (Power2 HP) within two-stage turbocharging (Power2).
Page 40 06 Gas inlet casing 02 Compressor wheel 07 Nozzle ring 03 Diffuser 08 Turbine 04 Bearing bush with heat shield 09 Bearing casing 05 Gas outlet casing 10 Compressor casing © Copyright 2019 ABB. All rights reserved. HZTL4061_EN Rev.B June 2019...
Page 41 Air or air/gas mixture inlet Air or air/gas mixture outlet and supply - - - Not included in the ABB Turbo Sys- to the charge air cooler tems scope of delivery The low-pressure stage (Power2 LP) is a turbomachine and consists of the main components turbine and compressor.
Page 42 01 Air suction branch Gas inlet casing 02 Compressor wheel Nozzle ring 03 Diffuser Turbine 04 Bearing bush with hood diffuser Bearing casing 05 Gas outlet casing Compressor casing © Copyright 2019 ABB. All rights reserved. HZTL4061_EN Rev.B June 2019...
Page 43 Air or air/gas mixture inlet Air or air/gas mixture outlet and supply - - - Not included in the ABB Turbo Sys- to the charge air cooler tems scope of delivery The high-pressure stage (Power2 HP) is a turbomachine, and its main components are a tur- bine and a compressor.
Page 44 If warning plates are not present in the designated locations or not readable, proceed as fol- lows: Order new warning plates from ABB Turbocharging Service Stations. Remove any warning plates that have become unreadable. Clean and degrease the areas designated for the warning plates.
Page 45 Fig. 9: Location of Power2 HP 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 high-pressure stage. © Copyright 2019 ABB. All rights reserved. HZTL4061_EN Rev.B...
Page 46 Operation Manual / Power2 … / 4.1 Low-pressure stage. For more information on how to remove and install the high-pressure stage, see docu- ment Operation Manual / Power2 … / 4.2 High-pressure stage. © Copyright 2019 ABB. All rights reserved. HZTL4061_EN Rev.B June 2019...
Page 47 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 3: Post-lubrication time © Copyright 2019 ABB. All rights reserved. HZTL4061_EN Rev.B June 2019...
Page 48 Monitoring during operation 3.1.7 Oil orifice Metering orifices are installed in the oil inlet of the low-pressure stage and the high-pressure stage in order to safeguard the oil pressures. © Copyright 2019 ABB. All rights reserved. HZTL4061_EN Rev.B June 2019...
Page 49 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 →18. © Copyright 2019 ABB. All rights reserved. HZTL4061_EN Rev.B June 2019...
Page 51 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 2019 ABB. All rights reserved. HZTL4061_EN Rev.B June 2019...
Page 52 < 0.7 Table 5: 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 2019 ABB. All rights reserved. HZTL4061_EN Rev.B June 2019...
Page 53 If the low-pressure or high-pressure stage has been operated outside of the admissible range for a long period of time, ABB Turbo Systems recommends having the low-pressure or high-pressure stage inspected by an ABB Turbocharging Service Station.
Page 54 CAUTION Do not strain cables If you pull the speed measurement cables too hard, contacts can be pulled out. Do not strain the speed measurement cables by pulling. © Copyright 2019 ABB. All rights reserved. HZTL4061_EN Rev.B June 2019...
Page 55 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 ABB Turbocharging Service Station is recommended. 4.3.4 Malfunction of the speed measurement system The possible reasons for malfunction of the speed measuring system are described in →44.
Page 56 Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7: A-rated emission sound pressure level The enginebuilder must provide acoustically equivalent measures in case of deviating in- sulation versions © Copyright 2019 ABB. All rights reserved. HZTL4061_EN Rev.B June 2019...
Page 57 Agree on a shortened service interval with ABB Turbo Systems. To prevent machine damage caused by ageing and downtime, we recommend having an in- spection carried out by an ABB Turbocharging Service Station no later than 5 years after the last service.
Page 58 5 Operation and service / 5.2 Service work 5.2.4 Service work every 12000 ... 16000 hours of operation The rotor and bearing parts must be checked and assessed by an ABB Turbocharging Service Station. Dismantle low-pressure and high-pressure stage. Measure clearances.
Page 59 Observe the post-lubrication times and the oil pressure specified for post-lubrication (see chapter Monitoring during operation / Lubricating oil pressure). © Copyright 2019 ABB. All rights reserved. HZTL4061_EN Rev.B June 2019...
Page 60 Compressor cleaning We recommend cleaning the HP compressor after the LP compressor. On V-engines with several low-pressure and/or high-pressure stages per engine, ABB Turbo Systems recommends the parallel cleaning of the LP compressors as well as the parallel cleaning of the HP compressors.
Page 61 Periodic cleaning of the compressor during operation prevents or delays any great increase in the contamination, but never replaces the regular service work where the low and high- pressure stages are completely dismantled and the compressors are mechanically cleaned. © Copyright 2019 ABB. All rights reserved. HZTL4061_EN Rev.B...
Page 62 ABB Turbocharging Service Station. The reduction of the engine load can lead to a reduction in the effectiveness of the compressor cleaning.
Page 63 Do not clean the compressors of the different high and low-pressure stages at the same time, but one after the other. On V-engines with several low-pressure and/or high-pressure stages per engine, ABB Turbo Systems recommends the parallel cleaning of the LP compressors as well as the parallel cleaning of the HP compressors.
Page 64 ABB Turbo Systems recommends using fuels with a mass ratio of vanadium to sodium of less than 3:1 so that the melting temperature of the sodium vanadyl vanadate is as high as possible.
Page 65 6.3.2 Cleaning method and principle Cleaning of the turbine and the nozzle ring during operation is carried out by the cleaning method described in the following and is tested and approved by ABB Turbo Systems: ¡ Wet cleaning Wet cleaning makes use of various effects. These effects are used with varying levels of in- tensity, depending on the type of contamination: ¡...
Page 66 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 2019 ABB. All rights reserved. HZTL4061_EN Rev.B...
Page 67 Maintenance of the holding time according to the specifications in the following table and subsequent adjustment of the desired engine operating point. Power2 Holding time at reduced load [min] ≥10 Table 13: Holding time © Copyright 2019 ABB. All rights reserved. HZTL4061_EN Rev.B June 2019...
Page 68 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 14: Surface of the flow channel © Copyright 2019 ABB. All rights reserved. HZTL4061_EN Rev.B June 2019...
Page 69 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 2019 ABB. All rights reserved. HZTL4061_EN Rev.B June 2019...
Page 70 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 Assemble the insert units (E) by inserting the absorption segments (81136) into the sheet-metal coverings (81137).
Page 71 (81135). Now alternately tighten the screws (81272) up to the maximum tightening torque shown above. Fit lock nuts (81273) to screws (81272) and tighten with the tightening torque shown above: Fit the filter ring (81265), if present. © Copyright 2019 ABB. All rights reserved. HZTL4061_EN Rev.B June 2019...
Page 72 To pre- vent significant loss of efficiency, specific tolerances must be fulfilled. ¡ If there is any doubt about the extent of the rubbing, contact an ABB Turbocharging Service Station. ¡...
Page 73 Operation Manual / Power2 850-M / 4 Product description 7 Troubleshooting / 7.2 Malfunctions during operation Possible causes Remedy Low-pressure or Axial clearance of the rotor excessive Contact ABB Turbocharging Service Sta- high-pressure tion stage Table 19: Malfunctions during operation – Lubricating oil pressure too low...
Page 74 Cooling water volume too low Fill cooler Inlet temperature of cooling water Check/clean cooling system too high Insufficient ventilation Improve ventilation Table 24: Malfunctions during operation – Exhaust gas temperature too high © Copyright 2019 ABB. All rights reserved. HZTL4061_EN Rev.B June 2019...
Page 75 Engine performance higher than ex- Check engine performance pected Low-pressure or Manometer display not correct Replace manometer high-pressure stage Table 26: Malfunctions during operation – Charge air pressure too high © Copyright 2019 ABB. All rights reserved. HZTL4061_EN Rev.B June 2019...
Page 76 Prevent exhaust gas leakages in the en- roded due to intake air containing ex- gine space haust gases or salt Clean the compressor Table 28: Malfunctions during operation – Compressor 2 contamination © Copyright 2019 ABB. All rights reserved. HZTL4061_EN Rev.B June 2019...
Page 77 Gradually reduce the engine load. Have the cause clarified and remedied immediately by an ABB Turbochar- ging Service Station. Have parts assessed for damage and, if necessary, replaced by an ABB Turbocharging Service Station. Sporadic surge blows Surging of the low-pressure stage can occur during certain operating states, such as when reducing the engine performance quickly when manoeuvring.
Page 78 Table 31: Malfunctions when stopping – Runout time too short Speed measurement system Measured speed incorrect Possible causes Remedy Low-pressure Contact ABB Turbocharging Service Station high-pressure stage Table 32: Measured speed incorrect © Copyright 2019 ABB. All rights reserved. HZTL4061_EN Rev.B June 2019...
Page 79 Operation Manual / Power2 … / 4.1 Low-pressure stage. For more information on the disassembly and assembly of the high-pressure stage, see document Operation Manual / Power2 … / 4.2 High-pressure stage. © Copyright 2019 ABB. All rights reserved. HZTL4061_EN Rev.B June 2019...
Page 80 Operation Manual / Power2 … / 4.1 Low-pressure stage. For more information on briefly taking the high-pressure stage out of operation, see doc- ument Operation Manual / Power2 … / 4.2 High-pressure stage. © Copyright 2019 ABB. All rights reserved. HZTL4061_EN Rev.B June 2019...
Page 81: Taking Out Of Operation For A Long Period
The engine lubricating oil is replaced by a preservative oil and circulated with the pre-lub- rication pump before the engine is taken out of operation. If neither of the criteria above are met, mothballing by an ABB Turbocharging Service Station is necessary. This includes cleaning and applying preservative oil to the relevant compon- ents.
Page 82: 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 2019 ABB. All rights reserved. HZTL4061_EN Rev.B June 2019...
Page 83: Spare Parts
Operation Manual / Power2 … / 4.1 Low-pressure stage. For more information on spare parts for the high-pressure stage, see document Operation Manual / Power2 … / 4.2 High-pressure stage. © Copyright 2019 ABB. All rights reserved. HZTL4061_EN Rev.B June 2019...
Page 84: Figures
Fig. 10: Lubricating oil pressure measuring point.. 18 Fig. 11: Functional principle ........20 Fig. 12: Load/time chart..........32 Fig. 13: Cleaning the filter silencer ......35 Fig. 14: Cover grid connecting rods......37 © Copyright 2019 ABB. All rights reserved. HZTL4061_EN Revision B June 2019...
Page 85 Table 25: Malfunctions during operation – Charge air pressure too low............41 Table 26: Malfunctions during operation – Charge air pressure too high ............41 Table 27: Malfunctions during operation – Com- pressor 1 contamination..........42 © Copyright 2019 ABB. All rights reserved. HZTL4061_EN Revision B June 2019...
Page 87 Possible emergency repairs..................34 Spare parts ......................37 Ordering spare parts....................37 View of low-pressure stage with part numbers ........... 40 Figures........................42 Tables ........................43 © Copyright 2019 ABB. All rights reserved. HZTL4062_EN Revision A March 2019...
Page 88: Further Applicable Documents
Operation Manual / Power2 / 3 Safety data sheet *) Power2 serial number (HT……) Operation Manual / Power2 800-M / 4 Product description HZTL4061 Table 1: Related documents *) This chapter is only available in serialised operation manuals. © Copyright 2019 ABB. All rights reserved. HZTL4062_EN Revision A March 2019...
Page 89: Removal And Installation
Transport / weight Swivel lifting eyes to be used Two swivel lifting eyes (S) are required for the safe lifting of loads. These are not included in the ABB Turbo Systems scope of delivery. Swivel lifting eye (S) Power2 Thread...
Page 90: Removing The Low-Pressure Stage
Lift the low-pressure stage from the engine. Put down the low-pressure stage so that all contact surfaces of the feet make contact. Also place a support made from hard wood beneath the compressor casing. © Copyright 2019 ABB. All rights reserved. HZTL4062_EN Revision A...
Page 91: Installing The Low-Pressure Stage
Attach all gas, air, cleaning and oil pipes according to the instructions of the engineb- uilder. Connect the cable connector to the speed sensor. Fit insulation according to the instructions of the enginebuilder. © Copyright 2019 ABB. All rights reserved. HZTL4062_EN Revision A March 2019...
Page 92: Expected Replacement Intervals
Table 4: 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 2019 ABB. All rights reserved. HZTL4062_EN Revision A March 2019...
Page 93 Lubricating oil quality (oil filtering, oil condition, oil monitoring) ¡ Load profile (speed, pressure conditions, temperature) ¡ Number of starts/stops ¡ Unbalance of the rotor (degree of contamination). © Copyright 2019 ABB. All rights reserved. HZTL4062_EN Revision A March 2019...
Page 94: Disassembly And Assembly
Table of →32). tightening torques Tightening torques for assembly devices Unless described otherwise, the screws and nuts of the assembly devices supplied by ABB must be tightened so they rest firmly against the surface. Definition of terms ¡ Suspension point Defined loading point on a component or an assembly (blind hole thread, eyelet, lug).
Page 95 Use assembly devices only for the described ap- plications. ¡ Lifting gear Equipment for the lifting and transporting of loads (ropes, chain block, crane). Lifting gear is not supplied by ABB Turbo Systems. © Copyright 2019 ABB. All rights reserved. HZTL4062_EN Revision A March 2019...
Page 96: Weights Of Assemblies
01 Air suction branch 02 Filter silencer 03 Wall insert 04 Diffuser 05 Compressor casing 06 Cartridge group 07 Turbine diffuser 08 Nozzle ring Table 5: Weights of the assemblies © Copyright 2019 ABB. All rights reserved. HZTL4062_EN Revision A March 2019...
Page 97: Removing The Filter Silencer
(90231) and loop through the eyelets at the rear of the filter silencer (81000). 2. Loosen and remove nuts (72004). Remove washers (72003). 3. Remove and put down filter silencer. 4. Loosen and remove nuts (77022). Remove sleeves (77023). © Copyright 2019 ABB. All rights reserved. HZTL4062_EN Revision A March 2019...
Page 98: Removing The Air Suction Branch
1. Loop around air suction branch (82000) with lifting gear. 2. Loosen and remove nuts (72004). Remove washers (72003). 3. Remove and put down the air suction branch. © Copyright 2019 ABB. All rights reserved. HZTL4062_EN Revision A March 2019...
Page 99: Axial Clearance A Prior To Disassembly
Clearances outside the tolerance 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 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.
Page 100: Removing Wall Insert
2. Use three press-off screws (90920) to press off the wall insert (77000) until the lifting device can be fitted. 3. Remove the press-off screws (90920). 4. Remove two studs (72002) in the upper area. © Copyright 2019 ABB. All rights reserved. HZTL4062_EN Revision A March 2019...
Page 101 10. Put down the wall insert (77000). 11. Remove plate (90032), screw (90656), nut (90432) and plates (90031). Remove lifting gear and bracket (90030). 12. Remove O-rings (77040 / 79020 / 79021). 13. Loosen screws (77016) and remove diffuser (79000). © Copyright 2019 ABB. All rights reserved. HZTL4062_EN Revision A March 2019...
Page 102: Removing The Compressor Casing
4. Secure lifting gear to swivel lifting eye (90231) and secure compressor casing (72000) to crane. 5. Loosen and remove nuts (61037). 6. Press off compressor casing (72000) with three press-off screws (90924). 7. Move out compressor casing (72000) and put down. © Copyright 2019 ABB. All rights reserved. HZTL4062_EN Revision A March 2019...
Page 103: Removing The Cartridge Group
5. Secure lifting gear to swivel lifting eye (90231) and secure cartridge group to crane. 6. Evenly press off cartridge group by screwing three press-off screws (90920) into the des- ignated holes. © Copyright 2019 ABB. All rights reserved. HZTL4062_EN Revision A...
Page 104 The cover must be on a level surface. The cover may not be used to transport the cartridge group. Fig. 14: Putting down cartridge group onto cover © Copyright 2019 ABB. All rights reserved. HZTL4062_EN Revision A March 2019...
Page 105: Removing Turbine Diffuser And Nozzle Ring
4. Loosely screw in three press-off screws (90902). 5. Secure guide tube (90422) to bracket (90030) with screws (90955) and nuts (90415). 6. Do not fit front bolt (90033) yet. © Copyright 2019 ABB. All rights reserved. HZTL4062_EN Revision A...
Page 106 Remove plate (90032), screw (90656), nut (90432) and plates (90031). Remove press-off screws (90902). 8. Loosen screws (56017) with box spanner insert (90770) and remove together with clamps (56018). 9. Remove nozzle ring (56001). © Copyright 2019 ABB. All rights reserved. HZTL4062_EN Revision A March 2019...
Page 107: Installing The Nozzle Ring And Turbine Diffuser
(see Fig. 17: Removing turbine diffuser and nozzle ring 3 →20)) 6. Insert turbine diffuser (63000) via the guide studs. 7. Coat a screw (61056) with high-temperature grease and screw in to secure the turbine diffuser. © Copyright 2019 ABB. All rights reserved. HZTL4062_EN Revision A March 2019...
Page 108 2. Loosen screws (90961) and remove together with star plate (90414). Remove guide stud (90316). 3. Coat thread of remaining screws (61056) with high-temperature grease and fit screws. Observe the tightening torque. © Copyright 2019 ABB. All rights reserved. HZTL4062_EN Revision A March 2019...
Page 109: Installing The Cartridge Group
2. Fit swivel lifting eye (90231) to bracket (90030) and secure lifting gear to swivel lifting eye. 3. Fit five plates (90031) and secure with plate (90032), screw (90656) and nut (90432). 4. Lift the cartridge group. © Copyright 2019 ABB. All rights reserved. HZTL4062_EN Revision A March 2019...
Page 110 5. Remove the guide stud (90321). 6. Coat thread of remaining screws (42087) with high-temperature grease and fit screws. Observe the tightening torque. 7. Fit a new O-ring (42012). © Copyright 2019 ABB. All rights reserved. HZTL4062_EN Revision A March 2019...
Page 111 Remove and reinstall the cartridge group. Always replace jammed gasket rings with new ones. If the control dimension is still out of tolerance, contact an ABB Tur- bocharging Service Station. Fig. 24: Measuring control dimension X After installing the cartridge group, the control dimension (X) must be measured.
Page 112: Installing The Compressor Casing
(see Fig. 10: Removing the compressor casing 1 →16)). 2. Fit nuts (61037). Observe the tightening torque. 3. Remove plates (90031) and bracket (90030). 4. Fit screw (72021). Observe the tightening torque. © Copyright 2019 ABB. All rights reserved. HZTL4062_EN Revision A March 2019...
Page 113: Installing The Wall Insert
5. Lift the wall insert and remove the support angle (90480). 6. Carefully insert the wall insert. 7. Fix the wall insert in place with two opposing nuts (72004) and washers (72003). © Copyright 2019 ABB. All rights reserved. HZTL4062_EN Revision A March 2019...
Page 114 2. Remove the bracket (90030). 3. Detach speed measurement cable from provisional holder and insert cable con- nector (86515). 4. Fit four studs (72002) in the upper area. Observe the tightening torque. © Copyright 2019 ABB. All rights reserved. HZTL4062_EN Revision A March 2019...
Page 115: Axial Clearance A After Assembly
Clearances outside the tolerance 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 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.
Page 116: Installing The Air Suction Branch
3. Position the air suction branch. 4. Fit nuts (72004) with washers (72003) and tighten nuts (72004). Reinstall dismantled insulation. Reinstall all air lines according to the instructions of the enginebuilder. © Copyright 2019 ABB. All rights reserved. HZTL4062_EN Revision A March 2019...
Page 117: Installing The Filter Silencer
4. Fit the filter silencer. 5. Fit nuts (72004) and washers (72003) and tighten nuts (72004). If present: Connect supply line for compressor cleaning to filter silencer. Reinstall dismantled insulation. © Copyright 2019 ABB. All rights reserved. HZTL4062_EN Revision A March 2019...
Page 118: Table Of Tightening Torques
Operation Manual / Power2 850-M / 4.1 Low-pressure stage 4 Disassembly and assembly / 4.17 Table of tightening torques 4.17 Table of tightening torques Fig. 31: Overview of tightening torques © Copyright 2019 ABB. All rights reserved. HZTL4062_EN Revision A March 2019...
Page 119 72004 (nuts that are difficult to access) Pre-tightening torque 60 Nm Tightening angle 60° ±5° 72021 M10x20 70 Nm 77016 M5x35 5 Nm 77022 200 Nm Table 17: Tightening torques © Copyright 2019 ABB. All rights reserved. HZTL4062_EN Revision A March 2019...
Page 120: Taking Out Of Operation At Short Notice
If damage has occurred to the low-pressure stage and the engine has to be brought back into operation again as quickly as possible, the following emergency repair option is avail- able: ¡ Attaching the cover plate © Copyright 2019 ABB. All rights reserved. HZTL4062_EN Revision A March 2019...
Page 121 The cover plate and the other parts that are required are not part of the scope of delivery of ABB Turbo Systems and must be manufactured by the operator on the basis of the drawing (see Fig. 32: Cover plate / gasket, sleeves and screws →35).
Page 122 Escaping lubricating oil If the cover plate is fitted, complete sealing of the lubricating oil supply is not guaranteed. Shut off lubricating oil supply to low-pressure stage at engine side. © Copyright 2019 ABB. All rights reserved. HZTL4062_EN Revision A March 2019...
Page 123: Spare Parts
Designation and part number. Spare parts can be ordered from an ABB Turbocharging Service Station. If different model variants are not taken into account in this document, contact an ABB Turbocharging Service Station. Dispose of placed and unusable parts in an environmentally-friendly and professional manner in accordance with the local regulations.
Page 124 56018 Clamp 61037 Hex nut 61056 Hexagon-head screw 72003 Washer 72004 / 77022 Hex nut 77016 Hexagon-head screw 77040 O-ring 79021 O-ring Table 20: Customer spare part set (97070) © Copyright 2019 ABB. All rights reserved. HZTL4062_EN Revision A March 2019...
Page 126: View Of Low-Pressure Stage With Part Numbers
6 Spare parts / 6.2 View of low-pressure stage with part numbers View of low-pressure stage with part numbers Fig. 35: Low-pressure stage with part numbers (……) only available in customer spare part set (97070). © Copyright 2019 ABB. All rights reserved. HZTL4062_EN Revision A March 2019...
Page 127 O-ring 79021 (in customer spare part set) O-ring 81000 Filter silencer 82000 Air suction branch 86505 / 86515 Speed sensor / connecting cable Table 21: Low-pressure stage part numbers © Copyright 2019 ABB. All rights reserved. HZTL4062_EN Revision A March 2019...
Page 128: Figures
Fig. 27: Installing wall insert 2 ........28 Fig. 28: Measuring axial clearance A ......29 Fig. 29: Installing the air suction branch ....30 Fig. 30: Installing the filter silencer ......31 © Copyright 2019 ABB. All rights reserved. HZTL4062_EN Revision A March 2019...
Page 129: Tables
Table 18: Cover plate / gasket ........35 Table 19: Tightening torque (42087) ......36 Table 20: Customer spare part set (97070) .... 38 Table 21: Low-pressure stage part numbers ... 41 © Copyright 2019 ABB. All rights reserved. HZTL4062_EN Revision A March 2019...
Page 131 Taking out of operation at short notice ............29 Possible emergency repairs..................29 Spare parts ......................32 Ordering spare parts....................32 View of high-pressure stage with part numbers..........34 Figures........................36 Tables ........................37 © Copyright 2018 ABB. All rights reserved. HZTL4063_EN Revision B October 2018...
Page 132: Further Applicable Documents
Operation Manual / Power2 / 3 Safety data sheet *) Power2 serial number (HT……) Operation Manual / Power2 800-M / 4 Product description HZTL4061 Table 1: Related documents *) This chapter is only available in serialised operation manuals. © Copyright 2018 ABB. All rights reserved. HZTL4063_EN Revision B October 2018...
Page 133: Removal And Installation
Transport / weight Swivel lifting eyes to be used Two swivel lifting eyes (S) are required for the safe lifting of loads. These are not included in the ABB Turbo Systems scope of delivery. Swivel lifting eye (S) Power2 Thread...
Page 134: 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. Undo fixing screws at foot and support. Lift the high-pressure stage from the engine and put it down. Cover the oil connection. © Copyright 2018 ABB. All rights reserved. HZTL4063_EN Revision B October 2018...
Page 135: Installing The High-Pressure Stage
Install air suction branch together with bellows (see Fig. 23: Installing the air suction branch →27). Attach all gas, air, water and oil pipes in accordance with the enginebuilder's instructions. Fit insulation. © Copyright 2018 ABB. All rights reserved. HZTL4063_EN Revision B October 2018...
Page 136: Expected Replacement Intervals
Table 4: 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 2018 ABB. All rights reserved. HZTL4063_EN Revision B October 2018...
Page 137 Lubricating oil quality (oil filtering, oil condition, oil monitoring) ¡ Load profile (speed, pressure conditions, temperature) ¡ Number of starts/stops ¡ Imbalance of the rotor (degree of contamination). © Copyright 2018 ABB. All rights reserved. HZTL4063_EN Revision B October 2018...
Page 138: Disassembly And Assembly
(see Table 13: Tightening torques →28). Tightening torques for assembly devices Unless described otherwise, the screws and nuts of the assembly devices supplied by ABB must be tightened so they rest firmly against the surface. Definition of terms ¡ Suspension point Defined loading point on a component or an assembly (blind hole thread, eyelet, lug).
Page 139 Use assembly devices only for the described ap- plications. ¡ Lifting gear Equipment for the lifting and transporting of loads (ropes, chain block, crane). Lifting gear is not supplied by ABB Turbo Systems. © Copyright 2018 ABB. All rights reserved. HZTL4063_EN Revision B October 2018...
Page 140: Weights Of Assemblies
Weight [kg] 01 Air suction branch 02 Bellows 03 Wall insert 04 Compressor casing 05 Cartridge group with hood diffuser and nozzle ring Table 5: Weights of the assemblies © Copyright 2018 ABB. All rights reserved. HZTL4063_EN Revision B October 2018...
Page 141: 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 2018 ABB. All rights reserved. HZTL4063_EN Revision B October 2018...
Page 142: Removing 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 2018 ABB. All rights reserved. HZTL4063_EN Revision B October 2018...
Page 143 4 Disassembly and assembly / 4.4 Removing wall insert Fig. 7: 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 2018 ABB. All rights reserved. HZTL4063_EN Revision B October 2018...
Page 144: 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 2018 ABB. All rights reserved. HZTL4063_EN Revision B...
Page 145: Removing The Cartridge Group
Fig. 10: 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 2018 ABB. All rights reserved. HZTL4063_EN Revision B October 2018...
Page 146 9. Lower the cartridge group into the holders of the turned-over toolbox cover (90010) and leave it secured to the crane. 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). © Copyright 2018 ABB. All rights reserved. HZTL4063_EN Revision B October 2018...
Page 147 Operation Manual / Power2 850-M / 4.2 High-pressure stage 4 Disassembly and assembly / 4.6 Removing the cartridge group Fig. 12: Moving out cartridge group 4 12. Remove O-rings (42017 / 42018). © Copyright 2018 ABB. All rights reserved. HZTL4063_EN Revision B October 2018...
Page 148: Removing The Nozzle Ring
4 Disassembly and assembly / 4.7 Removing the nozzle ring Removing the nozzle ring Fig. 13: Removing the nozzle ring 1. Slacken and remove screws (56017) with box spanner insert (90770). 2. Remove nozzle ring (56001). © Copyright 2018 ABB. All rights reserved. HZTL4063_EN Revision B October 2018...
Page 149: Measuring Axial Clearance A
Clearances outside the tolerance 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 an ABB Tur- bocharging Service Station. Fig. 14: Measuring axial clearance A The axial clearance (A) must be measured after removal and before installation of the cart- ridge group.
Page 150: Installing The Nozzle Ring
25 Nm Table 7: 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 2018 ABB. All rights reserved. HZTL4063_EN Revision B October 2018...
Page 151: Installing The Cartridge Group
2. Fit bracket (90030) and plates (90031) (Bracket assembly (see Fig. 9: Moving out cart- ridge group 1 →15)). 3. Fit lifting gear to swivel lifting eye (90657). 4. Lift cartridge group and carefully move in. © Copyright 2018 ABB. All rights reserved. HZTL4063_EN Revision B October 2018...
Page 152 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 the tightening torque. 9. Fit a new O-ring (42010). © Copyright 2018 ABB. All rights reserved. HZTL4063_EN Revision B October 2018...
Page 153 Remove and reinstall the cartridge group. Always replace jammed gasket rings with new ones. If the control dimension is still out of tolerance, contact an ABB Tur- bocharging Service Station. © Copyright 2018 ABB. All rights reserved.
Page 154: Installing The Compressor Casing
2. Secure lifting gear to swivel lifting eye (90657) and insert compressor casing. (Installation of bracket and plates (see Fig. 8: Removing the compressor casing →14)). 3. Fit nuts (61090). Observe the tightening torque. 4. Remove plates (90031) and bracket (90030). © Copyright 2018 ABB. All rights reserved. HZTL4063_EN Revision B October 2018...
Page 155: 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 2018 ABB. All rights reserved. HZTL4063_EN Revision B October 2018...
Page 156 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 2018 ABB. All rights reserved. HZTL4063_EN Revision B October 2018...
Page 157: 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 2018 ABB. All rights reserved. HZTL4063_EN Revision B October 2018...
Page 158: Table Of Tightening Torques
61090 (nuts that are difficult to access) Pre-tightening torque 40 Nm Tightening angle 40° ±5° 72002 M12x95 50 Nm 72004 120 Nm 82022 M12x45 210 Nm Table 13: Tightening torques © Copyright 2018 ABB. All rights reserved. HZTL4063_EN Revision B October 2018...
Page 159: 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 2018 ABB. All rights reserved. HZTL4063_EN Revision B October 2018...
Page 160 The cover plate and the other parts that are required are not part of the scope of delivery of ABB Turbo Systems and must be manufactured by the operator on the basis of the drawing (see Fig. 25: Cover plate / gasket and sleeves →30).
Page 161 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 2018 ABB. All rights reserved. HZTL4063_EN Revision B October 2018...
Page 162: Spare Parts
Designation and part number. Spare parts can be ordered from an ABB Turbocharging Service Station. If different model variants are not taken into account in this document, contact an ABB Turbocharging Service Station. Dispose of placed and unusable parts in an environmentally-friendly and professional manner in accordance with the local regulations.
Page 163 42012 / 77040 O-ring 42017 O-ring 42018 O-ring 42099 Socket screw 56017 Hexalobular-head screw 61090 / 72004 Hex nut 64001 Lamellar ring 72003 Washer Table 16: Customer spare part set (97070) © Copyright 2018 ABB. All rights reserved. HZTL4063_EN Revision B October 2018...
Page 164: View Of High-Pressure Stage With Part Numbers
6 Spare parts / 6.2 View of high-pressure stage with part numbers View of high-pressure stage with part numbers Fig. 28: High-pressure stage with part numbers (……) only available in customer spare part set (97070). © Copyright 2018 ABB. All rights reserved. HZTL4063_EN Revision B October 2018...
Page 165 77040 (in customer spare part set) O-ring 81000 Filter silencer 82000 Air suction branch 82022 Hexagon-head screw 82300 Bellows 86505 / 86515 Speed sensor / connecting cable Table 17: High-pressure stage part numbers © Copyright 2018 ABB. All rights reserved. HZTL4063_EN Revision B October 2018...
Page 166: Figures
Fig. 24: Tightening torques ........28 Fig. 25: Cover plate / gasket and sleeves ....30 Fig. 26: Fitting the cover plate........31 Fig. 27: Installing the casing........31 Fig. 28: High-pressure stage with part numbers... 34 © Copyright 2018 ABB. All rights reserved. HZTL4063_EN Revision B October 2018...
Page 167: Tables
Table 13: Tightening torques ........28 Table 14: Cover plate / gasket ........30 Table 15: Tightening torque (42099) ......31 Table 16: Customer spare part set (97070)....33 Table 17: High-pressure stage part numbers ..35 © Copyright 2018 ABB. All rights reserved. HZTL4063_EN Revision B October 2018...

ABB Power2 850-M46 Operation Manual

Quick Links

Related Manuals for ABB Power2 850-M46

Summary of Contents for ABB Power2 850-M46

Table of Contents