Page 1 Operation Manual Power2 850-M16 HT579962_A English Original Operation Manual Chapter Document-ID Introduction HZTL4004_EN_D Safety HZTL4025_EN_A Safety data sheets HT579962_A Product description HZTL4061_EN_A Low-pressure stage PT002040 HZTL4062_EN_- High-pressure stage PT002039 HZTL4063_EN_A 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: Table Of Contents
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 2018 ABB. All rights reserved. HZTL4025_EN Revision A March 2018...
Page 12: Introduction
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: Definition Of Mandatory Signs
CAUTION can lead to seri- ous damage to engine or property with grave consequences. Caution signs must always be observed. © Copyright 2018 ABB. All rights reserved. HZTL4025_EN Revision A March 2018...
Page 14: Intended Use
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: Deflagration On Gas Engines
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: Warning Plates On The Low-Pressure And High-Pressure Stage
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 2018 ABB. All rights reserved. HZTL4025_EN Revision A...
Page 17: Rating Plate Of The High-Pressure And 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 5 © Copyright 2018 ABB. All rights reserved. HZTL4025_EN Revision A March 2018...
Page 18: Periodic Check Of The Pressure Vessels
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: 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 2018 ABB. All rights reserved. HZTL4025_EN Revision A March 2018...
Page 20: Prerequisites For Operation And Maintenance
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: 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 2018 ABB. All rights reserved. HZTL4025_EN Revision A March 2018...
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: 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 2018 ABB. All rights reserved. HZTL4025_EN Revision A March 2018...
Page 24: Safe Maintenance
Keep the floor, equipment and the low-pressure and high-pressure stage clean. Have oil binding agents ready and provide or keep oil pans at hand. Welding work Wear personal protective equipment (PPE) for welding operations. © Copyright 2018 ABB. All rights reserved. HZTL4025_EN Revision A March 2018...
Page 25: Copyright 2018 Abb. All Rights Reserved. Hztl4025_En Revision A March
Secure rotor against turning. The rotor can rotate due to the stack draught alone. 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 2018 ABB. All rights reserved. HZTL4025_EN Revision A...
Page 26 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 2018 ABB. All rights reserved. HZTL4025_EN Revision A March 2018...
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 2018 ABB. All rights reserved. HZTL4025_EN Revision A March 2018...
Page 29 Operation Manual / Power2 850-M16 / Safety data sheets Contents Page 1 / 3 Safety data sheets Power2 850-M16 HT579962 Name Hardware ID Page Low-pressure stage PT002040 High-pressure stage PT002039 © Copyright 2018 ABB. All rights reserved. HT579962_A August 2018...
Page 30 Operation Manual / Power2 850-M16 / Safety data sheets Page 2 / 3 Safety data sheet Power2 850-M16 HT579962 Low-pressure stage PT002040 Power2 850-M16 HT579962 Low-pressure stage PT002040 2018 1800 HZTL53380D Additional Safety Data: Maximum permissible temperatures At engine overload (110 %) in test rig [°C]...
Page 31 Operation Manual / Power2 850-M16 / Safety data sheets Page 3 / 3 Safety data sheet Power2 850-M16 HT579962 High-pressure stage PT002039 Power2 850-M16 HT579962 High-pressure stage PT002039 2018 HZTL53380D Additional Safety Data: Maximum permissible temperatures At engine overload (110 %) in test rig [°C]...
Page 33: Power2 Layout And Function
Cleaning the filter silencer ................Troubleshooting ..................Malfunctions when starting ................. Malfunctions during operation ..............Surging of the low-pressure or high-pressure stage ........Malfunctions when stopping ............... Speed measurement system ..............© Copyright 2016 ABB. All rights reserved. HZTL4061_EN Revision A September 2016...
Page 34 10.2 Taking the engine out of operation for more than 12 months ...... Disposing of low-pressure and high-pressure stage components ....Spare parts ..................... Figures ....................Tables ....................© Copyright 2016 ABB. All rights reserved. HZTL4061_EN Revision A September 2016...
Page 35 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 36 01 Filter silencer / air suction branch Gas inlet casing 02 Compressor wheel Nozzle ring 03 Diffuser Turbine 04 Bearing bush with heat shield Bearing casing 05 Gas outlet casing Compressor casing © Copyright 2016 ABB. All rights reserved. HZTL4061_EN Revision A September 2016...
Page 37 Air or air/gas mixture inlet Air or air/gas mixture outlet and supply to - - - Not included in the ABB Turbo Sys- 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 38 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 2016 ABB. All rights reserved. HZTL4061_EN Revision A September 2016...
Page 39 Air or air/gas mixture inlet Air or air/gas mixture outlet and supply to - - - Not included in the ABB Turbo Sys- 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 40 Figure 7: Locations of Power2 HP warning plates If warning plates are not present in the designated locations or not readable, proceed as follows: Order new warning plates from ABB Turbocharging Service Stations.  Remove any warning plates that have become unreadable.
Page 41 Figure 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 2016 ABB. All rights reserved. HZTL4061_EN Revision A...
Page 43 Operation Manual / Power2 … / 4.1 Low-pressure stage. For more information on how to remove and install the high-pressure stage, see document  Operation Manual / Power2 … / 4.2 High-pressure stage. © Copyright 2016 ABB. All rights reserved. HZTL4061_EN Revision A September 2016...
Page 45 Let the oil pump run until the pump driven by the engine is generating sufficient oil pressure.  Power2 Pre-lubrication time 2 min … 6 h Table 1: Pre-lubrication time ABB Turbo Systems recommends integrating the entire pre-lubrication cycle into the engine control. © Copyright 2016 ABB. All rights reserved. HZTL4061_EN Revision A September 2016...
Page 46 Inspection procedures include preventative visual controls, monitoring and measuring work before and during commissioning. Inspection procedures enable changes to the low and high- pressure stage to be detected. Engine damage can be prevented. © Copyright 2016 ABB. All rights reserved. HZTL4061_EN Revision A...
Page 47  Check oil inlet temperature.  The admissible values are specified in chapter Monitoring during operation [➙ 17]. Tightness of pipes Check all the pipes for tightness.  © Copyright 2016 ABB. All rights reserved. HZTL4061_EN Revision A September 2016...
Page 48 NOTICE initial hours of operation. Continual escape of an oily fluid indicates a possi- ble oil leak. If there is a leak, contact an ABB Turbocharging Service Station. Commissioning after taking out of operation If present Remove cover plates (blind flanges) on the compressor casing, on the gas-inlet as well as ...
Page 49  necessary pressure assured at the oil inlet. For monitoring the lubricating oil pressure, ABB Turbo Systems recommends installing a ma- nometer "M". If the pressure is controlled electronically, the appropriate signals are to be trig- gered at the warning and alarm values.
Page 50 Table 6: Lubricating oil temperature at the outlet If the low or high-pressure stage was operated for a longer period of time outside of the ad- missible range, ABB Turbo Systems recommends to have the low or high-pressure stage in- spected by an ABB Turbocharging Service Station.
Page 51 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.  CAUTION © Copyright 2016 ABB. All rights reserved. HZTL4061_EN Revision A September 2016...
Page 52 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 chapter Troubleshooting / Speed measurement system [➙...
Page 53 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 insula- tion versions © Copyright 2016 ABB. All rights reserved. HZTL4061_EN Revision A September 2016...
Page 54 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. 5.2.1 Service procedures every 25 …...
Page 55 Operation and service Page 23 / 59 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 56 CAUTION occur. Observe the post-lubrication times and the oil pressure specified for post-  lubrication (see chapter Monitoring during operation / Lubricating oil pres- sure). © Copyright 2016 ABB. All rights reserved. HZTL4061_EN Revision A September 2016...
Page 57 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 58 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 2016 ABB. All rights reserved. HZTL4061_EN Revision A...
Page 59 ABB Turbocharging Service Station. The reduction of the engine load can lead to a reduction in the effectiveness of the compressor cleaning.
Page 60 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 61 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 possi- ble.
Page 62 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 63 NOTICE ing cleaning. If this is the case, the engine load is to be lowered until the permissible temperature is reached. © Copyright 2016 ABB. All rights reserved. HZTL4061_EN Revision A September 2016...
Page 64 If this is not possible, the specified water pressure at the cleaning connection of the turbocharger is to be set as a rough ap- proximation. © Copyright 2016 ABB. All rights reserved. HZTL4061_EN Revision A September 2016...
Page 65 In such cases, the cleaning operations must be stopped and the cleaning cycle restarted with reduced water pressure or higher engine load. © Copyright 2016 ABB. All rights reserved. HZTL4061_EN Revision A...
Page 66 Surface of the flow channel at the nozzle ring ring inlet of the HP turbine stage inlet of the LP turbine stage 0.031 0.068 Table 14: Surface of the flow channel © Copyright 2016 ABB. All rights reserved. HZTL4061_EN Revision A September 2016...
Page 67 Clean filter ring (81265) as required or every 500 hours of operation and replace after the  fifth cleaning process at the latest. Contamination of the filter ring depends on the degree of purity of the sucked-in air. © Copyright 2016 ABB. All rights reserved. HZTL4061_EN Revision A September 2016...
Page 68 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- ...
Page 69 Fit lock nuts (81273) to screws (81272) and tighten with the tightening torque shown  above: Fit the filter ring (81265), if present.  © Copyright 2016 ABB. All rights reserved. HZTL4061_EN Revision A September 2016...
Page 71 To prevent significant loss of efficiency, specific tolerances must be fulfilled.  If there is any doubt about the extent of the rubbing, contact an ABB Turbocharg- ing Service Station.  Have a dimension check carried out by an ABB Turbocharging Service Station.
Page 72 Defects on the connected cylinders Contact enginebuilder High-pressure Heavy contamination of the turbine Clean stage Damaged rotor components or bearing Contact ABB Turbocharging Service Sta- tion Change of operating state of low- Check the operating point of the low- pressure stage pressure stage.
Page 73 Table 22: Malfunctions during operation – Power2 LP speed increases Increase in high-pressure stage speed Possible causes Remedy High-pressure Heavy contamination of the nozzle ring Contact ABB Turbocharging Service Sta- stage tion Low-pressure stage defective Contact ABB Turbocharging Service Sta-...
Page 74 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 2016 ABB. All rights reserved. HZTL4061_EN Revision A September 2016...
Page 75 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 2016 ABB. All rights reserved. HZTL4061_EN Revision A September 2016...
Page 76  Have the cause clarified and remedied immediately by an ABB Turbo-  charging 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 77 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 2016 ABB. All rights reserved. HZTL4061_EN Revision A September 2016...
Page 79: Disassembly And Assembly
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 2016 ABB. All rights reserved. HZTL4061_EN Revision A September 2016...
Page 81: Taking Out Of Operation At Short Notice
Operation Manual / Power2 … / 4.1 Low-pressure stage. For more information on briefly taking the high-pressure stage out of operation, see docu-  ment Operation Manual / Power2 … / 4.2 High-pressure stage. © Copyright 2016 ABB. All rights reserved. HZTL4061_EN Revision A September 2016...
Page 83: Mothballing The Low-Pressure And High-Pressure Stage
If the acid number (TAN) is greater than 2 mg KOH/g, the following mothballing measures are necessary after taking the engine out of operation: Dismantle low-pressure and high-pressure stage  The rotor and bearing parts must be dismantled and subsequently refitted by an ABB  Turbocharging Service Station Clean all parts ...
Page 84: Taking The Engine Out Of Operation For More Than 12 Months
 Low-pressure and high-pressure stage remain attached to the engine.  The casings of the low-pressure and high-pressure stage remain attached to the engine, the rotor and the bearing parts are dismantled by an ABB Turbocharging Service Station and stored separately.
Page 85: 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. WARNING The enginebuilder's instructions must be followed for the handling and  disposal of the thermal insulation. © Copyright 2016 ABB. All rights reserved. HZTL4061_EN Revision A September 2016...
Page 87: 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 2016 ABB. All rights reserved. HZTL4061_EN Revision A September 2016...
Page 89: Figures
Fig. 10 Lubricating oil pressure measur- ing point ........Fig. 11 Functional principle ....Fig. 12 Load/time chart ......Fig. 13 Cleaning the filter silencer ..Fig. 14 Cover grid connecting rods ..© Copyright 2016 ABB. All rights reserved. HZTL4061_EN Revision A September 2016...
Page 91: Tables
Table 22 Malfunctions during operation – Power2 LP speed increases. Table 23 Malfunctions during operation – Power2 HP speed increases Table 24 Malfunctions during operation – Exhaust gas temperature too high......... © Copyright 2016 ABB. All rights reserved. HZTL4061_EN Revision A September 2016...
Page 93 Taking out of operation at short notice ............Possible emergency repairs ................ Spare parts ....................Ordering spare parts ................... View of low-pressure stage with part numbers ..........Figures ....................... Tables ......................HZTL4062_EN Revision - © Copyright 2015 ABB. All rights reserved. December 2015...
Page 95: Further Applicable Documents
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. HZTL4062_EN Revision - © Copyright 2015 ABB. All rights reserved. December 2015...
Page 97: 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 98: Removing The Low-Pressure Stage
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.  HZTL4062_EN Revision - © Copyright 2015 ABB. All rights reserved. December 2015...
Page 99: Installing The Low-Pressure Stage
Attach all gas, air, cleaning and oil pipes according to the instructions of the enginebuilder.  Connect the cable connector to the speed sensor.  Fit insulation according to the instructions of the enginebuilder.  HZTL4062_EN Revision - © Copyright 2015 ABB. All rights reserved. December 2015...
Page 101: 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 influence parameters. HZTL4062_EN Revision - © Copyright 2015 ABB. All rights reserved. December 2015...
Page 102  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). HZTL4062_EN Revision - © Copyright 2015 ABB. All rights reserved. December 2015...
Page 103: Disassembly And Assembly
ABB Turbo Systems recommends having further operations carried out  only by trained staff or an ABB Turbocharging Service Station. Marking casing position for assembly ABB Turbo Systems recommends marking the casing positions prior to disassembly.
Page 104 Disassembly and assembly Page 12 / 49 Tightening torques for assembly devices Unless described otherwise, the screws and nuts of the assembly devices supplied by ABB Turbo Systems must be tightened so they rest firmly against the surface. Definition of terms ...
Page 105: 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 HZTL4062_EN Revision - © Copyright 2015 ABB. All rights reserved. December 2015...
Page 106: 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. HZTL4062_EN Revision - © Copyright 2015 ABB. All rights reserved. December 2015...
Page 107: 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). HZTL4062_EN Revision - © Copyright 2015 ABB. All rights reserved. December 2015...
Page 108: Axial Clearance A Prior To Disassembly
Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. CAUTION Have the components assessed and, if necessary, replaced by an ABB  Turbocharging Service Station. Figure 6: Measuring axial clearance A The axial clearance (A) must be measured prior to removal and after installation of the cartridge group.
Page 109: 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. HZTL4062_EN Revision - © Copyright 2015 ABB. All rights reserved. December 2015...
Page 110 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). HZTL4062_EN Revision - © Copyright 2015 ABB. All rights reserved. December 2015...
Page 111: 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 and put down compressor casing (72000). HZTL4062_EN Revision - © Copyright 2015 ABB. All rights reserved. December 2015...
Page 112: 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 designated holes. HZTL4062_EN Revision - © Copyright 2015 ABB. All rights reserved. December 2015...
Page 113 The cover must be on a level surface.  The cover may not be used to transport the cartridge group.  Figure 14: Putting down cartridge group onto cover HZTL4062_EN Revision - © Copyright 2015 ABB. All rights reserved. December 2015...
Page 114: 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. HZTL4062_EN Revision - © Copyright 2015 ABB. All rights reserved. December 2015...
Page 115 Remove plate (90032), screw (90656), nut (90432) and plates (90031). Remove press-off screws (90902). 14. Loosen screws (56017) with box spanner insert (90770) and remove together with clamps (56018). 15. Remove nozzle ring (56001). HZTL4062_EN Revision - © Copyright 2015 ABB. All rights reserved. December 2015...
Page 116: Installing The Nozzle Ring And Turbine Diffuser
(For installation of bracket and plate, see [➙ 22]) 6. Insert turbine diffuser (6300) via the guide studs. 7. Coat a screw (61056) with high-temperature grease and screw in to secure the turbine diffuser. HZTL4062_EN Revision - © Copyright 2015 ABB. All rights reserved. December 2015...
Page 117 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, fit screws and tighten all screws. HZTL4062_EN Revision - © Copyright 2015 ABB. All rights reserved. December 2015...
Page 118: 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. HZTL4062_EN Revision - © Copyright 2015 ABB. All rights reserved. December 2015...
Page 119 5. Remove the guide stud (90321). 6. Coat thread of remaining screws (42087) with high-temperature grease, fit screws and tighten all screws. 7. Fit a new O-ring (42012). HZTL4062_EN Revision - © Copyright 2015 ABB. All rights reserved. December 2015...
Page 120 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  Turbocharging Service Station. Figure 24: Measuring control dimension X After installing the cartridge group, the control dimension (X) must be measured.
Page 121: Installing The Compressor Casing
(For installation of bracket and plate, see [➙ 19]) 2. Fit and tighten nuts (61037). 3. Remove plates (90031) and brackets (90030). 4. Fit and tighten screw (72021). HZTL4062_EN Revision - © Copyright 2015 ABB. All rights reserved. December 2015...
Page 122: 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). HZTL4062_EN Revision - © Copyright 2015 ABB. All rights reserved. December 2015...
Page 123 2. Remove the bracket (90030). 3. Detach speed measurement cable from provisional holder and insert cable connector (86515). 4. Screw in and tighten four studs (72002) in the upper area. HZTL4062_EN Revision - © Copyright 2015 ABB. All rights reserved. December 2015...
Page 124: Axial Clearance A After Assembly
Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. CAUTION Have the components assessed and, if necessary, replaced by an ABB  Turbocharging Service Station. Figure 28: Measuring axial clearance A The axial clearance (A) must be measured prior to removal and after installation of the cartridge group.
Page 125: 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.  HZTL4062_EN Revision - © Copyright 2015 ABB. All rights reserved. December 2015...
Page 126: 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.  HZTL4062_EN Revision - © Copyright 2015 ABB. All rights reserved. December 2015...
Page 128: Table Of Tightening Torques
Operation Manual / Power2 850-M / 4.1 Low-pressure stage Disassembly and assembly Page 36 / 49 4.17 Table of tightening torques Figure 31: Overview of tightening torques HZTL4062_EN Revision - © Copyright 2015 ABB. All rights reserved. December 2015...
Page 129 72004 (nuts that are difficult to access) Pre-tightening torque 60 Nm Tightening torque angle 60° ±5° 72021 70 Nm 77016 5 Nm 77022 200 Nm Table 17: Tightening torques HZTL4062_EN Revision - © Copyright 2015 ABB. All rights reserved. December 2015...
Page 131: 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 available:  Attaching the cover plate HZTL4062_EN Revision - © Copyright 2015 ABB. All rights reserved. December 2015...
Page 132 Manufacturing the cover plate The cover plate and the other parts that are required are not included in the scope of delivery of ABB Turbo Systems and must be manufactured in accordance with the drawing (see Figure 32) by the operator.
Page 133 If the cover plate is fitted, complete sealing of the lubricating oil supply is not guaranteed. CAUTION Shut off lubricating oil supply to low-pressure stage at engine side.  HZTL4062_EN Revision - © Copyright 2015 ABB. All rights reserved. December 2015...
Page 135: Spare Parts
 Serial number of the low or high-pressure stage (PT……)  Designation and part number. Spare parts can be ordered from an ABB Turbocharging Service Station. If different model variants are not taken into account in this document, contact an ABB  Turbocharging Service Station.
Page 136: View Of Low-Pressure Stage With Part Numbers
Operation Manual / Power2 850-M / 4.1 Low-pressure stage Spare parts Page 44 / 49 View of low-pressure stage with part numbers Figure 35: Low-pressure stage with part numbers HZTL4062_EN Revision - © Copyright 2015 ABB. All rights reserved. December 2015...
Page 137 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 HZTL4062_EN Revision - © Copyright 2015 ABB. All rights reserved. December 2015...
Page 139: Figures
Fig. 25 Installing the compressor casing Fig. 26 Installing the wall insert 1 ... 30 Fig. 27 Installing the wall insert 2 ... 31 Fig. 28 Measuring axial clearance A ..32 HZTL4062_EN Revision - © Copyright 2015 ABB. All rights reserved. December 2015...
Page 141: Tables
Table 18 Cover plate / gasket ....40 Table 19 Tightening torque (42087) ..41 Table 20 Customer spare part set (97070) ........43 Table 21 Low-pressure stage part numbers ........45 HZTL4062_EN Revision - © Copyright 2015 ABB. All rights reserved. December 2015...
Page 143 Taking out of operation at short notice ............28 Possible emergency repairs..................28 Spare parts ......................31 Ordering spare parts....................31 View of high-pressure stage with part numbers........... 32 Figures........................34 Tables ........................35 © Copyright 2017 ABB. All rights reserved. HZTL4063_EN Revision A August 2017...
Page 144: 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 2017 ABB. All rights reserved. HZTL4063_EN Revision A August 2017...
Page 145: 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 146: 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 2017 ABB. All rights reserved. HZTL4063_EN Revision A August 2017...
Page 147: Installing The High-Pressure Stage
Install air suction branch together with bellows (see Fig. 22: Installing the air suction branch →26). Attach all gas, air, water and oil pipes in accordance with the enginebuilder's instructions. Fit insulation. © Copyright 2017 ABB. All rights reserved. HZTL4063_EN Revision A August 2017...
Page 148: 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 2017 ABB. All rights reserved. HZTL4063_EN Revision A August 2017...
Page 149 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 2017 ABB. All rights reserved. HZTL4063_EN Revision A August 2017...
Page 150: Disassembly And Assembly
(see Table 13: Tightening torques →27). 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 151 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 2017 ABB. All rights reserved. HZTL4063_EN Revision A August 2017...
Page 152: 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 2017 ABB. All rights reserved. HZTL4063_EN Revision A August 2017...
Page 153: 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 2017 ABB. All rights reserved. HZTL4063_EN Revision A August 2017...
Page 154: 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 2017 ABB. All rights reserved. HZTL4063_EN Revision A August 2017...
Page 155 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 2017 ABB. All rights reserved. HZTL4063_EN Revision A August 2017...
Page 156: 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 2017 ABB. All rights reserved. HZTL4063_EN Revision A...
Page 157: 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 2017 ABB. All rights reserved. HZTL4063_EN Revision A August 2017...
Page 158 9. Put down the cartridge group in the holders of the turned-over toolbox cover (90010). 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). 12. Remove O-rings (42017 / 42018). © Copyright 2017 ABB. All rights reserved. HZTL4063_EN Revision A August 2017...
Page 159: Removing The Nozzle Ring
4 Disassembly and assembly / 4.7 Removing the nozzle ring Removing the nozzle ring Fig. 12: Removing the nozzle ring 1. Slacken and remove screws (56017) with box spanner insert (90770). 2. Remove nozzle ring (56001). © Copyright 2017 ABB. All rights reserved. HZTL4063_EN Revision A August 2017...
Page 160: 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. 13: Measuring axial clearance A The axial clearance (A) must be measured after removal and before installation of the cart- ridge group.
Page 161: 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 2017 ABB. All rights reserved. HZTL4063_EN Revision A August 2017...
Page 162: 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 2017 ABB. All rights reserved. HZTL4063_EN Revision A August 2017...
Page 163 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 2017 ABB. All rights reserved. HZTL4063_EN Revision A August 2017...
Page 164 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 2017 ABB. All rights reserved.
Page 165: 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 2017 ABB. All rights reserved. HZTL4063_EN Revision A August 2017...
Page 166: 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 2017 ABB. All rights reserved. HZTL4063_EN Revision A August 2017...
Page 167 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 2017 ABB. All rights reserved. HZTL4063_EN Revision A August 2017...
Page 168: 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 2017 ABB. All rights reserved. HZTL4063_EN Revision A August 2017...
Page 169: 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 2017 ABB. All rights reserved. HZTL4063_EN Revision A August 2017...
Page 170: 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 2017 ABB. All rights reserved. HZTL4063_EN Revision A August 2017...
Page 171 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. 24: Cover plate / gasket and sleeves →29).
Page 172 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 2017 ABB. All rights reserved. HZTL4063_EN Revision A August 2017...
Page 173: 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 174: 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. 27: High-pressure stage with part numbers (……) only available in customer spare part set (97070). © Copyright 2017 ABB. All rights reserved. HZTL4063_EN Revision A August 2017...
Page 175 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 2017 ABB. All rights reserved. HZTL4063_EN Revision A August 2017...
Page 176: Figures
Fig. 23: Tightening torques ......... 27 Fig. 24: Cover plate / gasket and sleeves....29 Fig. 25: Fitting the cover plate........30 Fig. 26: Installing the casing........30 Fig. 27: High-pressure stage with part numbers ..32 © Copyright 2017 ABB. All rights reserved. HZTL4063_EN Revision A August 2017...
Page 177: Tables
Table 13: Tightening torques ........27 Table 14: Cover plate / gasket ........29 Table 15: Tightening torque (42099) ......30 Table 16: Customer spare part set (97070)....31 Table 17: High-pressure stage part numbers ..33 © Copyright 2017 ABB. All rights reserved. HZTL4063_EN Revision A August 2017...

ABB Power2 850-M16 Operation Manual

Safety

Table of Contents

Low-Pressure Stage

1 Further Applicable Documents

2 Removal and Installation

3 Expected Replacement Intervals

4 Disassembly and Assembly

5 Taking out of Operation at Short Notice

6 Spare Parts

High-Pressure Stage

1 Further Applicable Documents

2 Removal and Installation

3 Expected Replacement Intervals

4 Disassembly and Assembly

5 Taking out of Operation at Short Notice

6 Spare Parts

Quick Links

Chapters

Related Manuals for ABB Power2 850-M16

Summary of Contents for ABB Power2 850-M16

Table of Contents