ABB Power2 340-H Operation Manual
ABB Power2 340-H Operation Manual

ABB Power2 340-H Operation Manual

Low-pressure stage
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Operation Manual / Power2 340-H / Low-pressure stage

Table of contents

Power2 340-H / Low-pressure stage
1
Introduction............................................................................................................ 4
1.1
Purpose of the manual................................................................................................. 4
1.2
Contact information..................................................................................................... 4
1.3
Essential information.................................................................................................... 5
1.4
Power2 layout and function ......................................................................................... 7
1.5
Layout and function of the low-pressure stage ..................................................... 8
1.6
Symbols, definitions.................................................................................................... 10
1.7
Registered trademarks ............................................................................................... 11
1.8
Storage of new low-pressure and high-pressure stages..................................... 12
2
Safety .................................................................................................................... 14
2.1
Introduction .................................................................................................................. 14
2.2
CE conformity ............................................................................................................... 14
2.3
Definition of mandatory signs .................................................................................. 15
2.4
Definition of safety instructions .............................................................................. 15
2.5
Intended use ................................................................................................................. 16
2.6
Deflagration on gas engines ..................................................................................... 17
2.7
Warning plates on the low-pressure stage............................................................. 18
2.8
Rating plate of the low-pressure stage................................................................... 19
2.9
Periodic check of the pressure vessels.................................................................... 21
2.10
Lifting of loads ............................................................................................................. 22
2.11
Prerequisites for operation and maintenance....................................................... 23
2.12
Hazards during operation and maintenance ........................................................ 24
2.13
Safe operation ............................................................................................................. 26
2.14
Safe maintenance ........................................................................................................ 27
3
Removal and installation .................................................................................... 31
3.1
Transport / weight ...................................................................................................... 31
3.2
Removing the low-pressure stage............................................................................ 31
3.3
Installing the low-pressure stage ............................................................................ 33
4
Commissioning .................................................................................................... 36
4.1
Oil supply ...................................................................................................................... 36
4.2
Inspection procedures ................................................................................................ 37
4.3
Commissioning after taking out of operation...................................................... 39
5
Monitoring during operation.............................................................................. 40
5.1
Lubricating oil pressure............................................................................................. 40
5.2
Lubricating oil temperature ...................................................................................... 41
5.3
Speeds........................................................................................................................... 42
6
Operation and service ......................................................................................... 45
6.1
Noise emission ............................................................................................................ 45
© Copyright 2022 ABB. All rights reserved.
HZTL4053_EN
Rev.F
March 2022

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Summary of Contents for ABB Power2 340-H

  • Page 1: Table Of Contents

    Operation Manual / Power2 340-H / Low-pressure stage Table of contents Power2 340-H / Low-pressure stage Introduction......................4 Purpose of the manual....................4 Contact information..................... 4 Essential information....................5 Power2 layout and function ..................7 Layout and function of the low-pressure stage ............. 8 Symbols, definitions....................
  • Page 2 Operation Manual / Power2 340-H / Low-pressure stage Table of contents Service work ......................... 47 Expected replacement intervals ................49 Stopping the engine....................51 Periodic maintenance..................52 Foreword to maintenance..................52 Cleaning the compressor during operation ............53 Cleaning the filter silencer ..................56 Cleaning turbine and nozzle ring during operation ..........
  • Page 3 Operation Manual / Power2 340-H / Low-pressure stage Table of contents 11.2 Taking the engine out of operation for more than 12 months ......97 Material and Disposal..................98 12.1 REACH and RoHS Compliance Declaration For Products ........98 12.2 Disposing of low-pressure and high-pressure stage components ....99 Spare parts ......................
  • Page 4: Introduction

    Operation Manual / Power2 340-H / Low-pressure stage 1 Introduction / 1.1 Purpose of the manual Introduction Purpose of the manual Operation Manual The Operation Manual explains the two-stage turbocharging (Power2) from Turbo Systems and contains instructions for safe operation.
  • Page 5: Essential Information

    Operation Manual / Power2 340-H / Low-pressure stage 1 Introduction / 1.3 Essential information Essential information Design variants This document is valid for different design variants of Power2 low-pressure stages. This may result in sections and descriptions of components that are not relevant for a specific Power2 low-pressure stage.
  • Page 6 Operation Manual / Power2 340-H / Low-pressure stage 1 Introduction / 1.3 Essential information © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F March 2022...
  • Page 7: Power2 Layout And Function

    Operation Manual / Power2 340-H / Low-pressure stage 1 Introduction / 1.4 Power2 layout and function Power2 layout and function Fig. 1: Layout and function Power2 Two-stage turbocharging HP compressor Power2 LP Low-pressure stage HP turbine Power2 HP High-pressure stage Gas piping (bellows)
  • Page 8: Layout And Function Of The Low-Pressure Stage

    Operation Manual / Power2 340-H / Low-pressure stage 1 Introduction / 1.5 Layout and function of the low-pressure stage Layout and function of the low-pressure stage Fig. 2 01 Air suction branch / filter silencer Gas outlet casing 02 Compressor casing...
  • Page 9: Fig. 3

    Operation Manual / Power2 340-H / Low-pressure stage 1 Introduction / 1.5 Layout and function of the low-pressure stage Mode of operation of the low-pressure stage (Power2 LP) Fig. 3 Power2 Two-stage turbocharging HP compressor Power2 LP Low-pressure stage HP turbine...
  • Page 10: Symbols, Definitions

    Operation Manual / Power2 340-H / Low-pressure stage 1 Introduction / 1.6 Symbols, definitions Symbols, definitions Symbols The following symbols are used in this document: Indicates an action step. 1. Indicates a numbered action step. →   Refers to a page number...
  • Page 11: Registered Trademarks

    Operation Manual / Power2 340-H / Low-pressure stage 1 Introduction / 1.7 Registered trademarks Definition of pictograms The following pictograms can occur in this document. These point out actions that must be taken in accordance with the meaning of the relevant pictogram.
  • Page 12: Storage Of New Low-Pressure And High-Pressure Stages

    Operation Manual / Power2 340-H / Low-pressure stage 1 Introduction / 1.8 Storage of new low-pressure and high-pressure stages Storage of new low-pressure and high-pressure stages Storage for up to 6 months New low-pressure and high-pressure stages and spare parts from Turbo Systems can be stored in their closed packages for 6 months from the date of delivery without additional...
  • Page 13: Fig. 5: Package With Hygrometer

    Operation Manual / Power2 340-H / Low-pressure stage 1 Introduction / 1.8 Storage of new low-pressure and high-pressure stages Long-term storage of low-pressure and high-pressure stages The low-pressure and high-pressure stages will be prepared for long-term storage if reques- ted in the purchase order. The package is equipped with a hygrometer (see illustration).
  • Page 14: Safety

    Operation Manual / Power2 340-H / Low-pressure stage 2 Safety / 2.1 Introduction Safety Introduction The two-stage turbocharging system (Power2) manufactured by 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.
  • Page 15: Definition Of Mandatory Signs

    Operation Manual / Power2 340-H / Low-pressure stage 2 Safety / 2.3 Definition of mandatory signs Definition of mandatory signs To be worn at all times Protective clothing Safety footwear to protect against mechanical hazard and risk of falling Table 2: Personal protective equipment to be worn at all times...
  • Page 16: Intended Use

    Operation Manual / Power2 340-H / Low-pressure stage 2 Safety / 2.5 Intended use Intended use Use on internal combustion engines Power2 from Turbo Systems is intended for charging internal combustion engines. To ensure compliance with the machinery directive 2006/42/EC when using on gas engines, the Power2 must be operated in an engine room classified as "not at risk of explosion".
  • Page 17: Deflagration On Gas Engines

    Operation Manual / Power2 340-H / Low-pressure stage 2 Safety / 2.6 Deflagration on gas engines Perfect condition The Power2 must be used in a technically perfect condition and in compliance with its inten- ded use. Turbo Systems excludes any liability for damage resulting from unauthorized modifications to the Power2 or improper operation.
  • Page 18: Warning Plates On The Low-Pressure Stage

    Operation Manual / Power2 340-H / Low-pressure stage 2 Safety / 2.7 Warning plates on the low-pressure stage Warning plates on the low-pressure stage Warning plates are affixed at the following locations: Fig. 6 Low-pressure stage If warning plates are not present in the designated locations or not readable, proceed as fol- lows: Order new warning plates from Turbo Systems service stations.
  • Page 19: Rating Plate Of The Low-Pressure Stage

    Operation Manual / Power2 340-H / Low-pressure stage 2 Safety / 2.8 Rating plate of the low-pressure stage Rating plate of the low-pressure stage Fig. 7: Rating plate Operating limits Operating limits at engine overload (110%). In test rig operation only, unless otherwise agreed with the enginebuilder.
  • Page 20: Fig. 8: Locations Of The Rating Plates

    Operation Manual / Power2 340-H / Low-pressure stage 2 Safety / 2.8 Rating plate of the low-pressure stage Explanations of the rating plate The recommended replacement intervals and the corresponding operating limits are jointly defined with the enginebuilder. This information is specific to the system.
  • Page 21: Periodic Check Of The Pressure Vessels

    Operation Manual / Power2 340-H / Low-pressure stage 2 Safety / 2.9 Periodic check of the pressure vessels Periodic check of the pressure vessels The pressure vessels used by Turbo Systems, such as those for wet or dry cleaning, are so- called "simple pressure vessels".
  • Page 22: Lifting Of Loads

    Operation Manual / Power2 340-H / Low-pressure stage 2 Safety / 2.10 Lifting of loads 2.10 Lifting of loads WARNING Suspended loads Loads that are not attached according to regulations can cause injury to personnel or fatal accidents. Loads must always be fastened to properly functional lifting gear with a sufficient load limit.
  • Page 23: Prerequisites For Operation And Maintenance

    Operation Manual / Power2 340-H / Low-pressure stage 2 Safety / 2.11 Prerequisites for operation and maintenance 2.11 Prerequisites for operation and maintenance Responsibility of the operating company In awareness of its responsibility, the operating company must ensure that only authorised personnel work on the Power2, who: ¡...
  • Page 24: Hazards During Operation And Maintenance

    Operation Manual / Power2 340-H / Low-pressure stage 2 Safety / 2.12 Hazards during operation and maintenance 2.12 Hazards during operation and maintenance Noise hazards The turbocharger's noise emission is influenced by its installation and operating conditions. A noise level exceeding 85 dB(A) is harmful.
  • Page 25 Operation Manual / Power2 340-H / Low-pressure stage 2 Safety / 2.12 Hazards during operation and maintenance WARNING Hot surfaces on the non-insulated low-pressure and high-pressure stage Non-insulated low-pressure and high-pressure stages can cause serious in- juries to personnel (burns).
  • Page 26: Safe Operation

    Operation Manual / Power2 340-H / Low-pressure stage 2 Safety / 2.13 Safe operation 2.13 Safe operation Mechanical hazards during operation During standard operation, no mechanical hazards are caused by the low-pressure and high- pressure stage, provided that it has been properly installed.
  • Page 27: Safe Maintenance

    Operation Manual / Power2 340-H / Low-pressure stage 2 Safety / 2.14 Safe maintenance 2.14 Safe maintenance Occupational safety WARNING Injuries to persons Severe injuries to personnel or fatal accidents can be caused by mechanical influences as a consequence of hazardous and inadequate operational pro- cedures or non-compliance with safety and health standards.
  • Page 28 Operation Manual / Power2 340-H / Low-pressure stage 2 Safety / 2.14 Safe maintenance Welding work Wear personal protective equipment (PPE) for welding operations. When performing welding work in the vicinity of the low-pressure stage, always cover the filter silencer to prevent the filter mat from being damaged.
  • Page 29 Operation Manual / Power2 340-H / Low-pressure stage 2 Safety / 2.14 Safe maintenance Mechanical hazards when working on the low-pressure and high-pressure stage WARNING Physical hazards due to rotating parts The rotor can rotate due to the stack draught alone. Contact with rotating parts can cause severe injury.
  • Page 30 Operation Manual / Power2 340-H / Low-pressure stage 2 Safety / 2.14 Safe maintenance CAUTION Environmental hazard Improper handling of operating materials and supplies can lead to environ- mental damage. Observe the information in the material safety data sheet for the operat- ing materials and supplies.
  • Page 31: Removal And Installation

    Operation Manual / Power2 340-H / Low-pressure stage 3 Removal and installation / 3.1 Transport / weight Removal and installation Transport / weight Lifting gear with a sufficient load limit must be used for removing and installing low-pres- sure and high-pressure stages. The following weight specifications apply to the heaviest variant possible.
  • Page 32: Fig. 12: Removing The Low-Pressure Stage

    Operation Manual / Power2 340-H / Low-pressure stage 3 Removal and installation / 3.2 Removing the low-pressure stage If present: Unplug the plug to the speed sensor (86505) and secure the rolled-up cable (2 m) on the low-pressure or high-pressure stage. This protects the plug from being crushed.
  • Page 33: Installing The Low-Pressure Stage

    Operation Manual / Power2 340-H / Low-pressure stage 3 Removal and installation / 3.3 Installing the low-pressure stage Installing the low-pressure stage 3.3.1 Inserting gaskets CAUTION Inserting the gaskets Gaskets that are forgotten, damaged or improperly inserted will lead to oil leaks.
  • Page 34: Fig. 14: Placing The Low-Pressure Stage On The Bracket

    Operation Manual / Power2 340-H / Low-pressure stage 3 Removal and installation / 3.3 Installing the low-pressure stage 3.3.2 Placing the low-pressure stage on the bracket and aligning The screws for attaching the low-pressure stage are not included in the Turbo Systems scope of delivery.
  • Page 35: Fig. 15: Low-Pressure Stage, Tightening The Fixing Screws

    Operation Manual / Power2 340-H / Low-pressure stage 3 Removal and installation / 3.3 Installing the low-pressure stage 3.3.3 Steps for fastening the low-pressure stage Fig. 15: Low-pressure stage, tightening the fixing screws. Tighten the fitted fixing screws (01) according to the following table:...
  • Page 36: Commissioning

    Operation Manual / Power2 340-H / Low-pressure stage 4 Commissioning / 4.1 Oil supply Commissioning Oil supply 4.1.1 Introduction In all operating states, a functioning and carefully executed oil supply is an important pre- requisite for trouble-free operation of the low-pressure and high-pressure stage.
  • Page 37: Inspection Procedures

    Operation Manual / Power2 340-H / Low-pressure stage 4 Commissioning / 4.2 Inspection procedures Inspection procedures 4.2.1 Introduction 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.
  • Page 38 Operation Manual / Power2 340-H / Low-pressure stage 4 Commissioning / 4.2 Inspection procedures 4.2.3 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 →40.
  • Page 39: Commissioning After Taking Out Of Operation

    Operation Manual / Power2 340-H / Low-pressure stage 4 Commissioning / 4.3 Commissioning after taking out of operation Commissioning after taking out of operation If present Remove cover plates (blind flanges) from the compressor casing, the gas inlet and the gas outlet.
  • Page 40: Monitoring During Operation

    Operation Manual / Power2 340-H / Low-pressure stage 5 Monitoring during operation / 5.1 Lubricating oil pressure Monitoring during operation Lubricating oil pressure CAUTION Assuring lubricating oil pressure Serious damage to the engine or property can result from a missing or insuf- ficient lubricating oil supply.
  • Page 41: Lubricating Oil Temperature

    Operation Manual / Power2 340-H / Low-pressure stage 5 Monitoring during operation / 5.2 Lubricating oil temperature Lubricating oil temperature Lubricating oil temperature at the inlet CAUTION Machine damage If the oil temperature at the oil inlet exceeds the admissible range, this may lead to engine damage.
  • Page 42: Speeds

    Operation Manual / Power2 340-H / Low-pressure stage 5 Monitoring during operation / 5.3 Speeds Speeds 5.3.1 Introduction Speed measurement systems enable the constant monitoring of the speeds of the low-pres- sure and the high-pressure stage. 5.3.2 Layout and overview Fig. 17: Low-pressure stage speed measurement system...
  • Page 43 Operation Manual / Power2 340-H / Low-pressure stage 5 Monitoring during operation / 5.3 Speeds 5.3.3 Differences in speed between the low-pressure or high- pressure stages The speeds of the low-pressure stages differ significantly from the speeds of the high-pres- sure stages.
  • Page 44 Operation Manual / Power2 340-H / Low-pressure stage 5 Monitoring during operation / 5.3 Speeds 5.3.4 Replacing the speed sensor WARNING Hot cable connector and hot speed sensor Danger of burns. The cable connector and speed sensor can reach temperat- ures in excess of 100 °C during operation.
  • Page 45: Operation And Service

    Operation Manual / Power2 340-H / Low-pressure stage 6 Operation and service / 6.1 Noise emission Operation and service Noise emission WARNING Noise hazards Exposure to noise can harm the hearing system, impair health and the psy- chological state and may lead to lack of attention and irritation.
  • Page 46: Fig. 18: Noise Insulation, Bellows

    Operation Manual / Power2 340-H / Low-pressure stage 6 Operation and service / 6.1 Noise emission Suggestion for noise insulation, bellows Fig. 18: Noise insulation, bellows Compressor casing Bellows Charge air duct / scavenging air duct Insulation cushion Insulation mat (at least 15 mm) Sheet metal cover ©...
  • Page 47: Service Work

    Operation Manual / Power2 340-H / Low-pressure stage 6 Operation and service / 6.2 Service work Service work Service work includes visual controls, monitoring, measuring and inspection as well as func- tional checks. Service work enables the detection and rectification of changes to the low and high-pressure stage and ensures full operability of the low and high-pressure stage.
  • Page 48 Operation Manual / Power2 340-H / Low-pressure stage 6 Operation and service / 6.2 Service work 6.2.3 Service work according to instructions of enginebuilder Clean or replace the oil filter located in the supply pipe to the low-pressure and high-pres- sure stage while the engine is stopped.
  • Page 49: Expected Replacement Intervals

    Operation Manual / Power2 340-H / Low-pressure stage 6 Operation and service / 6.3 Expected replacement intervals Expected replacement intervals Rotating components The recommended replacement intervals of the compressor and turbine wheels are spe- cified with the aid of the safety concept for rotating parts (SIKO) and dependent on the op- erating conditions.
  • Page 50 Operation Manual / Power2 340-H / Low-pressure stage 6 Operation and service / 6.3 Expected replacement intervals Influencing parameters The actual values can deviate considerably from the guideline values, for example, due to the following influences: ¡ Fuel quality and fuel treatment ¡...
  • Page 51: Stopping The Engine

    Operation Manual / Power2 340-H / Low-pressure stage 6 Operation and service / 6.4 Stopping the engine Stopping the engine Oil-cooled bearing casing variant Run the engine for 5 to 10 minutes at idling speed before stopping it (only diesel en- gines).
  • Page 52: Periodic Maintenance

    Operation Manual / Power2 340-H / Low-pressure stage 7 Periodic maintenance / 7.1 Foreword to maintenance Periodic maintenance Foreword to maintenance Maintenance work includes regular visual controls and cleaning operations which are inten- ded to ensure the trouble-free functioning of the low-pressure and high-pressure stage.
  • Page 53: Cleaning The Compressor During Operation

    Operation Manual / Power2 340-H / Low-pressure stage 7 Periodic maintenance / 7.2 Cleaning the compressor during operation Cleaning the compressor during operation 7.2.1 Prerequisite ¡ The enginebuilder approves the cleaning process and its specifications are adhered to. ¡ Instructions from Turbo Systems are followed.
  • Page 54 Operation Manual / Power2 340-H / Low-pressure stage 7 Periodic maintenance / 7.2 Cleaning the compressor during operation Principle of wet cleaning To clean the compressor stage during operation, water is injected before the compressor wheel. The water does not act as a solvent. The coating is removed by the mechanical action of the impacting droplets.
  • Page 55: Table 18: Parameters For Wet Cleaning Of Compressor

    Operation Manual / Power2 340-H / Low-pressure stage 7 Periodic maintenance / 7.2 Cleaning the compressor during operation 7.2.4 Wet cleaning of compressor Water pipe to filter silencer or air suction branch Pressurised air inlet pipe Valve activator 27000 External water pressure vessel...
  • Page 56: Cleaning The Filter Silencer

    Operation Manual / Power2 340-H / Low-pressure stage 7 Periodic maintenance / 7.3 Cleaning the filter silencer Cleaning the filter silencer Fig. 19: Cleaning the filter silencer 81135 Filter silencer body 81266 Cover grid 81136 Absorption segment 81270 Tension band 81137...
  • Page 57: Cleaning Turbine And Nozzle Ring During Operation

    Any tension bands that have become damaged must be replaced. Fit the filter ring (81265), if present. Cleaning turbine and nozzle ring during operation Power2 340-H is carried out without turbine cleaning function. © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F...
  • Page 58: Troubleshooting

    Operation Manual / Power2 340-H / Low-pressure stage 8 Troubleshooting / 8.1 Malfunctions when starting Troubleshooting Malfunctions when starting Delayed start-up Possible causes Remedy Low-pressure Pressure stage contaminated Clean Bearing damaged Contact a Turbo Systems service sta- high-pressure tion Rotor rubbing...
  • Page 59: Malfunctions During Operation

    Operation Manual / Power2 340-H / Low-pressure stage 8 Troubleshooting / 8.2 Malfunctions during operation Malfunctions during operation Lubricating oil pressure too low Possible causes Remedy Engine Oil filter heavily contaminated Clean Oil pump in lubricating system de- Check/replace fective...
  • Page 60: Table 26: Malfunctions During Operation - Power2 Hp Speed Increases

    Operation Manual / Power2 340-H / Low-pressure stage 8 Troubleshooting / 8.2 Malfunctions during operation Increase in high-pressure stage speed Possible causes Remedy High-pressure Heavy contamination of the nozzle Contact a Turbo Systems service sta- stage ring tion Low-pressure stage defective...
  • Page 61: Table 28: Malfunctions During Operation - Charge Air Pressure Too Low

    Operation Manual / Power2 340-H / Low-pressure stage 8 Troubleshooting / 8.2 Malfunctions during operation Charge air pressure too low Engine performance and engine speed unchanged, suction condition normal Possible causes Remedy Engine Air receiver not sealed Repair Gas piping between engine and tur-...
  • Page 62: Table 30: Malfunctions During Operation - Compressor 1 Contamination

    Operation Manual / Power2 340-H / Low-pressure stage 8 Troubleshooting / 8.2 Malfunctions during operation Contamination of the compressor Reduced compressor performance/efficiency and therefore engine performance losses Possible causes Remedy Low-pressure Heavy contamination of the com- Clean the compressor pressor components due to the in-...
  • Page 63: Surging Of The Low-Pressure Or High-Pressure Stage

    Operation Manual / Power2 340-H / Low-pressure stage 8 Troubleshooting / 8.3 Surging of the low-pressure or high-pressure stage Surging of the low-pressure or high-pressure stage Possible causes Remedy Engine Protective grating downstream of Clean/replace high-pressure stage contaminated or damaged...
  • Page 64: Malfunctions When Stopping

    Operation Manual / Power2 340-H / Low-pressure stage 8 Troubleshooting / 8.4 Malfunctions when stopping Malfunctions when stopping Runout noises Possible causes Remedy Low-pressure Pressure stage contaminated Clean Bearing damaged Contact a Turbo Systems service sta- high-pressure tion Rotor rubbing...
  • Page 65: Speed Measurement System

    Operation Manual / Power2 340-H / Low-pressure stage 8 Troubleshooting / 8.5 Speed measurement system Speed measurement system No signal or poor signal amplitude of the speed measurement Possible causes Remedy Low-pres- The speed sensor was acci- The screw plug for the sensor is fitted with an ad-...
  • Page 66: Disassembly And Assembly

    Operation Manual / Power2 340-H / Low-pressure stage 9 Disassembly and assembly / 9.1 Introduction Disassembly and assembly Introduction The precondition for the work described in the following is a low-pressure stage that has been removed from the engine (see Removal and installation →31).
  • Page 67: Material Required

    Operation Manual / Power2 340-H / Low-pressure stage 9 Disassembly and assembly / 9.2 Material required Material required Customer spare part set Before starting work, make sure the required customer spare part set is available (see chapter Spare parts →100).
  • Page 68: Fig. 20: Swivel Lifting Eye (Example)

    Operation Manual / Power2 340-H / Low-pressure stage 9 Disassembly and assembly / 9.2 Material required Swivel lifting eyes to be used Swivel lifting eyes are required for the safe lifting of loads, which are not supplied by Turbo Systems.
  • Page 69: Weights Of Assemblies

    Operation Manual / Power2 340-H / Low-pressure stage 9 Disassembly and assembly / 9.3 Weights of assemblies Weights of assemblies The specified weights of the individual parts or assemblies are rounded-up standard values. Fig. 21: Weights of the assemblies Designation Weight (kg)
  • Page 70: Removing The Gas Outlet Casing And Gas Outlet Flange

    Operation Manual / Power2 340-H / Low-pressure stage 9 Disassembly and assembly / 9.4 Removing the gas outlet casing and gas outlet flange Removing the gas outlet casing and gas outlet flange Fig. 22: Removing the gas outlet casing and gas outlet flange 1.
  • Page 71: Removing The Air Inlets

    Operation Manual / Power2 340-H / Low-pressure stage 9 Disassembly and assembly / 9.5 Removing the air inlets Removing the air inlets Mark the casing position for assembly. Fig. 23: Removing the air inlets 1. Attach lifting gear to the filter silencer (81000) or air suction branch (82000).
  • Page 72: Measuring Radial Clearances N And R

    Operation Manual / Power2 340-H / Low-pressure stage 9 Disassembly and assembly / 9.6 Measuring radial clearances N and R Measuring radial clearances N and R Fig. 24: Measuring clearances N and R Product N [mm] R [mm] Power2 340-H LP 0.45 ...
  • Page 73: Removing The Compressor Casing

    Operation Manual / Power2 340-H / Low-pressure stage 9 Disassembly and assembly / 9.7 Removing the compressor casing Removing the compressor casing Removing the compressor casing Mark the casing position for assembly. Fig. 25: Removing the compressor casing 1. Loosen screws (72011) and remove together with fastening strips (72012).
  • Page 74: Fig. 26: Dismantling The Wall Insert

    Operation Manual / Power2 340-H / Low-pressure stage 9 Disassembly and assembly / 9.7 Removing the compressor casing Dismantling the wall insert Fig. 26: Dismantling the wall insert 1. Knock the wall insert (77000) out of the compressor casing (72000) with a plastic tip hammer.
  • Page 75: Pressing Off The Casing

    Operation Manual / Power2 340-H / Low-pressure stage 9 Disassembly and assembly / 9.8 Pressing off the casing Pressing off the casing CAUTION Axial force of the press-off tool Using the press-off tool (90042), a high level of axial force can be generated.
  • Page 76: Removing The Cartridge Group

    Operation Manual / Power2 340-H / Low-pressure stage 9 Disassembly and assembly / 9.9 Removing the cartridge group Removing the cartridge group Mark the casing position for assembly. Do not remove oil orifice (if present) To limit the oil flow rate through the bearing casing during operation (engine under load) to the admissible values, an oil orifice is mandatory at the oil inlet of the bearing casing if the oil inlet pressure is > 3 bar (overpressure).
  • Page 77: Fig. 29: Removing Cartridge Group 1

    Operation Manual / Power2 340-H / Low-pressure stage 9 Disassembly and assembly / 9.9 Removing the cartridge group Fig. 29: Removing cartridge group 1 1. Treat threads of studs (51006) with penetrating oil and leave to take effect. 2. Loosen nuts (51007) and remove Verbus Ripp® washers (51003) together with fastening strips (51002).
  • Page 78: Removing The Nozzle Ring

    Operation Manual / Power2 340-H / Low-pressure stage 9 Disassembly and assembly / 9.10 Removing the nozzle ring 9.10 Removing the nozzle ring Fig. 31: Removing the nozzle ring 1. If present: Remove the metal C-ring (51105). 2. Position the fastening strips (51002) in place.
  • Page 79: Installing The Cartridge Group On The Service Support

    Operation Manual / Power2 340-H / Low-pressure stage 9 Disassembly and assembly / 9.11 Installing the cartridge group on the service support 9.11 Installing the cartridge group on the service support Fig. 32: Installing the cartridge group on the service support 1.
  • Page 80: Measuring Clearance A And B

    Operation Manual / Power2 340-H / Low-pressure stage 9 Disassembly and assembly / 9.12 Measuring clearance A and B 9.12 Measuring clearance A and B Measure and record clearances A and B after the removal and before the installation of the cartridge group.
  • Page 81: Nozzle Ring Compression Pd

    Operation Manual / Power2 340-H / Low-pressure stage 9 Disassembly and assembly / 9.13 Nozzle ring compression PD 9.13 Nozzle ring compression PD In order for the nozzle ring (56001) to be fixed during operation, it must be clamped between the heat shield (42400) and the turbine casing (51000).
  • Page 82: Installing The Nozzle Ring

    Operation Manual / Power2 340-H / Low-pressure stage 9 Disassembly and assembly / 9.14 Installing the nozzle ring 9.14 Installing the nozzle ring Fig. 35: Installing the nozzle ring *) Variant A1 or A2, depending on the nozzle ring version. 1. Fit the lamellar sealing ring (56005) in the correct slot (see detail A1/A2). When doing this, pay attention to correct winding of the lamellar sealing ring (see detail B).
  • Page 83: Installing The Cartridge Group

    Operation Manual / Power2 340-H / Low-pressure stage 9 Disassembly and assembly / 9.15 Installing the cartridge group 9.15 Installing the cartridge group Lifting the cartridge group and rotating it by 90° Fig. 36: Lifting the cartridge group and rotating it by 90°...
  • Page 84: Fig. 37: Installing The Cartridge Group

    Operation Manual / Power2 340-H / Low-pressure stage 9 Disassembly and assembly / 9.15 Installing the cartridge group Installing the cartridge group Fig. 37: Installing the cartridge group Product Size Tightening torque [Nm] Power2 340-H LP Table 45: Tightening torque (51007) 1. Coat the threads of the studs (51006) with high-temperature grease.
  • Page 85: Installing The Compressor Casing

    Operation Manual / Power2 340-H / Low-pressure stage 9 Disassembly and assembly / 9.16 Installing the compressor casing 9.16 Installing the compressor casing Fitting the wall insert and the diffuser Fig. 38: Fitting the wall insert and the diffuser Product Size...
  • Page 86: Fig. 39: Installing The Compressor Casing

    Operation Manual / Power2 340-H / Low-pressure stage 9 Disassembly and assembly / 9.16 Installing the compressor casing Installing the compressor casing Fig. 39: Installing the compressor casing *) In some installations a special graphite cord sealing (42126) is fitted instead of the O- ring (42012) (see...
  • Page 87: Measuring Radial Clearances N And R

    Operation Manual / Power2 340-H / Low-pressure stage 9 Disassembly and assembly / 9.17 Measuring radial clearances N and R 9.17 Measuring radial clearances N and R Fig. 40: Measuring clearances N and R Product N [mm] R [mm] Power2 340-H LP 0.45 ...
  • Page 88: Installing The Air Inlets

    Operation Manual / Power2 340-H / Low-pressure stage 9 Disassembly and assembly / 9.18 Installing the air inlets 9.18 Installing the air inlets Fig. 41: Installing the air inlets Product Size Tightening torque [Nm] Power2 340-H LP Table 49: Tightening torque (72020) 1.
  • Page 89: Installing The Gas Outlet Flange

    Operation Manual / Power2 340-H / Low-pressure stage 9 Disassembly and assembly / 9.19 Installing the gas outlet flange 9.19 Installing the gas outlet flange Fig. 42: Installing the gas outlet flange 1. If present: Insert the metal C-ring (57003) into the turbine casing (51000) and secure with high-vacuum grease.
  • Page 90: Installing The Gas Outlet Casing

    Operation Manual / Power2 340-H / Low-pressure stage 9 Disassembly and assembly / 9.20 Installing the gas outlet casing 9.20 Installing the gas outlet casing Fig. 43: Installing the gas outlet casing Product Part number Tightening torque Power2 340-LP 51009 65 Nm...
  • Page 91: Table Of Tightening Torques

    Operation Manual / Power2 340-H / Low-pressure stage 9 Disassembly and assembly / 9.21 Table of tightening torques 9.21 Table of tightening torques Fig. 44: Tightening torque overview The following tightening torques [Nm] must be observed for the designated screw fittings:...
  • Page 92: Taking Out Of Operation At Short Notice

    Operation Manual / Power2 340-H / Low-pressure stage 10 Taking out of operation at short notice / 10.1 Possible emergency re- pairs Taking out of operation at short notice 10.1 Possible emergency repairs WARNING Danger of fire and explosion due to lubricating oil leaks Leaking oil may ignite on hot surfaces.
  • Page 93: Installing A Replacement Cartridge Group

    Operation Manual / Power2 340-H / Low-pressure stage 10 Taking out of operation at short notice / 10.2 Installing a replace- ment cartridge group 10.2 Installing a replacement cartridge group The repair of a cartridge group requires special tools and the expertise of a Turbo Systems service station.
  • Page 94: Fitting The Cover Plate

    Operation Manual / Power2 340-H / Low-pressure stage 10 Taking out of operation at short notice / 10.3 Fitting the cover plate 10.3 Fitting the cover plate Remove low-pressure stage (see chapter Removal and installation). ¡ Gas outlet casing removed Fit the turbine casing with the gas outlet casing into the gas pipe again.
  • Page 95: Cover Plate Drawing

    Operation Manual / Power2 340-H / Low-pressure stage 10 Taking out of operation at short notice / 10.4 Cover plate drawing 10.4 Cover plate drawing The cover plate is not included in the Turbo Systems scope of delivery and must be manufac- tured by the operating company according to the following drawing.
  • Page 96: Mothballing The Low-Pressure Stage

    Operation Manual / Power2 340-H / Low-pressure stage 11 Mothballing the low-pressure stage / 11.1 Taking the engine out of operation for up to 12 months Mothballing the low-pressure stage 11.1 Taking the engine out of operation for up to 12 months State of the engine lubricating oil The low-pressure and high-pressure stage normally remain attached to the engine.
  • Page 97: Taking The Engine Out Of Operation For More Than 12 Months

    Operation Manual / Power2 340-H / Low-pressure stage 11 Mothballing the low-pressure stage / 11.2 Taking the engine out of operation for more than 12 months Completely fit low-pressure and high-pressure stage. Rotor turning in stack draught If the rotor turns as a result of the stack draught: Install a blind flange between the outlet flange of the compressor casing and the charge air duct.
  • Page 98: Material And Disposal

    Operation Manual / Power2 340-H / Low-pressure stage 12 Material and Disposal / 12.1 REACH and RoHS Compliance Declara- tion For Products Material and Disposal 12.1 REACH and RoHS Compliance Declaration For Products Turbo Systems hereby confirms that all genuine products, parts and components supplied...
  • Page 99: Disposing Of Low-Pressure And High-Pressure Stage Components

    Operation Manual / Power2 340-H / Low-pressure stage 12 Material and Disposal / 12.2 Disposing of low-pressure and high- pressure stage components 12.2 Disposing of low-pressure and high-pressure stage components Disposal must be environmentally compatible, professional, and in compliance with locally applicable regulations.
  • Page 100: Spare Parts

    Operation Manual / Power2 340-H / Low-pressure stage 13 Spare parts / 13.1 Ordering spare parts Spare parts 13.1 Ordering spare parts CAUTION Spare part storage All spare parts that were ordered together with the low-pressure and/or high-pressure stage must be kept intact and ready for use.
  • Page 101: Spare Part - Illustrations

    Operation Manual / Power2 340-H / Low-pressure stage 13 Spare parts / 13.2 Spare part – Illustrations 13.2 Spare part – Illustrations The spare parts lists shown below are only available in English. Cartridge, oil cooled 10900 42012* 42189 42188...
  • Page 102: Table 56

    Operation Manual / Power2 340-H / Low-pressure stage 13 Spare parts / 13.2 Spare part – Illustrations Cartridge, water cooled 10900 42012* 42189 42188 42196** 42197** ** = if provided * = Available within the spare part set HZTL443581 Mod. A Part no.
  • Page 103: Table 57

    Operation Manual / Power2 340-H / Low-pressure stage 13 Spare parts / 13.2 Spare part – Illustrations Rotor and Bearing parts 21000 21002* 32114* 25000 32112 32102* 32103* 32104* 32111* 32113* 32110 32101* 32109 42002 * = Available within the spare part set HZTL443579 Mod.
  • Page 104: Table 58

    Operation Manual / Power2 340-H / Low-pressure stage 13 Spare parts / 13.2 Spare part – Illustrations Bearing casing, oil cooled 42400 42001 42305* 42301 42008* 42197** 42196** 42302* ** = if provided * = Available within the spare part set HZTL443367 Mod.
  • Page 105: Table 59

    Operation Manual / Power2 340-H / Low-pressure stage 13 Spare parts / 13.2 Spare part – Illustrations Bearing casing, water cooled 42142* 42141* 42400 42140* 42001 42305* 42301 42008* 42189 42188 42196** 42197** 42302* ** = if provided * = Available within the spare part set HZTL443296 Mod.
  • Page 106: Table 60

    Operation Manual / Power2 340-H / Low-pressure stage 13 Spare parts / 13.2 Spare part – Illustrations Turbine casing 51009 57002 51000 51008 51027(p) 51006 51003 51101 51007 51102 51101 51102 57210 51103 51002 56005 51102 56001 51500 (p) = pre-assembled HZTL443297 Mod.
  • Page 107: Table 61

    Operation Manual / Power2 340-H / Low-pressure stage 13 Spare parts / 13.2 Spare part – Illustrations Gas outlet casing 61005 61003 61004 61300 61002* 61001 * = Available within the spare part set HZTL443298 Mod. A Part no. Designation...
  • Page 108: Table 62

    Operation Manual / Power2 340-H / Low-pressure stage 13 Spare parts / 13.2 Spare part – Illustrations Compressor casing 72011 72012 79000 77000 77005* 72000 72080 79041* 72020 79040 72080 72005 * = Available within the spare part set HZTL443299 Mod. A Part no.
  • Page 109: Table 63

    Operation Manual / Power2 340-H / Low-pressure stage 13 Spare parts / 13.2 Spare part – Illustrations Air suction branch axial 82006 82005 82010* 82007 82008 82000 * = Available within the spare part set HZTL443013 Mod. D Part no.
  • Page 110: Table 64

    Operation Manual / Power2 340-H / Low-pressure stage 13 Spare parts / 13.2 Spare part – Illustrations Air suction branch radial 82010* 82007 82008 82000 82006 82005 * = Available within the spare part set HZTL443012 Mod. D Part no.
  • Page 111: Table 65

    Operation Manual / Power2 340-H / Low-pressure stage 13 Spare parts / 13.2 Spare part – Illustrations Filter silencer 81136 81000 81137 82005 82006 81270 81171 81170 81265 81010* 81135 81271 81266 * = Available within the spare part set HZTL443011 Mod.
  • Page 112: Table 66

    Operation Manual / Power2 340-H / Low-pressure stage 13 Spare parts / 13.2 Spare part – Illustrations Speed measurement system 86526** 86505** 86528** 86517** ** = if provided HZTL443427 Mod. A Part no. Designation 86505** Speed sensor 86517** Adapter cable...
  • Page 113: Tools

    Operation Manual / Power2 340-H / Low-pressure stage 14 Tools / ​ Tools For the work described in the Operation Manual, the customer tool set 90000 is required. Part number Designation Quantity 90012 Service support 90013 Plastic insert 90042 Press-off tool...
  • Page 114: Gas Piping (Option)

    Operation Manual / Power2 340-H / Low-pressure stage 15 Gas piping (option) / 15.1 Commissioning and operating Gas piping (option) 15.1 Commissioning and operating Checks before commissioning All components of the gas piping must be checked visually: ¡ There must not be any damage to sealing surfaces (evenly fine surfaces) ¡...
  • Page 115: Periodic Maintenance

    Operation Manual / Power2 340-H / Low-pressure stage 15 Gas piping (option) / 15.2 Periodic maintenance 15.2 Periodic maintenance Component to be maintained Recommended cleaning interval Operating state Gas piping At every disassembly Engine stopped Table 69: Maintenance interval The following maintenance work must be carried out on the gas piping: If present: Remove insulation.
  • Page 116: Removal And Installation

    Operation Manual / Power2 340-H / Low-pressure stage 15 Gas piping (option) / 15.3 Removal and installation 15.3 Removal and installation 15.3.1 Weight Product Weight [kg] Gas piping (Power2 340-H) Table 70: Weight 15.3.2 Removing gas piping Only use textile lifting gear to lift the bellows.
  • Page 117: Fig. 48: Installing The Bellows

    Operation Manual / Power2 340-H / Low-pressure stage 15 Gas piping (option) / 15.3 Removal and installation 15.3.3 Installing gas piping WARNING Gas leakage Gaskets that were installed incorrectly or are defective can lead to gas leaks. Dispose of used or defective gaskets.
  • Page 118: Storage And Disposal

    Operation Manual / Power2 340-H / Low-pressure stage 15 Gas piping (option) / 15.4 Storage and disposal 15.4 Storage and disposal Storing gas piping The bellows of the gas piping are made of rustproof chromium-nickel steel and can be stored in their undamaged original packaging for an unlimited time.
  • Page 119: Fig. 49: Gas Piping With Part Numbers (Power2 340-H)

    Operation Manual / Power2 340-H / Low-pressure stage 15 Gas piping (option) / 15.5 Spare parts 15.5.2 View of gas piping with part numbers Fig. 49: Gas piping with part numbers (Power2 340-H) © Copyright 2022 ABB. All rights reserved. HZTL4053_EN Rev.F...
  • Page 120: Figures

    Operation Manual / Power2 340-H / Low-pressure stage Figures Figures Fig. 1: Layout and function ..........7 Fig. 32: Installing the cartridge group on the service support ................79 Fig. 2.................. 8 Fig. 33: Measuring clearance A and B......80 Fig. 3.................. 9 Fig. 34: Nozzle ring compression PD ......81 Fig. 4: Volatile Corrosion Inhibitor (VCI)....
  • Page 121: Tables

    Operation Manual / Power2 340-H / Low-pressure stage Tables   Tables Table 1: Definition of pictograms ......11 Table 26: Malfunctions during operation – Power2 HP speed increases ............60 Table 2: Personal protective equipment to be worn at all times ..............15 Table 27: Malfunctions during operation –...
  • Page 122 Operation Manual / Power2 340-H / Low-pressure stage Tables Table 53: Cover plate dimensions [mm] ....95 Table 54: Customer spare part set (97070) ..100 Table 55 ................. 101 Table 56 ................ 102 Table 57 ................ 103 Table 58 ................ 104 Table 59 ................ 105 Table 60................ 106 Table 61 .................

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