Power2 850-M16 Operation Manual...Power2 from ABB Turbo Systems is intended for charging internal combustion engines. To ensure compliance with the machinery directive 2006/42/EC when

ABB Switzerland Ltd, Turbocharging

Operation Manual

Power2 850-M16HT596567_A English

Original Operation Manual

Chapter Document-ID

1 Introduction HZTL4004_EN_D

2 Safety HZTL4025_EN_B

3 Safety data sheets HT596567_A

4 Product description HZTL4061_EN_D

4.1 Low-pressure stage PT003062 HZTL4062_EN_B

4.2 High-pressure stage PT003061 HZTL4063_EN_C

Operating limits and replacement intervals

The recommended replacement intervals and the corresponding operating limits in chapter 3 are jointly definedwith 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.

Operation Manual / Power2 / 1 IntroductionTable of contents

© Copyright 2017 ABB. All rights reserved. HZTL4004_EN Revision D June 2017

Introduction1 Introduction............................................................................................................ 21.1 Purpose of the manual.................................................................................................. 21.2 Symbols, definitions...................................................................................................... 21.3 Registered trademarks................................................................................................ 41.4 Power2 layout and function......................................................................................... 51.5 Storage of new low-pressure and high-pressure stages...................................... 61.6 Contact information..................................................................................................... 8

Operation Manual / Power2 / 1 Introduction1 Introduction / 1.1 Purpose of the manual


1 Introduction

1.1 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 foroccupational safety, accident prevention and environmental protection.

Target group

The Operation Manual is aimed at engineers and trained mechanics responsible for theproper operation of the engine and for the Power2 connected to it.

Availability of the Operation Manual

The Operation Manual must be available where the Power2 is used.

All persons operating or working on the Power2 must have read and fully understood theOperation Manual.

1.2 Symbols, definitions

Symbols

The following symbols are used in this document:

u Indicates an action step.

1. Indicates a numbered action step.

→ Refers to a page number.

Accuracy of illustrations

The illustrations in this document are general in nature and intended for ease of understand-ing. Differences in detail are therefore possible.

Definition of mandatory signs

Mandatory signs show the protective equipment to be worn for a task. The mandatory signsare described in chapter Safety and must be complied with.

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Operation Manual / Power2 / 1 Introduction1 Introduction / 1.2 Symbols, definitions


Definition of Caution / Warning

Caution and warning signs are described in chapter Safety.

Terms used

The following terms are used in this document:

¡ Two-stage turbocharging (Power2)

¡ Low-pressure stage (Power2 LP)

¡ High-pressure stage (Power2 HP)

¡ Low-pressure and high-pressure stage

ABB Turbo Systems

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.

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Operation Manual / Power2 / 1 Introduction1 Introduction / 1.3 Registered trademarks


Definition of pictograms

The following pictograms can occur in this document. These point out actions that must betaken in accordance with the meaning of the relevant pictogram.

Pictogram Meaning Pictogram MeaningTighten with specified torque Affix

Tighten over specified tighten-ing angle

Measure

Hand-tight, tighten withouttools

Note

Oil Visually inspect

Apply screw locking paste (e.g.Loctite)

Please note text for numberedwork step

Apply high-temperature grease See document

Apply other paste in accord-ance with specifications

Dispose of in an environmentallycompatible, professional way andin compliance with locally applic-able regulationsOil free, grease free and dry

Table 1: Definition of pictograms

1.3 Registered trademarksThe trademarks of outside companies are used in this document. These are marked with the® symbol.

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Operation Manual / Power2 / 1 Introduction1 Introduction / 1.4 Power2 layout and function


1.4 Power2 layout and function

Fig. 1: Power2 layout and function

Power2 Two-stage turbocharging 21 HP compressorPower2 LP Low-pressure stage 22 HP turbinePower2 HP High-pressure stage 24 LP turbineA Exhaust gas inlet from internal combus-

tion engine25 LP compressor

B Exhaust gas outlet 26 IntercoolerC Air or air/gas mixture inletD Air or air/gas mixture outlet and supply

to the charge air cooler- - - Not included in the ABB Turbo Sys-

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). The low-pressure stage is always op-erated in combination with a high-pressure stage connected in series. The two-stage tur-bocharging (Power2) supplies the engine with the air volume and associated charging pres-sure required for operation.

Here, the exhaust gases of the internal combustion engine flow through the turbine (22) ofthe high-pressure stage and then to the turbine (24) of the low-pressure stage. The com-pressor (25) of the low-pressure stage sucks in fresh air or the air/gas mixture, respectively.This precompressed air or air/gas mixture flows through the intercooler (26) into the com-pressor (21) of the high-pressure stage. Here the air or air/gas mixture is compressed fur-ther and leaves the two-stage turbocharging (Power2) in the direction of the charge aircooler.

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Operation Manual / Power2 / 1 Introduction1 Introduction / 1.5 Storage of new low-pressure and high-pressurestages


1.5 Storage of new low-pressure and high-pressurestages

Storage of new low-pressure and high-pressure stages and cartridge groups for up to6 months

New low-pressure and high-pressure stages and cartridge groups from ABB Turbo Systemscan 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).

Fig. 2: Volatile Corrosion Inhibitor (VCI)

Only dry rooms with 40...70 % atmospheric humidity, in which no water condensation canform, are suitable as storage locations.

Storage of new low-pressure and high-pressure stages and cartridge groups for morethan 6 months (VCI)

WARNINGHealth protection when handling VCIVCI products are not hazardous in terms of the Ordinance on HazardousSubstances. Nevertheless, the following points must be observed whenhandling VCI:

u Ensure proper space ventilation.

u Do not eat, drink or store food at the workplace while working with VCI.

u Wear safety gloves.

u Clean hands and face after working with VCI.

u For more information, see www.branopac.com.

Every 6 months, the following mothballing measures are required:

u Open package.

u Remove VCI corrosion protection emitter from package and replace with a new VCI corro-sion protection emitter of the same kind. New VCI corrosion protection emitters can beobtained from www.branopac.com.

u Old VCI corrosion protection emitters must be disposed of in an environmentally compat-ible, professional way and in compliance with locally applicable regulations.

u Close package. The more tightly the package is sealed, the longer the protection dura-tion.

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http://www.branopac.com

http://www.branopac.com

Operation Manual / Power2 / 1 Introduction1 Introduction / 1.5 Storage of new low-pressure and high-pressurestages


Long-term storage of replacement low-pressure and high-pressure stages orreplacement cartridge groups

ABB Turbo Systems will prepare low-pressure and high-pressure stages or cartridge groupsfor long-term storage if requested in the purchase order. The package is equipped with a hy-grometer (see illustration).

Fig. 3: Package with hygrometer

Every 6 months, the following measures are required:

u Check the hygrometer (02) in the sight-glass. There is an opening (01) in the woodencrate to enable you to perform this check. If the 70% indicator field has changed colour,the maximum admissible atmospheric humidity has been exceeded. In this case, the low-pressure or high-pressure stage or the cartridge group must be checked and repackagedby an ABB Turbocharging Service Station.

u Check the package for damage. If the package is damaged, the low or high-pressurestage or the cartridge group must be checked and repackaged by an ABB TurbochargingService Station.

After every 3 years, the following steps must be carried out by an ABB Turbocharging ServiceStation:

¡ Checking the component

¡ Replacing the desiccant

¡ Repackaging the component.

Replacement components which are ready for operation

If the 70% field of the hygrometer (02) has not changed colour and the package is not dam-aged, the replacement low-pressure or high-pressure stage or the replacement cartridgegroup can be put into operation without previously having been checked by an ABB Tur-bocharging Service Station.

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Operation Manual / Power2 / 1 Introduction1 Introduction / 1.6 Contact information


1.6 Contact informationContact information for the ABB Turbocharging Service Stations is available online.

u Scan the QR code to access our website.

ABB Turbo Systems LtdBruggerstrasse 71aCH-5401 BadenSwitzerland

www.abb.com/turbocharging

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http://www.abb.com/turbocharging

Operation Manual / Power2 800-M / 2 SafetyTable of contents

© Copyright 2019 ABB. All rights reserved. HZTL4025_EN Rev.B November 2019

Safety1 Safety ...................................................................................................................... 21.1 Introduction .................................................................................................................... 21.2 CE conformity................................................................................................................. 21.3 Definition of mandatory signs .................................................................................... 31.4 Definition of safety instructions ................................................................................ 31.5 Intended use .................................................................................................................. 41.6 Deflagration on gas engines ....................................................................................... 51.7 Warning plates on the low-pressure and high-pressure stage ........................... 61.8 Rating plate of the high-pressure and low-pressure stage .................................. 71.9 Periodic check of the pressure vessels..................................................................... 81.10 Lifting of loads .............................................................................................................. 91.11 Prerequisites for operation and maintenance....................................................... 101.12 Hazards during operation and maintenance ......................................................... 111.13 Safe operation .............................................................................................................. 131.14 Safe maintenance ........................................................................................................ 14

Operation Manual / Power2 800-M / 2 Safety1 Safety / 1.1 Introduction


1 Safety

1.1 IntroductionThe two-stage turbocharging system (Power2) manufactured by ABB Turbo Systems is stateof the art and complies with the respective health and safety standards in effect at the timethe system was built. Thus Power2 is safe to operate. Nevertheless, there may be some re-sidual risks during operation of the Power2 and work on Power2 components, such as low-pressure stage and high-pressure stage, which:

¡ Are caused by Power2 itself or its accessories.

¡ Are caused by the operating equipment used or supplies and materials.

¡ Are a consequence of insufficient compliance with safety instructions.

¡ Are a consequence of insufficient or inappropriate performance of maintenance and in-spection work.

The operating company is responsible for defining measures that regulate safe access toand safe handling of the Power2.

All instructions contained in this chapter must be observed for safe and trouble-free opera-tion of the Power2 and during all work on the Power2 components.

All further safety instructions contained and specifically identified in every chapter of thisdocument (see section Definition of safety instructions) must also be observed.

1.2 CE conformity

Information

Low-pressure and high-pressure stages from ABB Turbo Systems comply with the MachineryDirective 2006/42/EC and are partly completed machinery as defined by Article 2 g.

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Operation Manual / Power2 800-M / 2 Safety1 Safety / 1.3 Definition of mandatory signs


1.3 Definition of mandatory signs

To be worn at all timesProtective clothing Safety footwear to protect

against mechanical hazard andrisk of falling

Table 1: Personal protective equipment to be worn at all times

To be worn specific to the respective taskSafety glasses Safety goggles

Safety gloves to protectagainst- Mechanical hazard- Chemical hazard- Thermal hazard- Electrical hazard

Respiratory mask to protectagainst- Dusts- Gases

Safety helmet Ear protection

Table 2: Personal protective equipment to be worn specific to the respective task

1.4 Definition of safety instructions

WARNINGDefinition of WarningNon-compliance or inaccurate compliance with working or operating in-structions indicated by this symbol and the word WARNING can lead to seri-ous injuries to personnel and even to fatal accidents.

u Warning signs must always be observed.

CAUTIONDefinition of CautionNon-compliance or inaccurate compliance with working or operating in-structions indicated by this symbol and the word CAUTION can lead to seri-ous damage to engine or property with grave consequences.

u Caution signs must always be observed.

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Operation Manual / Power2 800-M / 2 Safety1 Safety / 1.5 Intended use


1.5 Intended use

Use on internal combustion engines

Power2 from ABB 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". Thisis in accordance with the position paper [2] relating to ATEX issued by EUROMOT [1].

The specific operating limits of Power2 were determined on the basis of information fromthe enginebuilder about the 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[2]Directive 94/9/EC concerning equipment and protective systems intended for use in po-

tentially explosive atmospheres (ATEX) The Euromot Position as of November 2003, ATEXEuromot Position 191103

WARNINGUnapproved operationOperation of the Power2 outside of the operating limits can be hazardous topersonnel.

u Power2 must only be operated within the operating limits.

u Power2 must only be operated by trained personnel.

The intended use of the Power2 includes compliance with all regulations and conditions.

In particular, the following must be observed:

¡ The Operation Manual

¡ The instructions of the enginebuilder

State of the art

The Power2 is designed and built according to the state of the art and is safe to operate.

Perfect condition

The Power2 must be used in a technically perfect condition and in compliance with its inten-ded use.

ABB Turbo Systems excludes any liability for damage resulting from unauthorized modifica-tions to the Power2 or improper operation.

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Operation Manual / Power2 800-M / 2 Safety1 Safety / 1.6 Deflagration on gas engines


1.6 Deflagration on gas enginesLow-pressure stages from ABB Turbo Systems can tolerate a deflagration with a transientpressure increase of 12 bar (guideline value).

High-pressure stages from ABB Turbo Systems can tolerate a deflagration with a transientpressure increase of 15 bar (guideline value).

After a deflagration event ABB Turbo Systems recommends verifying the following points onthe low-pressure and high-pressure stages:

¡ Position of the turbine and compressor casings to the bearing casing

¡ Shifting of the bearing casing in relation to the bracket

¡ Cracks in casings

If during external inspection anomalies are found or if a particularly strong deflagrationevent has taken place, it is also recommended to check the bearings of the low-pressure andhigh-pressure stages before the next start. This inspection and evaluation must be carriedout by an ABB Turbocharging Service Station.

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Operation Manual / Power2 800-M / 2 Safety1 Safety / 1.7 Warning plates on the low-pressure and high-pressurestage


1.7 Warning plates on the low-pressure and high-pressure stage

Warning plates are attached to the low-pressure and high-pressure stage, and must be com-plied with. The warning plates must always be present in the intended locations and must belegible.

Fig. 1: Warning plate

If warning plates are not present in the intended locations or are not legible, they must bereplaced with new warning plates. The information that is required can be found in the Oper-ation Manual / Product description.

Low-pressure and high-pressure stages supplied to the enginebuilder without insulationmust be retrofitted with warning plates to be affixed to the insulation. This is the responsib-ility of the enginebuilder.

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Operation Manual / Power2 800-M / 2 Safety1 Safety / 1.8 Rating plate of the high-pressure and low-pressure stage


1.8 Rating plate of the high-pressure and low-pressure stage

Fig. 2: Rating plate

Operating limits1 Operating limits at engine overload (110 %). In test rig operation only, unless otherwise

agreed with the enginebuilder.2 Operating limits during operationTable 3

Recommended replacement intervals3 Replacement interval of plain bearings in 1000 h4 Replacement interval of compressor in 1000 h5 Replacement interval of turbine in 1000 hTable 4

Further data6 Power2 designation7 Power2 serial number8 Power2 stage9 Serial number of the low or high-pressure stage10 Year of construction of the low or high-pressure stage11 Weight of the low or high-pressure stage12 Part number of the customer of the low or high-pressure stageTable 5

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Operation Manual / Power2 800-M / 2 Safety1 Safety / 1.9 Periodic check of the pressure vessels


Explanations of the rating plate

The recommended replacement intervals and the corresponding operating limits are jointlydefined with the enginebuilder. This information is specific to the system.

The operating limits of the low-pressure stage are generally different from the operatinglimits of the high-pressure stage.

Operation above the indicated values nBmax, tBmax can considerably shorten the recommendedreplacement intervals. In such cases ABB recommends contacting the nearest ABB Tur-bocharging Service Station.

nMmax, tMmax normally apply only when running at overload (110%) during trials on the enginetest bed. These limit values can also be permitted during operation for special applications.Operation above nMmax and tMmax is not permitted.

Non-observance of the recommended replacement intervals increases the risk of unpredict-able component failures.

Locations of the rating plates

The locations of the rating plates are defined in the Operation Manual, Chapter 4 Productdescription.

1.9 Periodic check of the pressure vesselsThe pressure vessels used by ABB Turbocharging, such as those for wet or dry cleaning, areso-called "simple pressure vessels".

¡ The locally applicable legal regulations regarding periodic checks of the pressure vesselsmust be observed.

¡ The operating company is responsible for the safe operation of the pressure vessel.

WARNINGDanger due to pressure vesselsThe operating company must make sure the pressure vessels are in properworking condition and monitor them. Necessary repair or maintenance workmust be performed promptly, and the required safety measures must betaken.

u Pressure equipment must not be operated if defects are present.

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Operation Manual / Power2 800-M / 2 Safety1 Safety / 1.10 Lifting of loads


1.10 Lifting of loads

WARNINGSuspended loadsLoads that are not attached according to regulations can cause injury topersonnel or fatal accidents.

u Loads must always be fastened to properly functional lifting gear with asufficient load limit.

u Pay attention to the correct attachment of loads on the crane hook.

u People must not stand beneath suspended loads.

Wear safety gloves to protect against mechanical hazards.

Wear safety helmet.

Fig. 3: Attachment of loads on the crane hook

Fig. 4: Attachment angle

If there are two or more suspension points, the attachment angle of 45° must not be ex-ceeded. This prevents excessive loading due to diagonal pull.

u Before looping around the components of the low-pressure and high-pressure stage, al-low them to cool down (maximum 80 °C).

u Attach components of the low-pressure and high-pressure stage as described in the re-spective action steps.

u Use a suitable edge guard if there are sharp edges.

u The assembly devices must be completely screwed in and must not unscrew during use.

u Use assembly devices only for the described applications.

u Put down dismantled components of the low-pressure and high-pressure stage in such away that they cannot tip over.

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Operation Manual / Power2 800-M / 2 Safety1 Safety / 1.11 Prerequisites for operation and maintenance


1.11 Prerequisites for operation and maintenance

Responsibility of the operating company

In awareness of its responsibility, the operating company must ensure that only authorisedpersonnel work on the Power2, who:

¡ Are versed in the general and locally applicable regulations for occupational safety andaccident prevention

¡ Are equipped with the prescribed personal protective equipment

¡ Have read and understood the Operation Manual

¡ Have been instructed in the use of the Power2.

The safety-conscious work of the personnel and adherence to the Operation Manual must bechecked periodically.

Suitable working materials and personal protective equipment must be kept in a perfectcondition.

Only authorised personnel may remain in the vicinity of the Power2 when the engine is run-ning.

Competence of personnel

The Power2 may only be operated and serviced by trained and authorised personnel. Basicmechanical training is a prerequisite.

Modifications to the Power2

Modifications to the Power2 must be approved by ABB Turbo Systems.

Original parts and safety

Original parts and accessories must be specially designed by ABB Turbo Systems for theABB Power2.

WARNINGUse original partsOperation of the Power2 with non-original parts can impair the safety of thePower2 and can cause serious damage to property and injury to personnel.

u 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.

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Operation Manual / Power2 800-M / 2 Safety1 Safety / 1.12 Hazards during operation and maintenance


1.12 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.

WARNINGNoise hazardsExposure to noise can harm the hearing system, impair health and the psy-chological state and may lead to lack of attention and irritation.

u When the engine is running, always wear ear protection.

u Always wear ear protection if the sound pressure level exceeds 85 dB(A).

Wear ear protection.

Hazards due to hot surfaces

Surfaces of the low-pressure and high-pressure stage, attached parts and operating fluids(lubricating oil) get hot during operation. The surface temperature depends on the efficacyof the existing insulation. The temperature may rise to a level that can cause burns.

WARNINGDanger of burnsTouching hot surfaces or contact with hot operating fluids can cause severeburns.

u Do not touch hot surfaces. Observe the warning plate on the low-pres-sure and high-pressure stage.

u Wear heat-resistant safety gloves and protective clothing.

u Wait for the low-pressure and high-pressure stage to cool down beforecarrying out any work.

Wear safety gloves to protect against thermal hazards.

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Operation Manual / Power2 800-M / 2 Safety1 Safety / 1.12 Hazards during operation and maintenance


WARNINGHot surfaces on the non-insulated low-pressure and high-pressure stageNon-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 withor without insulation in accordance with the purchase order received fromthe enginebuilder. If supply is without insulation, the enginebuilder is re-sponsible for providing the low-pressure and high-pressure stage withproper insulation and for providing protection against contact with hot sur-faces.

u Compliance with the instructions and specifications given by the en-ginebuilder to protect against contact with hot surfaces on the low-pres-sure and high-pressure stage is compulsory.


Hazards due to rotating parts

WARNINGPhysical hazards due to rotating partsContact with rotating parts can cause severe injury. The low-pressure stagemust never be used without the filter silencer or air inlet casing, respectively.With the engine stopped, the rotor can rotate due to the stack draughtalone.

u Operate the low-pressure and high-pressure stage in compliance with thespecifications.

u Secure the rotor against unintentional rotation during maintenance.

Wear safety gloves to protect against mechanical hazards.

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Operation Manual / Power2 800-M / 2 Safety1 Safety / 1.13 Safe operation


1.13 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.

Low-pressure and high-pressure stages are not designed for sudden pressure loss that mayoccur due to the piping system between the compressor or the turbine stages bursting.

1.13.1 Safety during commissioning and operation

Safety during commissioning and operation

u Visually inspect your working environment before starting work.

u Remove any obstacles and objects littering the workplace.

u Check all pipes to and from the Power2 for damage and leaks before commissioning.

u Check Power2 for recognisable damage or defects every 12 hours of operation or at leastonce a day.

u Report any damage and any alterations of operational characteristics to the responsibledepartment immediately.

u In case of damage, take the Power2 out of operation immediately and safeguard againstaccidental/unauthorised use.

u 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.

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Operation Manual / Power2 800-M / 2 Safety1 Safety / 1.14 Safe maintenance


1.14 Safe maintenance

Occupational safety

WARNINGInjuries to personsSevere injuries to personnel or fatal accidents can be caused by mechanicalinfluences as a consequence of hazardous and inadequate operational pro-cedures or non-compliance with safety and health standards.

u When working on the Power2, always wear safety footwear and protect-ive clothing to protect against mechanical hazards.

u Keep personal protective equipment in perfect condition.

u Obey mandatory signs.

u Observe the general rules for occupational safety and prevention of acci-dents.

u Only perform operations that are described in this chapter.

u Only perform operations for which you have received instruction or train-ing.

Wear safety footwear to protect against mechanical hazard and risk of fall-ing.

Wear protective clothing.

WARNINGRisk of fallingWhen work is performed on the low-pressure or high-pressure stage, thereis a risk of falling.

u Do not climb onto the low-pressure or high-pressure stage or onto at-tached parts and do not use them as climbing aids.

u Use suitable climbing aids and working platforms for work above bodyheight.

u Only perform work on the low-pressure or high-pressure stage when you are in a physic-ally and psychologically stable condition.

u Only work with suitable tools, equipment and appliances that function properly.

u Keep the workplace clean; clear away any loose objects and obstacles on the floor.

u Keep the floor, equipment and the low-pressure and high-pressure stage clean.

u Have oil binding agents ready and provide or keep oil pans at hand.

Use of assembly devices

Assembly devices are specially constructed and designed for the defined use; they are notcommercially available products.

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u Use assembly devices only for the described applications.

Welding work

u Wear personal protective equipment (PPE) for welding operations.

u When performing welding work in the vicinity of the low-pressure stage, always cover thefilter silencer to prevent the filter mat from being damaged.

u Keep flammable objects and substances out of the vicinity of flying sparks.

u Cover all connections on the low-pressure and high-pressure stage so that no foreign ob-jects can enter the low-pressure or high-pressure stage.

Safety during cleaning

If cleaning agents or solvents are used for cleaning, the corresponding material safety datasheet and the safety instructions in section Hazards due to operating materials and suppliesmust be observed.

u Observe the material safety data sheet for the cleaning agent or solvent.

u Wear personal protective equipment (PPE) according to the material safety data sheet.

u Inspect the electric cables for abrasion and damage before and after your cleaning work.

Safety during disassembly, assembly, maintenance and repair

u Observe the procedures for set-up, service and inspection work and the inspection inter-vals.

u Inform the operating staff before starting any service or repair work. Make sure the en-gine is not started while work is being conducted on the Power2.

u Before taking off any cover or removing any guard from the low-pressure or high-pres-sure stage, switch off the engine and wait until the low-pressure stage and the high-pres-sure stage have come to a standstill.

u Make sure that the oil supply is interrupted, especially with an external oil supply.

u Only restart the engine after all parts have been properly fitted again and oil supply is en-sured.

CAUTIONMechanical operations on the low-pressure and high-pressure stageComponents of the low-pressure or high-pressure stage can be damaged ordestroyed due to improper use.

u Only perform operations that are described in this manual.

u Only perform operations for which you have received instruction or train-ing.

Safety when taking out of operation or preparing for mothballing

u Observe the material safety data sheet for the cleaning and mothballing agents.

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u Wear personal protective equipment (PPE) according to the material safety data sheet.

Mechanical hazards when working on the low-pressure and high-pressure stage

WARNINGPhysical hazards due to rotating partsThe rotor can rotate due to the stack draught alone. Contact with rotatingparts can cause severe injury.

u Secure rotor against turning.

Hazards due to operating materials and supplies

Operating materials and supplies are substances required for the operation of the tur-bocharger or for the performance of maintenance work. Oils, greases, coolants, detergentsand solvents, acids and similar substances can be classified as hazardous substances.

WARNINGHandling operating materials and suppliesSwallowing or inhaling vapours of operating materials and supplies or con-tact with them may be harmful to health.

u Do not breathe in these substances and avoid contact with the skin.

u Ensure proper ventilation.

u Observe the information in the material safety data sheet for the operat-ing materials and supplies.

u Wear personal protective equipment (PPE) according to the materialsafety data sheet.

u Comply with local legislation.

Wear safety goggles.

Wear safety gloves to protect against chemical hazards.

Wear a respiratory mask to protect against gases.

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WARNINGDanger of fire or explosionFlammable and combustible operating materials and supplies can catch fireor resulting vapours can lead to an explosion.



u Do not allow any exposed flame or ignition source during cleaning work.

u Carry out cleaning in the open or provide sufficient ventilation.

CAUTIONEnvironmental hazardImproper handling of operating materials and supplies can lead to environ-mental damage.



Hazards due to the handling of insulation materials

WARNINGDanger from insulation materialsDust or fibres from insulation materials can have adverse effects on thehealth or cause irritations. Unsuitable and combustible insulation materialsare a fire hazard.

u Only use suitable and non-combustible insulation materials.

u Ensure good ventilation at the workplace.

u Avoid whirling up dust.

u Use dust-free tools and working methods.

u Remove package at the workplace only.

u Proceed with particular care when removing old insulation materials.

u 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.

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Operation Manual / Power2 850-M16 / Safety data sheets

Contents Page 1 / 3

Safety data sheets

© Copyright 2020 ABB. All rights reserved. HT596567_A July 2020

Power2 850-M16 HT596567

Name Hardware ID Page

Low-pressure stage PT003062 2

High-pressure stage PT003061 3


Page 2 / 3

Safety data sheet


Power2 850-M16 HT596567Low-pressure stage PT003062

Power2 850-M16

HT596567

Low-pressure stage

PT003062 32

420 420 80

2020 1900 80

HZTL53380D

Additional Safety Data:

Maximum permissible temperatures

Exhaust gas inlettemperature

At engine overload (110 %) in test rigoperation only, unless otherwise agreedwith the enginebuilder

tMmax [°C] 550

During operation tBmax [°C] 520


Page 3 / 3

Safety data sheet


Power2 850-M16 HT596567High-pressure stage PT003061

Power2 850-M16

HT596567

High-pressure stage

PT003061 32

612 612 80

2020 700 80

HZTL53380D

Additional Safety Data:

Maximum permissible temperatures

Exhaust gas inlettemperature

At engine overload (110 %) in test rigoperation only, unless otherwise agreedwith the enginebuilder

tMmax [°C] 650

During operation tBmax [°C] 620

Compressor inlettemperature afterintercooler

During operation tCmax [°C] 60

Operation Manual / Power2 850-M / 4 Product descriptionTable of contents

© Copyright 2020 ABB. All rights reserved. HZTL4061_EN Rev.D March 2020

Product description1 Introduction............................................................................................................ 31.1 Related documents........................................................................................................ 31.2 Power2 layout and function......................................................................................... 51.3 Layout and function of the low-pressure stage ..................................................... 61.4 Layout and function of the high-pressure stage.................................................... 81.5 Warning plates on the low-pressure and high-pressure stage .......................... 101.6 Locations of the rating plates................................................................................... 11

2 Removal and installation .................................................................................... 12

3 Commissioning .................................................................................................... 133.1 Oil supply ....................................................................................................................... 133.2 Inspection procedures................................................................................................ 153.3 Commissioning after taking out of operation....................................................... 17

4 Monitoring during operation.............................................................................. 184.1 Lubricating oil pressure.............................................................................................. 184.2 Lubricating oil temperature ...................................................................................... 194.3 Speed measurement .................................................................................................. 20

5 Operation and service ......................................................................................... 285.1 Noise emission ............................................................................................................ 285.2 Service work................................................................................................................. 295.3 Expected replacement intervals ............................................................................... 315.4 Stopping the engine.................................................................................................... 31

6 Periodic maintenance.......................................................................................... 326.1 Foreword to maintenance.......................................................................................... 326.2 Cleaning the compressor during operation .......................................................... 336.3 Cleaning turbine and nozzle ring during operation ............................................. 366.4 Cleaning the filter silencer ......................................................................................... 41

7 Troubleshooting................................................................................................... 457.1 Malfunctions when starting...................................................................................... 457.2 Malfunctions during operation ................................................................................ 457.3 Surging of the low-pressure or high-pressure stage .......................................... 507.4 Malfunctions when stopping..................................................................................... 517.5 Speed measurement system..................................................................................... 51

8 Disassembly and assembly................................................................................. 52

9 Taking out of operation at short notice ........................................................... 53

Operation Manual / Power2 850-M / 4 Product descriptionTable of contents


10 Taking out of operation for a long period........................................................ 5410.1 General .......................................................................................................................... 5410.2 Lubricating oil.............................................................................................................. 5410.3 Process for taking out of operation........................................................................ 54

11 Disposing of low-pressure and high-pressure stage components ............... 55

12 Spare parts ........................................................................................................... 56

Figures................................................................................................................... 57

Tables .................................................................................................................... 58

Operation Manual / Power2 850-M / 4 Product description1 Introduction / 1.1 Related documents


1 Introduction

1.1 Related documents

Chapter Document numberOperation Manual / 1 Introduction HZTL4004Operation Manual / 2 Safety HZTL4025Operation Manual / 3 Safety data sheet *) Serial number of Power2Table 1: Related documents

*) This chapter is only present in serialised operation manuals.

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Operation Manual / Power2 850-M / 4 Product description1 Introduction / 1.1 Related documents


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Operation Manual / Power2 850-M / 4 Product description1 Introduction / 1.2 Power2 layout and function


1.2 Power2 layout and function

Fig. 1: Power2 layout and function




to the charge air cooler- - - Not included in the ABB 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). The low-pressure stage is always op-erated in combination with a high-pressure stage connected in series. The two-stage tur-bocharging (Power2) supplies the engine with the air volume and associated charging pres-sure required for operation.

Here, the exhaust gases of the internal combustion engine flow through the turbine (22) ofthe high-pressure stage and then to the turbine (24) of the low-pressure stage. The com-pressor (25) of the low-pressure stage sucks in fresh air or the air/gas mixture, respectively.This precompressed air or air/gas mixture flows through the intercooler (26) into the com-pressor (21) of the high-pressure stage. Here the air or air/gas mixture is compressed fur-ther and leaves the two-stage turbocharging (Power2) in the direction of the charge aircooler.

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Operation Manual / Power2 850-M / 4 Product description1 Introduction / 1.3 Layout and function of the low-pressure stage


1.3 Layout and function of the low-pressure stage

Fig. 2: Layout and function of the low-pressure stage

01 Filter silencer / air suction branch 06 Gas inlet casing02 Compressor wheel 07 Nozzle ring03 Diffuser 08 Turbine04 Bearing bush with heat shield 09 Bearing casing05 Gas outlet casing 10 Compressor casing

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Operation Manual / Power2 850-M / 4 Product description1 Introduction / 1.3 Layout and function of the low-pressure stage


Mode of operation of the low-pressure stage (Power2 LP)

Fig. 3: Power2 LP diagram





delivery

The low-pressure stage (Power2 LP) is a turbomachine and its main components are a tur-bine and a compressor. These components are installed on a common shaft and form the ro-tor.

In the low-pressure stage (Power2 LP) shown in the illustration (see Fig. 2: Layout and func-tion of the low-pressure stage →6), the exhaust gas coming from the high-pressurestage (Power2 HP) flows through the gas inlet casing (06) and the nozzle ring (07) andreaches the turbine (08). The LP turbine uses the energy contained in the exhaust gas todrive the rotor. The exhaust gases then reach the atmosphere through the gas outlet cas-ing (05) and the exhaust gas pipe connected to it.

The rotor runs in two radial plain bearings, which are located between the compressor andthe turbine. The axial bearing is also in the form of a plain bearing. The plain bearings areconnected to a central lubricating oil duct which is normally supplied by the lubricating oilcircuit of the engine. The oil outlet lies at the deepest point of the bearing casing (09).

The LP compressor wheel (02) connected to the shaft sucks in fresh air or an air/gas mixturethrough the filter silencer (01) or the air suction branch. The air is compressed in the LP com-pressor and the downstream diffuser (03). The compressed air is passed on to the inter-cooler (26) via the compressor casing (10). The air is cooled in the intercooler (26) and sub-sequently supplied to the HP compressor (21).

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Operation Manual / Power2 850-M / 4 Product description1 Introduction / 1.4 Layout and function of the high-pressure stage


1.4 Layout and function of the high-pressure stage

Fig. 4: Layout and function of the high-pressure stage

01 Air suction branch 06 Gas inlet casing02 Compressor wheel 07 Nozzle ring03 Diffuser 08 Turbine04 Bearing bush with hood diffuser 09 Bearing casing05 Gas outlet casing 10 Compressor casing

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Operation Manual / Power2 850-M / 4 Product description1 Introduction / 1.4 Layout and function of the high-pressure stage


Mode of operation of the high-pressure stage (Power2 HP)

Fig. 5: Power2 HP diagram





delivery

The high-pressure stage (Power2 HP) is a turbomachine, and its main components are a tur-bine and a compressor. These components are installed on a common shaft and form the ro-tor.

In the high-pressure stage (Power2 HP) shown in the illustration (see Fig. 4: Layout andfunction of the high-pressure stage →8), the exhaust gas flows through the gas inlet cas-ing (06) and the nozzle ring (07) and reaches the turbine (08). The HP turbine uses the en-ergy contained in the exhaust gas to drive the rotor. The exhaust gases then flow throughthe gas outlet casing (05) and the exhaust gas pipe connected to it before reaching the tur-bine of the low-pressure stage (Power2 LP).

The rotor runs in two radial plain bearings, which are located between the compressor andthe turbine. The axial bearing is also in the form of a plain bearing. The plain bearings areconnected to a central lubricating oil duct which is normally supplied by the lubricating oilcircuit of the engine. The oil outlet lies at the deepest point of the bearing casing (09).

The HP compressor wheel (02) connected to the shaft sucks in the precompressed air or anair/gas mixture from the low-pressure stage (25) through the air suction branch (01). The airis compressed further in the HP compressor and the downstream diffuser (03) and sub-sequently supplied to the charge air cooler via the compressor casing (10).

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Operation Manual / Power2 850-M / 4 Product description1 Introduction / 1.5 Warning plates on the low-pressure and high-pres-sure stage


1.5 Warning plates on the low-pressure and high-pressure stage

Warning plates are affixed at the following locations of the high and low-pressure stage:

Fig. 6: Locations of Power2 LP warning plates

Fig. 7: Locations of Power2 HP warning plates

If warning plates are not present in the designated locations or not readable, proceed as fol-lows:

u Order new warning plates from ABB Turbocharging Service Stations.

u Remove any warning plates that have become unreadable.

u Clean and degrease the areas designated for the warning plates.

u Fit new warning plates and remove protective sheets.

Non-insulated high and low-pressure stages

High and low-pressure stages supplied to the enginebuilder without insulation must beequipped later with warning plates to be attached to the insulation. This is the responsibilityof the enginebuilder.

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Operation Manual / Power2 850-M / 4 Product description1 Introduction / 1.6 Locations of the rating plates


1.6 Locations of the rating platesLow-pressure stage

Fig. 8: Location of Power2 LP rating plate

One rating plate each is attached on the left and the right side of the foot (bearing casing)and to the filter silencer and air suction branch of the low-pressure stage.

High-pressure stage

Fig. 9: Location of Power2 HP rating plate

One rating plate each is attached on the left and the right side of the foot (bearing casing)and to the air suction branch of the high-pressure stage.

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Operation Manual / Power2 850-M / 4 Product description2 Removal and installation /


2 Removal and installationu For more information on how to remove and install the low-pressure stage, see document

Operation Manual / Power2 … / 4.1 Low-pressure stage.

u For more information on how to remove and install the high-pressure stage, see docu-mentOperation Manual / Power2 … / 4.2 High-pressure stage.

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Operation Manual / Power2 850-M / 4 Product description3 Commissioning / 3.1 Oil supply


3 Commissioning

3.1 Oil supply

3.1.1 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.

The low-pressure and high-pressure stage are usually lubricated with oil from the engine oilcirculation.

u The directives of the enginebuilder on the selection of the lubricating oil and the oilchange intervals must be followed.

3.1.2 Pre-lubrication

Before the engine is started, the plain bearings of the low-pressure and high-pressure stagemust be pre-lubricated, in order to avoid bearing damage caused by dry running.

u Adhere to the admissible oil pressure range (see Table 5: Oil pressure range →18).

An electrically driven oil pump is recommended for pre-lubrication.

Power2 Pre-lubrication time850 2 minTable 2: Pre-lubrication time

3.1.3 Post-lubrication

Post-lubrication is necessary after switching the engine off, in order to avoid oil coking inthe vicinity of the shaft seal. The post-lubrication time starts as soon as the oil pressuredrops below the admissible value due to switching off the engine.


An electrically driven oil pump is recommended for post-lubrication.

Power2 Post-lubrication time850 LP 30 min850 HP 1.5 h or until turbine inlet temperature TTE <180 °CTable 3: Post-lubrication time

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Operation Manual / Power2 850-M / 4 Product description3 Commissioning / 3.1 Oil supply


3.1.4 Long-term lubrication

Long-term lubrication occurs if the times specified for the pre- or post-lubrication are ex-ceeded with the engine at a standstill.


CAUTIONOil leak while stoppedThe shaft sealing system of the low-pressure and high-pressure stage hasbeen designed to ensure optimum tightness during operation of the engine.During standstill, the pressure level in the bearing space may increase until itis above the pressure outside the shaft seal, resulting in a risk of oil leakage.

u Observe the points mentioned in the following to reduce the risk of oilleakage during standstill.

The following measures are recommended for reducing the risk of oil leakage during stand-still:

¡ Reduction of the pressure in the bearing space by a means of an appropriate crankcasevent design.

¡ Reduction of the pressure decrease outside the shaft seal due to stack draft effect by taking measures at the system side.

¡ Reduction of the pressure increase in the engine space by taking measures at the systemside.

¡ Interruption of the oil supply to the turbocharger through the shut-off valve.

3.1.5 Oil filtering

Power2 Filter mesh width [mm]850 ≤ 0.034Table 4: Filter mesh width

3.1.6 Oil pressure

Comply precisely with the oil pressure before the low-pressure and high-pressure stage fortrouble-free operation.

The admissible values are specified in chapter Monitoring during operation →18.

3.1.7 Oil orifice

Metering orifices are installed in the oil inlet of the low-pressure stage and the high-pressurestage in order to safeguard the oil pressures.

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Operation Manual / Power2 850-M / 4 Product description3 Commissioning / 3.2 Inspection procedures


3.2 Inspection procedures

3.2.1 Introduction

Inspection procedures include preventative visual controls, monitoring and measuring workbefore and during commissioning. Inspection procedures enable changes to the low andhigh-pressure stage to be detected. Engine damage can be prevented.

3.2.2 Checks before commissioning

Filter mat (if available)

u Check for damage and contamination.

Lubricating system

CAUTIONContaminated oilSerious damage to engine or property can be caused by dirt and solid ma-terial particles in the oil.

u For the initial commissioning phase and after all service work, flush thecomplete lubricating system with warm oil.

u Use special running-in filters when running in the engine and after all ser-vice work on the lubricating system.

u Check that the oil filter is clean before commissioning.

u Check the oil pressure in the oil supply pipes.

Warning plates

u Check whether warning plates are present and legible.

u Check whether the protective sheets have been removed from new warning plates.

3.2.3 Checks after commissioning (engine in idle mode)

Lubricating system

u Check the oil pressure in the oil supply pipes.

u Check oil inlet temperature.

The admissible values are specified in chapter Monitoring during operation →18.

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Operation Manual / Power2 850-M / 4 Product description3 Commissioning / 3.2 Inspection procedures


Leaktightness of pipes

WARNINGRisk of burning from hot gasEscaping gases are hot and will lead to serious burns in the event of contact.

u Check all pipes for leaks in accordance with the enginebuilder’s instruc-tions.


3.2.4 Checks when starting up the engine

u Measure speed, oil pressure and charging pressure at various engine performances.

u Measure the exhaust gas temperature before and after the turbine.

u Measure the air temperature before and after the compressor.

The measured values must be compared with the values of the acceptance protocol; differ-ent operating conditions must be taken into account here.

Escape of oily fluids

Lubricants and pastes used for the assembly of the low-pressure and high-pressure stagecan liquefy or vaporise and escape as oily fluids during the initial hours of operation. Con-tinual escape of an oily fluid indicates a possible oil leak.

If there is a leak, contact an ABB Turbocharging Service Station.

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Operation Manual / Power2 850-M / 4 Product description3 Commissioning / 3.3 Commissioning after taking out of operation


3.3 Commissioning after taking out of operation

If present

u Remove cover plates (blind flanges) from the compressor casing, the gas inlet and thegas outlet.

u Remove the locking screws on the water connections and fit the water pipe.

General

u Check the exhaust gas pipe before and after the turbine for combustion residues or wa-ter residues and clean it. Remove any foreign objects that may be present.

u Check and clean filter silencer or air supply line, and remove any foreign objects that maybe present.

u With the high-pressure stage, check the bellows located between the radial air suctionbranch and the compressor casing for damage and replace if necessary.

u Put engine-side oil circulation to the low-pressure and high-pressure stage into opera-tion.

u Prepare the low-pressure and high-pressure stage for operation according to sectionChecks before commissioning.

u The low-pressure and high-pressure stage is now operational.

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Operation Manual / Power2 850-M / 4 Product description4 Monitoring during operation / 4.1 Lubricating oil pressure


4 Monitoring during operation

4.1 Lubricating oil pressure

CAUTIONAssuring lubricating oil pressureSerious damage to the engine or property can result from a missing or insuf-ficient lubricating oil supply.

u The lubricating oil pressure must be monitored during operation and thenecessary pressure assured at the oil inlet.

Fig. 10: Lubricating oil pressure measuring point

The measuring point M is at the oil supply channel of the high and low-pressure stage that isnot used for the oil supply.

Power2 StatusEngine

StatusLow-pressure and high-pressure stage

Oil pressure at measuringpoint M

poil, in [bar]850 Engine run-

ningAdmissible 1.3 ... 2.5Temporarily admissible(<15 min) after engine start (cold oil)

1.3 ... 5.0

Temporarily admissible (<1 h )-> Warning signal

1.0 ... 1.3

Not admissible-> Alarm signal -> stop the engine imme-diately

< 1.0

Enginestopped

Pre-lubrication 1.3 … 2.5Post-lubrication 1.3 … 2.5Long-term lubrication < 0.7

Table 5: Oil pressure range

Metering orifices are installed in the oil inlet of the low-pressure stage and the high-pressurestage in order to safeguard the oil pressures.

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Operation Manual / Power2 850-M / 4 Product description4 Monitoring during operation / 4.2 Lubricating oil temperature


4.2 Lubricating oil temperature

CAUTIONMachine damageIf the oil temperature at the oil inlet exceeds the admissible range, this maylead to engine damage.

u Observe oil temperature at the oil inlet according to the following table.

Power2 Status for operation Oil temperature atthe inlet

Toil,inlet [°C]

Oil temperature atthe outletToil,inlet [°C]

850 Admissible < 90 < 150Temporarily admissible (< 1 h) -> Alarm 90 … 95 150 … 155Not admissible -> stop engine > 95 > 155Not admissible -> preheat oil prior beforestart

< 30 - -

Table 6: Lubricating oil temperature

The specified maximum oil outlet temperature is considered to be an alarm value for the op-eration of the low-pressure and high-pressure stage and must be monitored according tothe current regulations.

If the low-pressure or high-pressure stage has been operated outside of the admissiblerange for a long period of time, ABB Turbocharging recommends having the low-pressure orhigh-pressure stage inspected by an ABB Turbocharging Service Station. Pa

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Operation Manual / Power2 850-M / 4 Product description4 Monitoring during operation / 4.3 Speed measurement


4.3 Speed measurement

4.3.1 Introduction

Speed measurement systems enable the constant monitoring of the speeds of the low-pres-sure and the high-pressure stage.

4.3.2 Layout and functional principle

Fig. 11: Functional principle

01 Speed sensor02 Cable03 Casing flange04 Electronics05 Cable06 Plug

The speed measurement system consists of a sensor (01) with integrated cables (02, 05), anelectronic unit (04) and a plug (06). The sensor operates according to the eddy current prin-ciple, and is installed in a radial direction in relation to the compressor wheel. The electron-ics must be provided with a power supply, and deliver a square pulse signal. The signal fre-quency depends on the number of main blades on the compressor wheel. The signal amp-litude depends on the level of the feed voltage.

CAUTIONDo not put the speed measurement cables under strain by pulling themIf you pull the speed measurement cables too hard, contacts can be pulledout.

u Do not strain the speed measurement cables by pulling.

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4.3.3 Differences in speed between the low-pressure or high-pressure stages on one engine

The speeds of the low-pressure stages differ significantly from the speeds of the high-pres-sure stages.

A Power2 turbocharging system for V-engines, for example, can consist of multiple low-pres-sure and multiple high-pressure stages. In this case the speeds of the low-pressure stagesonly differ a little from each other. The same also applies to the high-pressure stages.

The difference between the highest and the lowest speed must not be more than 3 %, relat-ive to the speed limit nBmax.

If this admissible difference range is exceeded, the following steps must be performed:

u Reduce the engine performance until the maximum speed of all low and high pressurestages does not exceed 70% of nBmax.

u If the engine cannot be stopped, it can continue to be driven with this reduced engineperformance or at this low-pressure and high-pressure stage speed.

u If a low-pressure or high-pressure stage surges continuously, the engine performancemust be reduced further.

u Measure the temperatures in the air lines and exhaust gas pipes from and to the low-pressure and high-pressure stages and compare with normal values.

u Check the pressure loss of the alternative air inlet and compare it with normal values.

If the engine can be stopped temporarily:

u Inspect air lines, exhaust gas pipes and the low-pressure and high-pressure stages andremedy any malfunctions.

u 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 inchapter Troubleshooting / Speed measurement system →51.

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4.3.5 Replacing the speed measurement system

4.3.5.1 Low-pressure stage

Removing the speed measurement system

Fig. 12: Dimension X

u Measure and note down dimension X.

Fig. 13: Removing the speed measurement system

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Installing the speed measurement system

Fig. 14: Setting dimension X

1. Set speed sensor (86505) in the plate (86507) to dimension X.

2. Secure speed sensor with wedge lock washer (86509) and clamping nut (86505). Observetightening torque.

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Fig. 15: Control dimension S

3. Secure plate with wedge lock washer (86508) and socket screw (86510). Observe tighten-ing torque.

4. Adjust dimension X until S = 0 mm is reached.

5. Position cable and secure it with rubber grommet (86516).

6. Screw in pressure nut (86505) secured with Loctite® 243. Observe tightening torque.

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4.3.5.2 High-pressure stage

Removing the speed measurement system

Fig. 16: Dimension X

u Measure and note down dimension X.

Fig. 17: Removing the speed measurement system

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Installing the speed measurement system

Fig. 18: Setting dimension X

1. Set speed sensor (86505) in the plate (86507) to dimension X.

2. Secure speed sensor with wedge lock washer (86509) and clamping nut (86505). Observetightening torque.

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Fig. 19: Control dimension S

3. Secure plate with wedge lock washer (86508) and socket screw (86510). Observe tighten-ing torque.

4. Adjust dimension X until S = 0 mm is reached.

5. Position cable and secure it with rubber grommet (86516).

6. Screw in pressure nut (86505) secured with Loctite® 243. Observe tightening torque.

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Operation Manual / Power2 850-M / 4 Product description5 Operation and service / 5.1 Noise emission


5 Operation and service

5.1 Noise emission

WARNINGNoise hazardsExposure to noise can harm the hearing system, impair health and the psy-chological state and may lead to lack of attention and irritation.

u When the engine is running, always wear ear protection.

u Always wear ear protection if the sound pressure level exceeds 85 dB(A).

Wear ear protection.

The emission sound pressure level (A-weighted) is measured at a distance of 1 metre fromthe low-pressure and high-pressure stage.

The highest value of the emission sound pressure level1) reaches a maximum of 105 dB(A)near the compressor end (compressor casing, filter silencer, air suction branch).

The following prerequisites must be fulfilled with regard to the low-pressure and high-pres-sure stage to observe this limit value:

¡ Air inlet system and piping fitted

¡ All standard, noise-reducing measures2) have been fitted

The enginebuilder is also responsible for insulating other components such as the chargeair/scavenging air lines and the cooler.

1) Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7: A-rated emission sound pressure level

2) The enginebuilder must provide acoustically equivalent measures in case of deviating in-sulation versions

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Operation Manual / Power2 850-M / 4 Product description5 Operation and service / 5.2 Service work


5.2 Service workService work includes visual controls, monitoring, measuring and inspection as well as func-tion checks. Service work enables the detection and rectification of changes to the low andhigh-pressure stage and ensures full operability of the low and high-pressure stage.

CAUTIONService intervalsService work on the low-pressure and high-pressure stage that is omitted orperformed too late can cause excessive contamination and wear as well asoperating failures.

u Carry out the service work at the specified time intervals.

CAUTIONSpecific service intervalExceptional stresses such as a high number of starts and stops, harsh envir-onmental conditions, poor fuel quality or high system vibrations can lead tountimely machine damage even if the prescribed service intervals are ob-served.

u Agree on a specific service interval with ABB Turbocharging.

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 thelast service.

5.2.1 Service work every 25 … 50 hours

u Visual check for air, exhaust gas, water and oil leaks.

u Record operating data and enter in the engine logbook.

u In case of deviations, determine the cause.

5.2.2 Service work at 100 hours after commissioning

u 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.

5.2.3 Service work according to instructions of enginebuilder

u 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.

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Operation Manual / Power2 850-M / 4 Product description5 Operation and service / 5.2 Service work


5.2.4 Service work every 12000 ... 16000 hours of operation

The rotor and bearing parts must be checked and assessed by an ABB Turbocharging ServiceStation.

u Dismantle low-pressure and high-pressure stage. Measure clearances.

u Clean nozzle ring and casing and check for cracks and erosion/corrosion.

Additional measures in conjunction with the high-pressure stage:

u Replace gaskets every time after disassembly.

u Check bellows between air-inlet casing and compressor casing for cracks and clean (seealso chapter Cleaning the HP bellows (if present)).

5.2.5 Service work according to specifications on the ratingplate

The following work must be carried out by an ABB Turbocharging Service Station:

¡ Replacement of the bearing parts

¡ Replacement of the turbine and the compressor

5.2.6 Entries in the engine logbook

The monitoring of the engine enables conclusions to be drawn on the behaviour of the low-pressure and high-pressure stage.

The following operating data and measured values must be entered regularly in the enginelogbook of the enginebuilder:

¡ Performance and speed of the engine

¡ Air intake temperature

¡ Pressure of the charge air

¡ Pressure loss in the charge air cooler and intercooler

¡ Lubricating oil pressure and lubricating oil temperature

If present:

¡ Speed of low-pressure and high-pressure stage

¡ Air temperature before and after the compressor and after the charge air cooler

¡ Exhaust gas temperature before and after the turbine

¡ Atmospheric humidity of the suction air (before the low-pressure stage)

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Operation Manual / Power2 850-M / 4 Product description5 Operation and service / 5.3 Expected replacement intervals


5.3 Expected replacement intervalsu For information on the expected replacement intervals of the components of the low-

pressure stage, see documentOperation Manual / Power2 … / 4.1 Low-pressure stage.

u For information on the expected replacement intervals of the components of the high-pressure stage, see documentOperation Manual / Power2 … / 4.2 High-pressure stage.

5.4 Stopping the engine

CAUTIONResidual heat in the low-pressure and high-pressure stageIf the residual heat in the low-pressure and high-pressure stage is not suffi-ciently dissipated by the circulating lubricating oil, machine damage couldoccur.

u Observe the post-lubrication times and the oil pressure specified forpost-lubrication (see chapter Monitoring during operation / Lubricatingoil pressure).

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Operation Manual / Power2 850-M / 4 Product description6 Periodic maintenance / 6.1 Foreword to maintenance


6 Periodic maintenance

6.1 Foreword to maintenanceMaintenance 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. In this process, the exterior condition and the degree of contamination of the componentson which maintenance work is to be performed are determined.

Component to be main-tained

Recommended cleaning interval1) Operating state

LP compressor 25 … 100 h Engine load: 50 … 100 %HP compressorHP turbine stage 80 … 200 h Engine load: 25%LP turbine stageLP filter silencer2) 500 h Engine stoppedTable 7: Maintenance intervals

1) If the recommended cleaning intervals are incompatible with operation of the engine, con-tact ABB.

2) If present.

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 Tur-bocharging recommends the parallel cleaning of the LP compressors as well as the parallelcleaning of the HP compressors.

This cleaning process is faster and reduces the risk of surging of the low-pressure and high-pressure stages.

Turbine stages cleaning

We recommend cleaning the LP turbine stage after the HP turbine stage.

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Operation Manual / Power2 850-M / 4 Product description6 Periodic maintenance / 6.2 Cleaning the compressor during opera-tion


6.2 Cleaning the compressor during operation

6.2.1 Introduction

Approval by enginebuilder

The following instructions for wet cleaning only apply to cleaning with pure water and underthe precondition that the enginebuilder approves the process.

General

The contamination of the compressor stage (compressor wheel and diffuser) depends onthe degree of purity of the sucked-in air.

Deposits can form in the flow channels if salt, oil mist or dust are sucked in with the air.

Consequences of contamination:

¡ Impaired compressor efficiency

¡ Higher exhaust gas temperatures

¡ Increased fuel consumption

¡ Increased rotor unbalance

Periodic cleaning of the compressor during operation prevents or delays any great increasein 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. Pa

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6.2.2 Principle of wet cleaning

Principle of wet cleaning

To clean the compressor stage during operation, water is injected before the compressorwheel.

The water does not act as a solvent. The coating is removed by the mechanical action of theimpacting droplets. The process is particularly suitable as long as the contamination is nottoo advanced.

CAUTIONCorrosion and deposits when cleaningSalt water and cooling water treatment substances damage and adverselyaffect parts of the low-pressure and high-pressure stage.

u Never use salt water, but only pure water for cleaning.

CAUTIONVolume of waterUncontrolled volumes of water can damage the pressure stages and the en-gine.

u Never connect the water line without the orifice specified for the low-pressure and high-pressure stages.

Surging of the compressor

Should repeated surging of the compressor stage occur during compressor cleaning, firstthe cleaning parameters (water flow rate) as well as the engine-side system must bechecked with regard to deviations (e.g. an increased pressure loss in the charge air cooler)and corrected if necessary.

If surging of the compressor stage continues to occur during compressor cleaning despitecorrect settings, this can be remedied by reducing the engine load further during cleaning ofthe compressor after consulting an ABB Turbocharging Service Station. The reduction of theengine load can lead to a reduction in the effectiveness of the compressor cleaning.

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6.2.3 Wet cleaning with direct water supply

Prerequisites

Do not clean the compressors of the different high and low-pressure stages at the sametime, but one after the other.

On V-engines with several low-pressure and/or high-pressure stages per engine, ABB Tur-bocharging recommends the parallel cleaning of the LP compressors as well as the parallelcleaning of the HP compressors. This cleaning process is faster and reduces the risk of sur-ging of the low-pressure and high-pressure stages.

Wet cleaning operations for compressor with direct water supply

u Trigger water injection according to the instructions of the enginebuilder.

u Observe water pressure before connection to pressure stage.

u Operate engine for at least five additional minutes after cleaning.

The cleaning process can be repeated up to three times.

The success of the cleaning can be recognised based on the charging pressure or the ex-haust gas temperature.

If the cleaning is still unsuccessful after three processes and the engine values are unsatis-factory, it is recommended to have the low-pressure and / or high-pressure stage checkedand cleaned by an ABB Turbocharging Service Station.

Cleaning parameters for each compressor

Power2 Engine load Water pressure[bar]

Water injection time[s]

850 LP 50 … 100 % 3 10Table 8: Cleaning parameters Power2 LP

Power2 Engine load Water pressure[bar]

Water injection time[s]

850 HP 50 … 100 % pVE* + 3 10Table 9: Cleaning parameters Power2 HP

* Compressor inlet pressure depending on the operating point

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Operation Manual / Power2 850-M / 4 Product description6 Periodic maintenance / 6.3 Cleaning turbine and nozzle ring duringoperation


6.3 Cleaning turbine and nozzle ring during operation

6.3.1 Introduction

Approval by enginebuilder

The following instructions for wet cleaning only apply to cleaning with pure water and underthe precondition that the enginebuilder approves the process.

General

The combustion of fuels such as marine diesel oil (MDO) and heavy fuel oil (HFO) in dieselengines causes contamination of the turbine components of the low and high-pressurestages. Poor quality fuel in conjunction with a high exhaust gas temperature can lead to veryhard deposits on the nozzle ring, the turbine blades and particularly on the casing walls sur-rounding the impellers.

The formation of deposits on the turbine components stems from the following combustionproducts:

¡ Soot

¡ Molten ash

¡ Cinders

¡ Incompletely burnt fuel

¡ Sodium vanadyl vanadate

It is advantageous to use fuels with low ash, sulphur, sodium and vanadium contents. Thefuel must also be correctly stored, prepared and handled.

ABB Turbocharging recommends using fuels with a mass ratio of vanadium to sodium ofless than 3:1 so that the melting temperature of the sodium vanadyl vanadate is as high aspossible.

Consequences of contamination:

¡ Poor turbine efficiency

¡ Elevated exhaust gas temperatures

¡ Higher charging and ignition pressures with increasing speed of the low and high-pres-sure stages

¡ Lower engine performance

¡ Increased rotor unbalance

Experience in operation shows that, with periodic cleaning during operation, the intervalbetween overhauls can be extended. The wet cleaning of a turbine described in the followingcan be used for 4-stroke applications with heavy deposits (such as MDO and HFO applica-tions, for example). Generally, turbine cleaning is not required for the other applications.

Periodic cleaning of the turbines during operation never replaces the service work where thelow and high-pressure stages are completely dismantled and mechanically cleaned.

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Very heavily contaminated turbines can no longer be cleaned in this way. In this case, thecontaminated components must be cleaned mechanically by an ABB Turbocharging ServiceStation.

6.3.2 Cleaning method and principle

Cleaning of the turbine and the nozzle ring during operation is carried out by the cleaningmethod described in the following and is tested and approved by ABB:

¡ 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:

¡ ErosionThe contamination is removed by the mechanical action of the impacting water droplets

¡ SolubilityWater solubility of the contamination deposits in water

¡ Thermal shockSpalling of contamination due to the temperature differential

CAUTIONCorrosion and deposits when cleaningSalt water and cooling water treatment substances damage and adverselyaffect parts of the low-pressure and high-pressure stage.

u Never use salt water, but only pure water for cleaning.

The turbine-end components are cleaned at reduced engine load. The exhaust gas temperat-ure must not exceed the value specified in the cleaning instructions (see section Prerequis-ites).

CAUTIONReduced service life of the componentsFailure to comply with the minimum stabilisation time before cleaning, theprescribed turbine inlet temperatures and the drying time after cleaning sig-nificantly reduces the expected service life of the components.

u Comply with the cleaning parameters specified in the tables (see Table 11:Cleaning parameters HP →39) and (see Table 12: Cleaning parametersLP →39).

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6.3.3 Wet cleaning of turbine blades and nozzle ring

Cleaning procedure

The individual phases of the turbine cleaning procedure are shown in the following illustra-tion.

Fig. 20: Load/time chart

1. Cool down phase

u Reduction of the engine load to the operating point for turbine cleaning and subsequentmaintenance of the holding time according to the specifications in the following table.

Power2 Gas pulse atthe inlet in the

HP stage[N/m2]

Gas pulse atthe inlet in the

LP stage[N/m2]

Engine load[%]

Max. gas inlettemperature

when startingcleaning

[°C]

Holding timeat reduced

load[min]

850 9500 ±2500 3200 ±800 25 430 ≥10Table 10: Operating point for turbine cleaning

Algorithm for the gas pulse

For an optimum cleaning result, the gas pulse adopted when designing the cleaning processshould be set via the control system on the engine side. The algorithm for the gas pulse isspecified in the section Calculation of the gas pulse →40. If this is not possible, the spe-cified engine load point is to be set as an approximation.

Thermomechanical stress

Due to the thermomechanical stress of the turbine casing, the gas inlet temperature shouldnot exceed the specified maximum temperature before starting cleaning. If this is the case,the engine load is to be lowered until the permissible temperature is reached.

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2. Cleaning the high-pressure turbine stage (HP stage)

u If present, open the drain pipe in the low-pressure stage during cleaning.

u Switch the 3-way valve during cleaning from scavenging air to water supply.

u Carry out the cleaning process with cleaning parameters according to the specificationsin the following table.

Power2 Water flow rate[l/min]

Water pressure(guideline value)

[bar]

Duration of water injection[min]

850 HP 20.0 ±1.0 3.0 10Table 11: Cleaning parameters HP

Water flow rate

For an optimum cleaning result, the water flow rate adopted when designing the cleaningprocess should be set via the corresponding control valves and monitored by a flowmeter. Ifthis is not possible, the specified water pressure at the cleaning connection of the tur-bocharger is to be set as a rough approximation.

3. Cleaning the low-pressure turbine stage (LP stage)

u If present, open the drain pipe in the low-pressure stage during cleaning.

u Switch the 3-way valve during cleaning from scavenging air to water supply.

u Carry out the cleaning process with cleaning parameters according to the specificationsin the following table.

Power2 Water flow rate[l/min]

Water pressure(guideline value)

[bar]

Duration of water injection[min]

850 LP 20.0 ±1.0 1.5 10Table 12: Cleaning parameters LP

Water flow rate

For an optimum cleaning result, the water flow rate adopted when designing the cleaningprocess should be set via the corresponding control valves and monitored by a flowmeter. Ifthis is not possible, the specified water pressure at the cleaning connection of the tur-bocharger is to be set as a rough approximation.

4. Drying phase

u Maintenance of the holding time according to the specifications in the following tableand subsequent adjustment of the desired engine operating point.

Power2 Holding time at reduced load[min]

850 ≥10Table 13: Holding time

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Repetitions of wet cleaning

The repeating of cleaning cycles one immediately after the other must be avoided as thiscan lead to excessive mechanical stress, hence reducing the operating life of the compon-ents.

The action of the cleaning water on the peripheral units (such as boiler) must be clarified bythe operator.

Draining the gas outlet casing of the low-pressure stage

The following points must be observed with regard to draining the gas outlet casing:

¡ The exhaust gas temperature downstream of the low-pressure stage drops drasticallyduring cleaning (typical gas outlet temperatures during cleaning: 50 ... 150 °C).

¡ Depending on the engine load, the drainage can take place through the drain pipe. Thisdrainage may occur after 2 … 3 minutes or not at all.

¡ If the drainage of the gas outlet casing is omitted, the low-pressure stage speed and/orthe gas inlet temperature must be monitored during the cleaning process. If the load istoo low, water can collect in the gas outlet casing. Indications for this are a suddensevere drop in the low-pressure stage speed or a very large increase in the gas inlet tem-perature. In such cases, the cleaning operations must be stopped and the cleaning cyclerestarted with reduced water pressure or higher engine load.

Calculation of the gas pulse

The pulse IG for the flow of gas is calculated according to the following relationship:

pG is the density of the exhaust gas at the inlet into the gas inlet casing.

VG corresponds to the flow rate at the nozzle ring inlet.

ANR corresponds to a reference surface of the flow channel at the nozzle ring inlet. The valuesare specified in the following table.

Power2 Surface of the flow channel at thenozzle ring inlet of the HP turbine stage

[m2]

Surface of the flow channel at thenozzle ring inlet of the LP turbine stage

[m2]850 0.031 0.068Table 14: Surface of the flow channel

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Operation Manual / Power2 850-M / 4 Product description6 Periodic maintenance / 6.4 Cleaning the filter silencer


6.4 Cleaning the filter silencer

6.4.1 Variant with connecting rods

Fig. 21: Cleaning the filter silencer

81135 Filter silencer body 81266 Cover grid81136 Absorption segment 81269 Connecting rods81137 Sheet-metal covering 81272 Screw81265 Filter ring (if present) 81273 Lock nutE Insert unit = absorption segment +

sheet-metal covering

Cleaning the filter ring (if present)

u Remove filter ring (81265).

u Clean filter ring (81265) as required or every 500 hours of operation and replace after thefifth cleaning process at the latest.Contamination of the filter ring depends on the degree of purity of the sucked-in air.

u Rinse the filter ring (81265) with water and mild detergent or, in the case of heavy con-tamination, soak and carefully push through. Rinse in cold water. Avoid high mechanicalloads (water jet).

u Let the filter ring dry completely before assembling.

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u Dirty water and mild detergent must be disposed of in compliance with locally applicableregulations.

Cleaning the absorption segments

u Loosen and remove lock nuts (81273).

u Loosen and remove screws (81272) to the connecting rods (81269).

u Remove connecting rods (81269).

u Remove and clean cover grid (81266).

u Pull out insert units (E), bend up sheet-metal coverings (81137), then take out absorptionsegments (81136).

u Clean the absorption segments (81136).When cleaning, note that the absorption segments (81136) must only be cleaned lightlywith pressurized air, with a soft brush or a moist cleaning cloth.

u Have any heavily contaminated absorption segments and filter rings as well as damagedconnecting rods replaced by an ABB Turbocharging Service Station.

Fitting the filter silencer

u Assemble the insert units (E) by inserting the absorption segments (81136) into thesheet-metal coverings (81137).

u Bend the sheet-metal coverings (81137) back into the original shape.

u Insert the insert units (E) into the slotted guides in the filter silencer body (81135).

u Place the cover grids (81266) evenly and in the correct position.

u Push the connecting rods (81269) through the lugs of the cover grids (81266).

CAUTIONPenetration of dirt and foreign particlesAny penetration of dirt and foreign particles into the compressor can dam-age it.

u Fit the connecting rods (81269) correctly in the slots on the filter silencerbody (81135).

u It must not be possible to rotate or move the cover grid (81266) after as-sembly.

u Check the position and alignment of the connecting rods during and afterassembly.

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Fig. 22: Cover grid connecting rods

Part number Tightening torque [Nm]81272 2081273 40Table 15: Tightening torque (81272) / (81273)

u Connect the connecting rods (81269) with the screws (81272). While tightening the screws(81272), make sure that the connecting rods (81269) lie correctly in the slots on the filtersilencer body (81135). Now alternately tighten the screws (81272) up to the maximumtightening torque shown above.

u Fit lock nuts (81273) to screws (81272) and tighten with the tightening torque shownabove:

u Fit the filter ring (81265), if present.

6.4.2 Variant with tension bands

Fig. 23: Cleaning the filter silencer

81135 Filter silencer body 81266 Cover grid

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81136 Absorption segment 81270 Tension band81137 Sheet-metal covering 81271 Lock81265 Filter ring

Cleaning the filter ring (if present)

u Remove filter ring (81265).

u Clean filter ring (81265) as required or every 500 hours of operation and replace after thefifth cleaning process at the latest.Contamination of the filter ring depends on the degree of purity of the sucked-in air.

u Rinse the filter ring (81265) with water and mild detergent or, in the case of heavy con-tamination, soak and carefully push through. Rinse in cold water. Avoid high mechanicalloads (water jet).

u Let the filter ring dry completely before assembling.

u Dirty water and mild detergent must be disposed of in compliance with locally applicableregulations.

Cleaning the absorption segments

(see Fig. 23: Cleaning the filter silencer →43)

u Loosen the tension bands (81270).

u Remove the cover grid (81266).

u Pull out and bend up the sheet-metal coverings (81137), and remove the absorption seg-ments (81136).

u Clean the absorption segments (81136).When cleaning, note that the absorption segments (81136) must only be cleaned lightlywith compressed air, a soft brush or a moist cleaning cloth.

u Have any heavily contaminated absorption segments replaced by an ABB TurbochargingService Station.

Fitting the filter silencer

(see Fig. 23: Cleaning the filter silencer →43)

u Insert the absorption segments (81136) into the sheet-metal coverings (81137).

u Bend the sheet-metal coverings (81137) back to their original shape and insert into theslotted guides in the filter silencer body (81135).

u Fit the cover grid (81266).

u Fit the tension bands (81270) and tighten them at the locks (81271).

u Any tension bands that have become damaged must be replaced.

u Fit the filter ring (81265), if present.

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Operation Manual / Power2 850-M / 4 Product description7 Troubleshooting / 7.1 Malfunctions when starting


7 Troubleshooting

7.1 Malfunctions when starting

Delayed start-up

Possible causes RemedyLow-pressureorhigh-pressurestage

Pressure stage contaminated CleanBearing damaged Contact ABB Turbocharging Service

StationRotor rubbingForeign object in pressure stage

Table 16: Malfunctions when starting – Delayed start-up

Vibrations

Possible causes RemedyEngine Vibrations from engine Contact enginebuilderLow-pressureorhigh-pressurestage

Rotor unbalance Contact ABB Turbocharging ServiceStationTurbine or compressor damaged

Bearing damaged

Table 17: Malfunctions when starting – Vibrations

Rubbing of rotating parts

Normal behaviour, not a malfunctionLow-pressureorhigh-pressurestage

A minimal and uniform wear at the circumference of the rotor componentscaused by slight local rubbing against adjacent components is permitted. Thiscauses the compressor or turbine blades to be somewhat shortened. To pre-vent significant loss of efficiency, specific tolerances must be fulfilled.

¡ If there is any doubt about the extent of the rubbing, contact an ABBTurbocharging Service Station.

¡ Have a dimension check carried out by an ABB Turbocharging ServiceStation.

Table 18: Malfunctions when starting – Rubbing of rotating parts

7.2 Malfunctions during operation

Lubricating oil pressure too low

Possible causes RemedyEngine Oil filter heavily contaminated Clean

Oil pump in lubricating system de-fective

Check/replace

Manometer displays incorrectly Replace manometer

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Operation Manual / Power2 850-M / 4 Product description7 Troubleshooting / 7.2 Malfunctions during operation



Axial clearance of the rotor excessive Contact ABB Turbocharging ServiceStation

Table 19: Malfunctions during operation – Lubricating oil pressure too low

Drop in low-pressure stage speed

Possible causes RemedyEngine Defects on the connected cylinders Contact enginebuilderLow-pressurestage

Heavy contamination of the tur-bine

Clean

Damaged rotor components orbearing

Contact ABB Turbocharging ServiceStation

Change of operating state of high-pressure stage

Check the operating point of the high-pressure stage.

Pipes Defects, such as leaks, in the ex-haust gas pipes or charge air ducts

Repair

Table 20: Malfunctions during operation – Power2 LP speed reductions

Drop in high-pressure stage speed

Possible causes RemedyEngine Defects on the connected cylinders Contact enginebuilderHigh-pressurestage

Heavy contamination of the turbine CleanDamaged rotor components or bear-ing


Change of operating state of low-pressure stage

Check the operating point of the low-pressure stage.

Pipes Defects, such as leaks, in the exhaustgas pipes or charge air ducts

Repair

Table 21: Malfunctions during operation – Power2 HP speed reductions

Increase in low-pressure stage speed

Possible causes RemedyLow-pressurestage

Heavy contamination of the nozzlering


Table 22: Malfunctions during operation – Power2 LP speed increases

Increase in high-pressure stage speed

Possible causes RemedyHigh-pressurestage

Heavy contamination of the nozzlering


Low-pressure stage defective Contact ABB Turbocharging ServiceStation

Pipes Leak in exhaust gas pipe before thelow-pressure stage

Repair

Table 23: Malfunctions during operation – Power2 HP speed increases

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Exhaust gas temperature too high

Engine performance and engine speed unchanged

Possible causes RemedyEngine Malfunction in the injection system Repair or contact manufacturerLow-pressureorhigh-pressurestage

Insufficient air, for example, becausefilter silencer is blocked by contam-ination

Clean

Compressor/turbine contaminatedExhaust gas back pressure too high Clean or repair boiler or exhaust gas si-

lencerTurbine damaged or eroded Contact ABB Turbocharging Service

StationCharge aircooler/inter-cooler

Cooler contaminated CleanCooling water volume too low FillInlet temperature of cooling watertoo high

Check/clean cooling system

Insufficient ventilation Improve ventilationTable 24: Malfunctions during operation – Exhaust gas temperature too high

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Charge air pressure too low

Engine performance and engine speed unchanged, suction condition normal

Possible causes RemedyEngine Air receiver not sealed Repair

Gas piping between engine and tur-bine not sealedInjection mistimed Set correctlyValve control misadjusted

Low-pressureorhigh-pressurestage

Manometer display not correct Replace manometerSupply pipe to manometer notsealed

Repair leak

Filter silencer contaminated, there-fore pressure drop too high

Clean

Compressor/turbine contaminatedCompressor/turbine damaged Contact ABB Turbocharging Service

StationExhaust gas back pressure too high Clean or repair boiler or exhaust gas si-

lencerTable 25: Malfunctions during operation – Charge air pressure too low

Charge air pressure too high

Engine performance and engine speed unchanged, suction condition normal

Possible causes RemedyEngine Malfunction in the injection system Repair or contact manufacturer

Injection mistimed Set correctlyEngine performance higher than ex-pected

Check engine performance

Low-pressureorhigh-pressurestage

Manometer display not correct Replace manometer

Table 26: Malfunctions during operation – Charge air pressure too high

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Contamination of the compressor

Reduced compressor performance/efficiency and therefore engine performance losses


Heavy contamination of the com-pressor components due to the in-flux of ventilation gases

Clean the compressorOptimize oil separation

Increased vibration, compressorblade damage due to the influx ofventilation gases

Correct the influx of ventilation gases inaccordance with the enginebuilder's in-structions.

Table 27: Malfunctions during operation – Compressor 1 contamination

Reduced fatigue strength of the compressor wheel, compressor blade breakage.


Material of the compressor wheelcorroded due to the influx of ventila-tion gases containing corrosive com-ponents

Correct the influx of ventilation gases inaccordance with the enginebuilder's in-structions.

Material of the compressor wheelcorroded due to intake air containingexhaust gases or salt

Prevent exhaust gas leakages in the en-gine spaceClean the compressor

Table 28: Malfunctions during operation – Compressor 2 contamination

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Operation Manual / Power2 850-M / 4 Product description7 Troubleshooting / 7.3 Surging of the low-pressure or high-pressurestage


7.3 Surging of the low-pressure or high-pressurestage


Filter silencer or diffuser contamin-ated

Clean

Charge aircooler/inter-cooler

Cooler contaminated CleanCharge air duct blocked

Table 29: Surging of the low-pressure or high-pressure stage

CAUTIONContinuous or periodic surgingIf the low-pressure or high-pressure stages surge continuously or periodic-ally, their components may be damaged.

u Gradually reduce the engine load.

u Have the cause clarified and remedied immediately by an ABB Turbochar-ging Service Station.

u Have parts assessed for damage and, if necessary, replaced by an ABBTurbocharging Service Station.

Sporadic surge blows

Surging of the low-pressure stage can occur during certain operating states, such as whenreducing the engine performance quickly when manoeuvring. When this happens, the flowdirection in the compressor is momentarily reversed. Such sporadic surge blows do not im-pair the safe operation of the low-pressure stage.

¡ A surge blow is accompanied by a loud bang and the escape of hot air from the filter si-lencer of the low-pressure stage. No air escapes from the high-pressure stage.

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Operation Manual / Power2 850-M / 4 Product description7 Troubleshooting / 7.4 Malfunctions when stopping


7.4 Malfunctions when stopping

Runout noises



StationRotor rubbingForeign object in the pressure stage

Table 30: Malfunctions when stopping – Runout noises

Runout time too short



StationRotor rubbingForeign object in the pressure stage

Table 31: Malfunctions when stopping – Runout time too short

7.5 Speed measurement system

Measured speed incorrect

Possible causes RemedyLow-pres-sure orhigh-pres-sure stage

- - Contact ABB Turbocharging Service Station

Table 32: Measured speed incorrect

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Operation Manual / Power2 850-M / 4 Product description8 Disassembly and assembly /


8 Disassembly and assemblyu For more information on the disassembly and assembly of the low-pressure stage, see

documentOperation Manual / Power2 … / 4.1 Low-pressure stage.

u For more information on the disassembly and assembly of the high-pressure stage, seedocumentOperation Manual / Power2 … / 4.2 High-pressure stage.

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Operation Manual / Power2 850-M / 4 Product description9 Taking out of operation at short notice /


9 Taking out of operation at short noticeu For more information on briefly taking the low-pressure stage out of operation, see docu-

mentOperation Manual / Power2 … / 4.1 Low-pressure stage.

u For more information on briefly taking the high-pressure stage out of operation, see doc-umentOperation Manual / Power2 … / 4.2 High-pressure stage.

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Operation Manual / Power2 850-M / 4 Product description10 Taking out of operation for a long period / 10.1 General


10 Taking out of operation for a longperiod

10.1 GeneralWhen taking the low-pressure and high-pressure stage out of operation, mothballing meas-ures must be taken in order to minimise the risk of corrosion on components. The necessarymeasures depend on the condition of the lubricating oil and the process used to take thelow-pressure and high-pressure stage out of operation.

10.2 Lubricating oilNo measures must be taken with regard to the lubricating oil if:

¡ The directives of the enginebuilder on lubricating oil selection and on the oil change in-tervals are followed.

Or:

¡ The engine lubricating oil is replaced by a preservative oil and circulated with the pre-lub-rication pump before the engine is taken out of operation.

If neither of the criteria above are met, mothballing by an ABB Turbocharging Service Stationis necessary. This includes cleaning and applying preservative oil to the relevant compon-ents.

10.3 Process for taking out of operationDifferent measures are required depending on the process used to take the low-pressureand high-pressure stage out of operation.

¡ The low-pressure and high-pressure stage remains on the engine– Take countermeasures if there is a risk that the rotor will turn due to the stack

draught. One option is to install a blind flange on the outlet flange of the gas outletcasing or the compressor casing.

– If the engine is being taken out of operation for a long period in a corrosive environ-ment, all components through which air flows must be provided with corrosion pro-tection. Contact an ABB Turbocharging Service Station for this purpose.

¡ Disassembly of the low-pressure and high-pressure stage as a whole unit or in individualparts

– Seal all openings of the low-pressure and high-pressure stage with paraffin paper andwooden lids.

– Store the disassembled parts in a dry room with 40-70% atmospheric humidity inwhich no condensation can form.

– Check all low-pressure and high-pressure stage parts for corrosion annually.– If there are signs of rust, thoroughly clean the parts and renew the corrosion protec-

tion.

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Operation Manual / Power2 850-M / 4 Product description11 Disposing of low-pressure and high-pressure stage components /


11 Disposing of low-pressure and high-pressure stage components

Disposal must be environmentally compatible, professional, and in compliance with locallyapplicable regulations.

The low-pressure and high-pressure stages mainly consist of metal (cast iron materials,steel, nickel-steel alloys, aluminium and bearing brass).

Further components are: Non-metallic materials (filter components of felt and polyethylene),lubricants (engine oil), electronic parts (speed sensor and associated components).

u Dispose of metals as scrap metal for recycling.

u Dispose of non-metallic materials as waste.

u Dispose of residues of lubricants as waste oil.

u Dispose of electronic components as electronic waste.

WARNINGHandling damaged thermal insulationDamaged thermal insulation can lead to dust exposure. The glass fibres cancause mechanical irritation of the eyes, skin, and respiratory tracts.

u The enginebuilder's instructions must be followed for the handling anddisposal of the thermal insulation.

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Operation Manual / Power2 850-M / 4 Product description12 Spare parts /


12 Spare partsu For more information on spare parts for the low-pressure stage, see document

Operation Manual / Power2 … / 4.1 Low-pressure stage.

u For more information on spare parts for the high-pressure stage, see documentOperation Manual / Power2 … / 4.2 High-pressure stage.

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Operation Manual / Power2 850-M / 4 Product description Figures

© Copyright 2020 ABB. All rights reserved. HZTL4061_EN Revision D March 2020

FiguresFig. 1: Power2 layout and function............................... 5

Fig. 2: Layout and function of the low-pressurestage ................................................................................. 6

Fig. 3: Power2 LP diagram ............................................. 7

Fig. 4: Layout and function of the high-pressurestage ................................................................................. 8

Fig. 5: Power2 HP diagram ........................................... 9

Fig. 6: Locations of Power2 LP warning plates ....... 10

Fig. 7: Locations of Power2 HP warning plates....... 10

Fig. 8: Location of Power2 LP rating plate ............... 11

Fig. 9: Location of Power2 HP rating plate .............. 11

Fig. 10: Lubricating oil pressure measuring point.. 18

Fig. 11: Functional principle ........................................ 20

Fig. 12: Dimension X...................................................... 22

Fig. 13: Removing the speed measurement system....22

Fig. 14: Setting dimension X ....................................... 23

Fig. 15: Control dimension S ...................................... 24

Fig. 16: Dimension X..................................................... 25

Fig. 17: Removing the speed measurement system....25

Fig. 18: Setting dimension X....................................... 26

Fig. 19: Control dimension S ....................................... 27

Fig. 20: Load/time chart ............................................. 38

Fig. 21: Cleaning the filter silencer ............................. 41

Fig. 22: Cover grid connecting rods.......................... 43

Fig. 23: Cleaning the filter silencer............................ 43

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Operation Manual / Power2 850-M / 4 Product description Tables

© Copyright 2020 ABB. All rights reserved. HZTL4061_EN Revision D March 2020

TablesTable 1: Related documents .......................................... 3

Table 2: Pre-lubrication time....................................... 13

Table 3: Post-lubrication time .................................... 13

Table 4: Filter mesh width ........................................... 14

Table 5: Oil pressure range.......................................... 18

Table 6: Lubricating oil temperature......................... 19

Table 7: Maintenance intervals ................................... 32

Table 8: Cleaning parameters Power2 LP................ 35

Table 9: Cleaning parameters Power2 HP ............... 35

Table 10: Operating point for turbine cleaning...... 38

Table 11: Cleaning parameters HP ............................ 39

Table 12: Cleaning parameters LP............................. 39

Table 13: Holding time................................................. 39

Table 14: Surface of the flow channel....................... 40

Table 15: Tightening torque (81272) / (81273) ........ 43

Table 16: Malfunctions when starting – Delayedstart-up .......................................................................... 45

Table 17: Malfunctions when starting – Vibrations 45

Table 18: Malfunctions when starting – Rubbing ofrotating parts................................................................ 45

Table 19: Malfunctions during operation – Lubricat-ing oil pressure too low............................................... 46

Table 20: Malfunctions during operation – Power2LP speed reductions .................................................... 46

Table 21: Malfunctions during operation – Power2HP speed reductions ................................................... 46

Table 22: Malfunctions during operation – Power2 LPspeed increases ............................................................ 46

Table 23: Malfunctions during operation – Power2HP speed increases...................................................... 46

Table 24: Malfunctions during operation – Exhaustgas temperature too high .......................................... 47

Table 25: Malfunctions during operation – Charge airpressure too low........................................................... 48

Table 26: Malfunctions during operation – Charge airpressure too high ......................................................... 48

Table 27: Malfunctions during operation – Com-pressor 1 contamination............................................. 49

Table 28: Malfunctions during operation – Com-pressor 2 contamination.............................................. 49

Table 29: Surging of the low-pressure or high-pres-sure stage........................................................................ 50

Table 30: Malfunctions when stopping – Runoutnoises............................................................................... 51

Table 31: Malfunctions when stopping – Runout timetoo short.......................................................................... 51

Table 32: Measured speed incorrect.......................... 51

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Operation Manual / Power2 850-M / 4.1 Low-pressure stageTable of contents

© Copyright 2020 ABB. All rights reserved. HZTL4062_EN Rev.B March 2020

Low-pressure stage1 Further applicable documents ............................................................................. 2

2 Removal and installation...................................................................................... 32.1 Transport / weight ........................................................................................................ 32.2 Removing the low-pressure stage............................................................................. 42.3 Installing the low-pressure stage ............................................................................... 5

3 Expected replacement intervals .......................................................................... 6

4 Disassembly and assembly .................................................................................. 84.1 Introduction ................................................................................................................... 84.2 Weights of assemblies................................................................................................ 104.3 Removing the filter silencer ....................................................................................... 114.4 Removing the air suction branch.............................................................................. 124.5 Axial clearance A prior to disassembly .................................................................... 134.6 Removing the wall insert ............................................................................................ 144.7 Removing the compressor casing............................................................................ 154.8 Removing the cartridge group.................................................................................. 164.9 Removing turbine diffuser and nozzle ring ............................................................ 184.10 Installing turbine diffuser and nozzle ring............................................................. 204.11 Installing the cartridge group ................................................................................... 224.12 Installing the compressor casing ............................................................................ 244.13 Installing the wall insert ............................................................................................ 254.14 Axial clearance A after assembly.............................................................................. 284.15 Installing the air suction branch .............................................................................. 294.16 Installing the filter silencer ....................................................................................... 304.17 Table of tightening torques....................................................................................... 31

5 Taking out of operation at short notice ........................................................... 335.1 Possible emergency repairs...................................................................................... 33

6 Spare parts ........................................................................................................... 366.1 Ordering spare parts.................................................................................................. 366.2 View of low-pressure stage with part numbers ................................................... 39

7 Tools ...................................................................................................................... 41

Figures................................................................................................................... 42

Tables .................................................................................................................... 43

Operation Manual / Power2 850-M / 4.1 Low-pressure stage1 Further applicable documents /


1 Further applicable documentsChapter Document numberOperation Manual / Power2 / 1 Introduction HZTL4004Operation Manual / Power2 / 2 Safety HZTL4025Operation Manual / Power2 / 3 Safety data sheet *) Power2 serial number (HT……)Operation Manual / Power2 800-M / 4 Product description HZTL4061Table 1: Related documents

*) This chapter is only present in serialised Operation Manuals.

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Operation Manual / Power2 850-M / 4.1 Low-pressure stage2 Removal and installation / 2.1 Transport / weight


2 Removal and installation

2.1 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 inthe ABB scope of delivery.

Swivel lifting eye (S) Power2 Thread Length Minimum loadlimit

Lmin Lmax850 LP M24 30 mm 40 mm 1900 kg

Table 2: Swivel lifting eyes to be used

Lifting gear with a sufficient load limit must be used for removing and installing the low-pressure stage. The following weight specification is the heaviest variant possible. Thisstandard value may deviate from the data on the rating plate depending on the specifica-tion.

Complete low-pressure stageSuspension Weight [kg]

1900

Table 3: Transporting the low-pressure stage

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Operation Manual / Power2 850-M / 4.1 Low-pressure stage2 Removal and installation / 2.2 Removing the low-pressure stage


2.2 Removing the low-pressure stage

WARNINGRisk of tippingIf the turbocharger is not sufficiently supported or not supported at all dur-ing removal and installation, it may tip over and cause severe injury to per-sonnel or accidents resulting in fatalities.

u Support the turbocharger at a suitable location.

u Secure with lifting gear wherever possible.

Fig. 1: Suspension of complete low-pressure stage

u Remove insulation according to the instructions of the enginebuilder.

u Disconnect all gas, air, cleaning and oil pipes according to the instructions of the en-ginebuilder.

u Disconnect the cable connector from the speed sensor.

u Attach one lifting gear to each of the two bearing casing suspension points.

u Loosen the fixing elements on the foot.

u Lift the low-pressure stage from the engine.

u Put down the low-pressure stage so that all contact surfaces of the feet make contact.

u Also place a support made from hard wood beneath the compressor casing.

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Operation Manual / Power2 850-M / 4.1 Low-pressure stage2 Removal and installation / 2.3 Installing the low-pressure stage


2.3 Installing the low-pressure stage

Fig. 2: Suspension of complete low-pressure stage

u Attach one lifting gear to each of the two bearing casing suspension points.

u Check that the orifices specified for the low-pressure stage have been installed in both oilsupply lines.

u Check that the gaskets have been correctly fitted at the oil inlet and the oil outlet in thebracket.

u Align the low-pressure stage on the engine.

u Tighten the fixing elements on the foot according to the instructions of the engineb-uilder.

u Attach all gas, air, water and oil pipes in accordance with the instructions of the engineb-uilder.

u Connect the cable connector to the speed sensor.

u Fit insulation according to the instructions of the enginebuilder.

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Operation Manual / Power2 850-M / 4.1 Low-pressure stage3 Expected replacement intervals /


3 Expected replacement intervals

Rotating components

The recommended replacement intervals for compressor and turbine wheels are specifiedbased on the safety concept for rotating parts (SIKO) and dependant on the operating con-ditions. These intervals are shown on the rating plate of the low-pressure and high-pressurestage.

Non-rotating components

Depending on the system-specific operating conditions, a differentiation must be madebetween the intervals to be expected for:

¡ replacing the bearing parts and

¡ replacing the non-rotating components exposed to hot gas.

A decisive role is played by various influencing parameters which, in extreme cases, candrastically reduce the replacement interval of these parts.

During the prescribed periodic service work, the individual parts are examined for wear andreplaced if necessary.

Expected replacement intervals [h]

GAS / MDO HFOGas inlet casing 50000 … 100000 35000 … 50000Gas outlet casing 50000 … 100000 50000 … 100000Nozzle ring 35000 … 50000 25000 … 50000Turbine diffuser / cover ring 35000 … 50000 25000 … 50000Other casings 100000 100000Rotor components See rating plate informationBearing parts See rating plate informationTurbine blades(due to wear)

- - ≥ 12000

Table 4: Expected replacement intervals [h]

GAS = GasMDO = Marine Diesel OilHFO = Heavy Fuel Oil

The specified values are guideline values and are not guaranteed, see influencing paramet-ers.

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Operation Manual / Power2 850-M / 4.1 Low-pressure stage3 Expected replacement intervals /


Influencing parameters

The actual values can deviate considerably from the guideline values, for example, due to thefollowing influences:

¡ Fuel quality and fuel treatment

¡ Load profile (thermal cycling, also number of starts/stops, emergency shutdowns)

¡ Gas inlet temperature

¡ Frequency and execution of turbine and compressor cleaning

¡ Specification of the low-pressure stage

¡ System-specific operating conditions (combustion quality, exhaust gas composition)

For bearing parts

¡ 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).

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Operation Manual / Power2 850-M / 4.1 Low-pressure stage4 Disassembly and assembly / 4.1 Introduction


4 Disassembly and assembly

4.1 Introduction

WARNINGNon-observance of the work steps and further operationsIncorrectly performed work or further operations can cause injury to person-nel or damage to the machine.

u Only perform operations that are described in this document.

u Only perform operations for which you have previously received instruc-tion or training.

u Have further operations carried out only by trained personnel from anABB Turbocharging Service Station.

u Mark the casing position for assembly.

Customer tool set

Before starting work, make sure the required tool set is available (see chapter Tools →41).

Not all tools are marked with a part number. Identification is guaranteed by the tool list. Thislist is enclosed with the tool set.

WARNINGServicing the assembly devicesAssembly devices must be checked for damage before and after use.

u Visually inspect for corrosion, cracks, deformation and wear.

u Damaged assembly devices must no longer be used and must be re-placed.

Customer spare part set

Before starting work, make sure the required customer spare part set is available (seechapter Spare parts →36).

Tightening torques for components

The specified bolted connection tightening torques must be observed (see chapter Table oftightening torques →31)

Tightening torques for assembly devices

Unless described otherwise, the screws and nuts of the assembly devices supplied by ABBmust be tightened so they are tight-fitting.

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Operation Manual / Power2 850-M / 4.1 Low-pressure stage4 Disassembly and assembly / 4.1 Introduction


Definition of terms

¡ Suspension pointDefined loading point on a component or an assembly (blind hole thread, eyelet, lug).

¡ Assembly deviceDevices that are fitted on the low-pressure or high-pressure stage in order to obtain asuspension point. Assembly devices are specially constructed and designed for thedefined use; they are not commercially available products. Use assembly devices only forthe described applications.

¡ Lifting gearEquipment for the lifting and transporting of loads (lifting slings, chain block, crane).Lifting gear is not supplied by ABB.

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Operation Manual / Power2 850-M / 4.1 Low-pressure stage4 Disassembly and assembly / 4.2 Weights of assemblies


4.2 Weights of assembliesThe specified weights of the individual parts or assemblies are rounded-up standard values.

Fig. 3: Overview of assemblies

Designation Weight [kg]01 Air suction branch 8002 Filter silencer 19003 Wall insert 19004 Diffuser 2505 Compressor casing 21006 Cartridge group 33007 Turbine diffuser 4008 Nozzle ring 15

Table 5: Weights of the assemblies

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Operation Manual / Power2 850-M / 4.1 Low-pressure stage4 Disassembly and assembly / 4.3 Removing the filter silencer


4.3 Removing the filter silenceru Dismantle insulation as far as necessary.

u If present: Disconnect supply line for compressor cleaning from filter silencer.

Fig. 4: Removing the filter silencer

1. Fit the swivel lifting eye (90231) to the silencer (81000). Attach the lifting gear to theswivel lifting eye (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).

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Operation Manual / Power2 850-M / 4.1 Low-pressure stage4 Disassembly and assembly / 4.4 Removing the air suction branch


4.4 Removing the air suction branchu Disconnect air line according to the instructions of the enginebuilder.

u Dismantle insulation as far as necessary.

u If present: Disconnect supply line for compressor cleaning from air suction branch.

Fig. 5: 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.

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Operation Manual / Power2 850-M / 4.1 Low-pressure stage4 Disassembly and assembly / 4.5 Axial clearance A prior to disas-sembly


4.5 Axial clearance A prior to disassembly

CAUTIONClearances outside the toleranceSerious damage to engines or property can be caused by clearances outsidethe tolerance and excessively worn parts.

u Have the components assessed and, if necessary, replaced by an ABB Tur-bocharging Service Station.

Fig. 6: Measuring axial clearance A

The axial clearance (A) must be measured prior to removal and after installation of the cart-ridge group.

u Measure and note axial clearance (A).

Axial clearance A [mm]0.32 ... 0.53

Table 6: Axial clearance A

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Operation Manual / Power2 850-M / 4.1 Low-pressure stage4 Disassembly and assembly / 4.6 Removing the wall insert


4.6 Removing the wall insert

CAUTIONClearance between compressor wheel and wall insertSerious damage to machinery or property can result from rubbing or jam-ming of the compressor wheel at the wall insert.

u Check that the compressor wheel does not rub against the wall insertduring disassembly/assembly by rotating the rotor.

Fig. 7: Removing wall insert 1

1. Screw nut (72004) onto end of bolt thread as protection.

2. Use three press-off screws (90920) to press off the wall insert (77000) until the liftingdevice can be fitted.

3. Remove the press-off screws (90920).

4. Remove two studs (72002) in the upper area.


5. Unplug cable connector (86515) and fix speed measurement cable in wall insert.

6. Fit bracket (90030) with screws (90955) and nuts (90415).Fit two plates (90031) and secure with plate (90032), screw (90656) and nut (90432).

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Operation Manual / Power2 850-M / 4.1 Low-pressure stage4 Disassembly and assembly / 4.7 Removing the compressor casing


7. Secure lifting gear to swivel lifting eye (90231).

8. Remove nut (72004) and carefully move out wall insert.


9. Fit support angle (90480) with screws (90955) and nut (90415).

10. Put down the wall insert (77000).

11. Remove plate (90032), screw (90656), nut (90432) and plates (90031). Remove lifting gear and bracket (90030).

12. Remove O-rings (77040 / 79020 / 79021).

13. Loosen screws (77016) and remove diffuser (79000).

4.7 Removing the compressor casing

Fig. 10: Removing the compressor casing 1

1. Loosen two studs (72002) and screw (72021) in the upper area.

2. Fit bracket (90030) with four screws (90959).

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Operation Manual / Power2 850-M / 4.1 Low-pressure stage4 Disassembly and assembly / 4.8 Removing the cartridge group


3. Fit four plates (90031) and secure with plate (90032), screw (90656) and nut (90432).

Fig. 11: Removing the compressor casing 2

4. Secure lifting gear to swivel lifting eye (90231) and secure compressor casing (72000) tocrane.

5. Loosen and remove nuts (61037).

6. Press off compressor casing (72000) with three press-off screws (90924).

7. Move out compressor casing (72000) and put down.

4.8 Removing the cartridge group

CAUTIONClearance between blade tip and casingSerious damage to machinery or property can result from the rubbing orjamming of the blade tips on the casing.

u Check that the blades do not rub on the turbine diffuser during disas-sembly/assembly by rotating the rotor.

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Operation Manual / Power2 850-M / 4.1 Low-pressure stage4 Disassembly and assembly / 4.8 Removing the cartridge group


Fig. 12: Moving out cartridge group 1

1. Remove the O-ring (42012).

2. Loosen and remove the screws (42087).

3. Fit swivel lifting eye (90231) to bracket (90030) and screw bracket to cartridge groupwith two screws (90955).

4. Fit five plates (90031) and secure with plate (90032), screw (90656) and nut (90432).

5. Secure lifting gear to swivel lifting eye (90231) and secure cartridge group to crane.

6. Evenly press off cartridge group by screwing three press-off screws (90920) into the des-ignated holes.


7. Carefully move out cartridge group.

8. Put cartridge group into the fixtures in the turned-over toolbox cover.

9. Remove plate (90032), screw (90656), nut (90432) and plates (90031).

10. Remove the press-off screws (90920).

11. Remove O-rings (42017 / 42018).

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Operation Manual / Power2 850-M / 4.1 Low-pressure stage4 Disassembly and assembly / 4.9 Removing turbine diffuser andnozzle ring


Putting down cartridge group onto cover

CAUTIONDamage to cartridge group and toolbox coverThe turned-over toolbox cover may only be used for intermediate storage ofthe cartridge group.

u The cover must be on a level surface.

u The cover may not be used to transport the cartridge group.

Fig. 14: Putting down cartridge group onto cover

4.9 Removing turbine diffuser and nozzle ring

Fig. 15: Removing turbine diffuser and nozzle ring 1


2. Secure connecting flange (90428) to star plate (90414) with screws (90950) andnuts (90431).

3. Align arm of star plate (90414) marked FRONT in direction of gas outlet flange and screwstar plate to turbine diffuser with screws (90961).

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Operation Manual / Power2 850-M / 4.1 Low-pressure stage4 Disassembly and assembly / 4.9 Removing turbine diffuser andnozzle 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.


7. Insert bracket with guide tube into connecting flange.

8. Secure guide tube with bolt (90033).


10. Fit four plates (90031) and secure with plate (90032), screw (90656) and nut (90432).

11. Press off turbine diffuser evenly using the press-off screws (90902).

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Operation Manual / Power2 850-M / 4.1 Low-pressure stage4 Disassembly and assembly / 4.10 Installing turbine diffuser andnozzle ring



12. Carefully move out turbine diffuser (63000).

13. Put down turbine diffuser.Remove plate (90032), screw (90656), nut (90432) and plates (90031).Remove the press-off screws (90902).

14. Loosen screws (56017) with box spanner insert (90770) and remove together withclamps (56018).

15. Remove nozzle ring (56001).

4.10 Installing turbine diffuser and nozzle ring

Fig. 19: Installing the nozzle ring and turbine diffuser 1

Part number Thread and tightening torque56017 M8 Tx40

25 NmTable 7: Tightening torque (56017)

1. Fit nozzle ring (56001).

2. Coat thread of screws (56017) with high-temperature grease. Fit clamps (56018) andscrews (56017).

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Operation Manual / Power2 850-M / 4.1 Low-pressure stage4 Disassembly and assembly / 4.10 Installing turbine diffuser andnozzle ring


3. Tighten screws with torque spanner using the box spanner insert (90770). Observe tight-ening torque.

4. Screw in a guide stud (90316) in the upper area on the left and right.

5. Secure lifting gear to swivel lifting eye (90231).(Installation of bracket and plate see Removing turbine diffuser and nozzle ring →18)

6. Insert turbine diffuser (63000) via the guide studs.

7. Coat a screw (61056) with high-temperature grease and screw in to secure the turbinediffuser.

Fig. 20: Installing the nozzle ring and turbine diffuser 2

Part number Thread and tightening torque61056 M10x90


1. Remove plates and brackets.

2. Loosen screws (90961) and remove together with star plate (90414). Remove guidestud (90316).

3. Coat thread of remaining screws (61056) with high-temperature grease and fit screws.Observe tightening torque.

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Operation Manual / Power2 850-M / 4.1 Low-pressure stage4 Disassembly and assembly / 4.11 Installing the cartridge group


4.11 Installing the cartridge group

CAUTIONClearance between blade tip and casingSerious damage to machinery or property can result from the rubbing orjamming of the blade tips on the casing.

u Check that the blades do not rub on the turbine diffuser during disas-sembly/assembly by rotating the rotor.

Fig. 21: Installing O-rings

u Fit new O-rings (42017 / 42018).

Fig. 22: Installing the cartridge group 1

1. Screw bracket to cartridge group with two screws (90955).

2. Fit swivel lifting eye (90231) to bracket (90030) and secure lifting gear to swivel liftingeye.

3. Fit five plates (90031) and secure with plate (90032), screw (90656) and nut (90432).

4. Lift the cartridge group.

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Operation Manual / Power2 850-M / 4.1 Low-pressure stage4 Disassembly and assembly / 4.11 Installing the cartridge group


Fig. 23: Inserting the cartridge group



1. Screw in a guide stud (90321) in the upper area on the left and right.

2. Insert cartridge group via the guide studs.

3. Coat a screw (42087) with high-temperature grease and screw in to secure the cartridgegroup.

4. Remove plates (90031) and bracket (90030).

5. Remove the guide stud (90321).

6. Coat thread of remaining screws (42087) with high-temperature grease and fit screws.Observe tightening torque.

7. Fit a new O-ring (42012).

Control dimension after installing cartridge group

CAUTIONControl dimension outside the tolerance valueIf the control dimension is out of tolerance, the cartridge group has notbeen correctly installed and can be the cause of serious damage to the ma-chine or property.

u Remove and reinstall the cartridge group.

u Always replace jammed gasket rings with new ones.

u If the control dimension is still out of tolerance, contact an ABB Tur-bocharging Service Station.

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Operation Manual / Power2 850-M / 4.1 Low-pressure stage4 Disassembly and assembly / 4.12 Installing the compressor casing


Fig. 24: Measuring control dimension X

After installing the cartridge group, the control dimension (X) must be measured.

Control dimension X[mm]

63.0 ±0.1Table 10: Control dimension X

4.12 Installing the compressor casing

Fig. 25: Installing the compressor casing

Part number Thread and tightening torque61037 M16

250 Nm61037 (nuts that are difficult to access) Pre-tightening torque 60 Nm

Tightening angle 90° ±5°190 Nm 1)

72021 M10x2070 Nm

Table 11: Tightening torque (61037 / 72021)

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Operation Manual / Power2 850-M / 4.1 Low-pressure stage4 Disassembly and assembly / 4.13 Installing the wall insert


1) Application with adapter 90249 and special key 90250/90251, see below

1. Secure lifting gear to swivel lifting eye (90231) and insert compressor casing.(For installation of bracket and plates, see Removing the compressor casing →15).

2. Fit nuts (61037). Observe tightening torque.


4. Fit screw (72021). Observe tightening torque.

Application of special key for nuts that are difficult to access

u Attach the special key (90250 / 91250 / 90251 / 91251) to the torque spanner by using theadapter (90249 / 91249).

u Use the special key in an angle range between 30° and 90°.

u Use the special key only for nuts that are difficult to access and observe the reducedtorque.

4.13 Installing the wall insert

CAUTIONClearance between compressor wheel and wall insertSerious damage to machinery or property can result from rubbing or jam-ming of the compressor wheel at the wall insert.

u Check that the compressor wheel does not rub against the wall insertduring disassembly/assembly by rotating the rotor.

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Fig. 26: Installing the wall insert 1



1. Coat the threads of screws (77016) with Loctite® 243 and secure diffuser (79000) withscrews (77016). Observe tightening torque.

2. Install new O-rings (77040 / 79020 / 79021).


4. Fit two plates (90031) and secure with plate (90032), screw (90656) and nut (90432).

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).


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Part number Tightening torque72002 M16x104



2. Remove the bracket (90030).

3. Detach speed measurement cable from provisional holder and insert cable con-nector (86515).

4. Fit four studs (72002) in the upper area. Observe tightening torque.

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Operation Manual / Power2 850-M / 4.1 Low-pressure stage4 Disassembly and assembly / 4.14 Axial clearance A after assembly


4.14 Axial clearance A after assembly




The axial clearance (A) must be measured prior to removal and after installation of the cart-ridge group.


Axial clearance A [mm]0.32 ... 0.53

Table 14: Axial clearance A

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Operation Manual / Power2 850-M / 4.1 Low-pressure stage4 Disassembly and assembly / 4.15 Installing the air suction branch


4.15 Installing the air suction branch

Fig. 29: Installing the air suction branch



1. Remove the two opposing nuts (72004) and washers (72003) that were used to securethe wall insert.

2. Loop around air suction branch (82000) with lifting gear.

3. Position the air suction branch.

4. Fit nuts (72004) with washers (72003) and tighten nuts (72004).

u Reinstall dismantled insulation.

u Reinstall all air lines according to the instructions of the enginebuilder.Pa

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Operation Manual / Power2 850-M / 4.1 Low-pressure stage4 Disassembly and assembly / 4.16 Installing the filter silencer


4.16 Installing the filter silencer

Fig. 30: Installing the filter silencer




77022 M16200 Nm

Table 16: Tightening torque (72004 / 77022)

1) Application with adapter 90249 and special key 90250/90251, see below

1. Fit sleeves (77023) and nuts (77022) in accordance with position of filter silencer andtighten nuts (77022).

2. Remove the two opposing nuts (72004) and washers (72003) that were used to securethe wall insert.

3. Fit the swivel lifting eye (90231) to the filter silencer (81000). Attach the lifting gear tothe swivel lifting eye (90231) and loop through the eyelets at the rear of the filter silen-cer (81000).

4. Fit the filter silencer.

5. Fit nuts (72004) and washers (72003) and tighten nuts (72004).

u If present: Fit supply line for compressor cleaning to filter silencer.

u Reinstall dismantled insulation.

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Operation Manual / Power2 850-M / 4.1 Low-pressure stage4 Disassembly and assembly / 4.17 Table of tightening torques






4.17 Table of tightening torques

Fig. 31: Overview of tightening torques

The following tightening torques [Nm] must be observed for the designated bolted connec-tions:


80 Nm56017 M8 Tx40

25 Nm61037 M16

250 Nm

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Operation Manual / Power2 850-M / 4.1 Low-pressure stage4 Disassembly and assembly / 4.17 Table of tightening torques


Part number Thread and tightening torque61037 (nuts that are difficult to access) Pre-tightening torque 60 Nm


61056 M10x9050 Nm

72002 M16x10450 Nm

72004 M16200 Nm

72004 (nuts that are difficult to access) Pre-tightening torque 60 NmTightening angle 60° ±5°

150 Nm 1)

72021 M10x2070 Nm

77016 M5x355 Nm

77022 M16200 Nm

Table 17: Tightening torques

1) Application with adapter 90249 and special key 90250/90251

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Operation Manual / Power2 850-M / 4.1 Low-pressure stage5 Taking out of operation at short notice / 5.1 Possible emergency re-pairs


5 Taking out of operation at short notice

5.1 Possible emergency repairs

WARNINGDanger of fire and explosion due to lubricating oil leaksLeaking oil may ignite on hot surfaces. This can result in serious injuries topersonnel or fatal accidents.

u Cordon off danger area.

u Raise the alarm and, depending on the situation, stop the engine.

u Seal the oil leak.

u Soak up oil and dispose of in an environmentally compatible manner.


CAUTIONDirectives for taking out of operationSerious damage to engine or property can be caused by non-compliancewith the directives for blanking off the low-pressure or high-pressure stageon the engine.

u Follow the directives of the enginebuilder.

If damage has occurred to the low-pressure stage and the engine has to be brought backinto operation again as quickly as possible, the following emergency repair option is avail-able:

¡ Attaching the cover plate

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5.1.1 Manufacturing the cover plate

The cover plate and the other parts that are required are not part of the scope of delivery ofABB and must be manufactured by the operator on the basis of the drawing (see Fig. 32:Cover plate / gasket, sleeves and screws →34).

Parts required

¡ 1 cover plate (01) (recommended material: 1.4541 / 1.4571)

¡ 1 gasket (02) (temperature resistant up to 550 °C)

¡ 8 additional screws (03) to the screws (42087) from the scope of delivery

¡ 15 sleeves (04)

Fig. 32: Cover plate / gasket, sleeves and screws

Cover plate (gasket), sleeves and screws, dimensions [mm]

Ø1 Ø2 Ø3 Ø4 Ø5 B1 B2 L1 M1655 600 14 14 20 10 32 60 M12

Table 18: Cover plate / gasket

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5.1.2 Fitting the cover plate

Fig. 33: Fitting the cover plate



1. Remove alternative air inlet, wall insert, compressor casing and cartridge group.

2. Close opening in bearing casing with gasket (02) and cover plate (01).

3. Secure cover plate (01) with spacer sleeves (04) and screws (42087 / 03).

Fig. 34: Installing the casing

4. Reinstall compressor casing, wall insert and alternative air inlet.

CAUTIONEscaping lubricating oilIf the cover plate is fitted, complete sealing of the lubricating oil supply isnot guaranteed.

u Shut off lubricating oil supply to low-pressure stage at engine side.

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Operation Manual / Power2 850-M / 4.1 Low-pressure stage6 Spare parts / 6.1 Ordering spare parts


6 Spare parts

6.1 Ordering spare parts

CAUTIONSpare part storageAll spare parts that were ordered together with the low-pressure and/orhigh-pressure stage must be kept intact and ready for use.

u Carefully clean any rusted parts and grease them.

Please quote the following data when making queries and ordering spare parts:

¡ Serial number of Power2 (HT……)

¡ 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.

u If different model variants are not taken into account in this document, contact an ABBTurbocharging Service Station.

u Dispose of placed and unusable parts in an environmentally-friendly and professionalmanner in accordance with the local regulations.

u Dispose of the packaging of new parts in an environmentally-friendly and professionalmanner in accordance with the local regulations.

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Required customer spare part set (97070) for a low-pressure stage

For the operations described in the Operation Manual, the customer spare part set (97070)is required. These parts are only available in the complete set.

Part number Designation Quantity42012 / 79020 O-ring 242017 O-ring 142018 O-ring 242087 Hexagon-head screw 156017 Hexalobular-head screw 356018 Clamp 361037 Hex nut 361056 Hexagon-head screw 872003 Washer 372004 / 77022 Hex nut 477016 Hexagon-head screw 577040 O-ring 179021 O-ring 1Table 20: Customer spare part set (97070)

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Operation Manual / Power2 850-M / 4.1 Low-pressure stage6 Spare parts / 6.2 View of low-pressure stage with part numbers


6.2 View of low-pressure stage with part numbers

Fig. 35: Low-pressure stage with part numbers

(……) only available in customer spare part set (97070).

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Operation Manual / Power2 850-M / 4.1 Low-pressure stage6 Spare parts / 6.2 View of low-pressure stage with part numbers


Part number Designation01 Cartridge group42001 Bearing casing42012 (in customer spare part set) O-ring42017 (in customer spare part set) O-ring42018 (in customer spare part set) O-ring42087 (in customer spare part set) Hexagon-head screw51001 Gas inlet casing, radial51001 Gas inlet casing, axial56001 Nozzle ring56017 (in customer spare part set) Hexalobular-head screw56018 (in customer spare part set) Clamp61001 Gas outlet casing61009 Hexagon-head screw61037 (in customer spare part set) Hexagon nut61050 Spiral-wound gasket61056 (in customer spare part set) Hexagon-head screw63000 Turbine diffuser68002 Foot, turbine end72000 Compressor casing72002 Stud72003 (in customer spare part set) Washer72004 (in customer spare part set) Hexagon nut72021 Socket screw77000 Wall insert77016 (in customer spare part set) Hexagon-head screw77022 (in customer spare part set) Hexagon nut77023 Sleeve77040 (in customer spare part set) O-ring79000 Diffuser79020 (in customer spare part set) O-ring79021 (in customer spare part set) O-ring81000 Filter silencer82000 Air suction branch86505 / 86515 Speed sensor / connecting cableTable 21: Low-pressure stage part numbers

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Operation Manual / Power2 850-M / 4.1 Low-pressure stage7 Tools /


7 ToolsFor the work described in the Operation Manual, the customer tool set 90000 is required.

Part number Designation Quantity90010 Wooden crate 190030 Bracket 190031 Plate 590032 Plate 190033 Bolt 290770 Box spanner 190422 Guide tube 190428 Connecting flange 191414 Star-shaped plate 190480 Support 290231 Shackle 190920 Press-off screw 390924 Press-off screw 390902 Press-off screw 390320 Guide stud 290321 Guide stud 290316 Guide stud 290955 Hexagon-head screw 690959 Hexagon-head screw 490950 Hexagon-head screw 390961 Hexagon-head screw 390656 Hexagon-head screw 190415 Hexagon nut 690431 Hexagon nut 390432 Hexagon nut 190430 Nut 190161 Protective bag 190250 Special key 190251 Special key 190249 Adapter 1Table 22: Customer tool set 90000

This tool set can be ordered from any ABB Turbocharging Service Station. The following spe-cifications must be included in the order:

¡ Equipment type

¡ Designation and part number of the tool set.

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Operation Manual / Power2 850-M / 4.1 Low-pressure stage Figures

© Copyright 2020 ABB. All rights reserved. HZTL4062_EN Revision B March 2020

FiguresFig. 1: Suspension of complete low-pressure stage 4

Fig. 2: Suspension of complete low-pressure stage 5

Fig. 3: Overview of assemblies ................................... 10

Fig. 4: Removing the filter silencer ............................ 11

Fig. 5: Removing the air suction branch ................... 12

Fig. 6: Measuring axial clearance A ............................ 13

Fig. 7: Removing wall insert 1 ...................................... 14

Fig. 8: Removing wall insert 2 ..................................... 14


Fig. 10: Removing the compressor casing 1............. 15

Fig. 11: Removing the compressor casing 2 ............. 16

Fig. 12: Moving out cartridge group 1........................ 17

Fig. 13: Moving out cartridge group 2 ....................... 17

Fig. 14: Putting down cartridge group onto cover . 18

Fig. 15: Removing turbine diffuser and nozzle ring 1 ..18



Fig. 18: Removing turbine diffuser and nozzle ring 4..20

Fig. 19: Installing the nozzle ring and turbine diffuser1........................................................................................ 20

Fig. 20: Installing the nozzle ring and turbine dif-fuser 2 .............................................................................. 21

Fig. 21: Installing O-rings ............................................. 22

Fig. 22: Installing the cartridge group 1 .................... 22

Fig. 23: Inserting the cartridge group ....................... 23

Fig. 24: Measuring control dimension X .................. 24

Fig. 25: Installing the compressor casing................ 24

Fig. 26: Installing the wall insert 1 ............................. 26


Fig. 28: Measuring axial clearance A ......................... 28

Fig. 29: Installing the air suction branch ................. 29

Fig. 30: Installing the filter silencer .......................... 30

Fig. 31: Overview of tightening torques..................... 31

Fig. 32: Cover plate / gasket, sleeves and screws... 34

Fig. 33: Fitting the cover plate .................................... 35

Fig. 34: Installing the casing........................................ 35

Fig. 35: Low-pressure stage with part numbers ..... 39

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Operation Manual / Power2 850-M / 4.1 Low-pressure stage Tables

© Copyright 2020 ABB. All rights reserved. HZTL4062_EN Revision B March 2020


Table 2: Swivel lifting eyes to be used ........................ 3

Table 3: Transporting the low-pressure stage .......... 3

Table 4: Expected replacement intervals [h]............. 6

Table 5: Weights of the assemblies........................... 10

Table 6: Axial clearance A............................................. 13

Table 7: Tightening torque (56017)........................... 20

Table 8: Tightening torque (61056) ........................... 21


Table 10: Control dimension X................................... 24

Table 11: Tightening torque (61037 / 72021)........... 24

Table 12: Tightening torque (77016) ......................... 26

Table 13: Tightening torque (72002) ......................... 27

Table 14: Axial clearance A.......................................... 28

Table 15: Tightening torque (72004) ........................ 29

Table 16: Tightening torque (72004 / 77022) ......... 30

Table 17: Tightening torques ...................................... 32

Table 18: Cover plate / gasket ................................... 34


Table 20: Customer spare part set (97070) ............. 37

Table 21: Low-pressure stage part numbers .......... 40

Table 22: Customer tool set 90000 ........................... 41

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43

Operation Manual / Power2 850-M / 4.2 High-pressure stageTable of contents

© Copyright 2020 ABB. All rights reserved. HZTL4063_EN Rev.C March 2020

High-pressure stage1 Further applicable documents ............................................................................. 2

2 Removal and installation...................................................................................... 32.1 Transport / weight ........................................................................................................ 32.2 Removing the high-pressure stage ........................................................................... 42.3 Installing the high-pressure stage ............................................................................. 5

3 Expected replacement intervals .......................................................................... 6

4 Disassembly and assembly................................................................................... 84.1 Introduction ................................................................................................................... 84.2 Weights of assemblies................................................................................................ 104.3 Removing the air suction branch together with bellows..................................... 114.4 Removing the wall insert ............................................................................................ 124.5 Removing the compressor casing............................................................................ 144.6 Removing the cartridge group.................................................................................. 154.7 Removing the nozzle ring ........................................................................................... 174.8 Measuring axial clearance A....................................................................................... 184.9 Installing the nozzle ring ............................................................................................ 194.10 Installing the cartridge group .................................................................................. 204.11 Installing the compressor casing ............................................................................. 234.12 Installing the wall insert ............................................................................................ 244.13 Installing the air suction branch together with bellows ..................................... 264.14 Table of tightening torques....................................................................................... 27

5 Taking out of operation at short notice ........................................................... 285.1 Possible emergency repairs...................................................................................... 28

6 Spare parts ........................................................................................................... 316.1 Ordering spare parts................................................................................................... 316.2 View of high-pressure stage with part numbers.................................................. 33

7 Tools ...................................................................................................................... 35

Figures................................................................................................................... 36

Tables .................................................................................................................... 37

Operation Manual / Power2 850-M / 4.2 High-pressure stage1 Further applicable documents /


1 Further applicable documentsChapter Document numberOperation Manual / Power2 / 1 Introduction HZTL4004Operation Manual / Power2 / 2 Safety HZTL4025Operation Manual / Power2 / 3 Safety data sheet *) Power2 serial number (HT……)Operation Manual / Power2 800-M / 4 Product description HZTL4061Table 1: Related documents

*) This chapter is only present in serialised Operation Manuals.

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Operation Manual / Power2 850-M / 4.2 High-pressure stage2 Removal and installation / 2.1 Transport / weight


2 Removal and installation

2.1 Transport / weightSwivel lifting eyes are required for the safe lifting of loads, which are not supplied by ABB.

Fig. 1: Swivel lifting eyes

Thread M Length L Minimum load limit Quantity12 min.15mm

max. 20mm700kg 2

Table 2: Swivel lifting eyes

Lifting gear with a sufficient load limit must be used for removing and installing the high-pressure stage. The following weight specification is the heaviest variant possible. Thisstandard value may deviate from the data on the rating plate depending on the specifica-tion.

Complete high-pressure stageSuspension Weight [kg]

700

Table 3: Transporting the high-pressure stage

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Operation Manual / Power2 850-M / 4.2 High-pressure stage2 Removal and installation / 2.2 Removing the high-pressure stage


2.2 Removing the high-pressure stage

CAUTIONTilting of high-pressure stage and leaks at the bellowsThe high-pressure stage may not be transported or put down with the airsuction branch and the bellows fitted.

u The air suction branch / bellows combination must be transported andfitted separately.

Fig. 2: Suspension of complete high-pressure stage

u Remove insulation.

u Disconnect all gas, air, water and oil pipes in accordance with the enginebuilder's instruc-tions.

u Unplug the cable connector at the speed sensor.

u Remove the air suction branch together with the bellows (see Fig. 5: Removing the airsuction branch →11).

u Check lifting gear.

u Attach one lifting gear to the two suspension points of the bearing casing and one liftinggear to the support.

u Loosen fixing screws at foot and support.

u Lift the high-pressure stage from the engine and put it down.

u Cover the oil connection.

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Operation Manual / Power2 850-M / 4.2 High-pressure stage2 Removal and installation / 2.3 Installing the high-pressure stage


2.3 Installing the high-pressure stage

CAUTIONTilting of high-pressure stage and leaks at the bellowsThe high-pressure stage may not be transported or put down with the airsuction branch and the bellows fitted.

u The air suction branch / bellows combination must be transported andfitted separately.

Fig. 3: Suspension of complete high-pressure stage

u Attach one lifting gear to the two suspension points of the bearing casing and one liftinggear to the support.

u Check that the orifices specified for the high-pressure stage are installed in the two oilsupply pipes.

u Check that the gaskets have been correctly fitted at the oil inlet and the oil outlet in thebracket.

u Check that the sleeves of the bearing casing fixing screws have been correctly fitted.

u Align the high-pressure stage on the engine.

u Tighten fixing elements at the foot and support in accordance with the enginebuilder's in-structions.

u Connect the cable connector to the speed sensor.

u Install the air suction branch together with the bellows (see Fig. 24: Installing the air suc-tion branch →26).

u Attach all gas, air, water and oil pipes in accordance with the enginebuilder's instructions.

u Fit insulation.

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Operation Manual / Power2 850-M / 4.2 High-pressure stage3 Expected replacement intervals /


3 Expected replacement intervals

Rotating components

The recommended replacement intervals for compressor and turbine wheels are specifiedbased on the safety concept for rotating parts (SIKO) and dependant on the operating con-ditions. These intervals are shown on the rating plate of the low-pressure and high-pressurestage.

Non-rotating components

Depending on the system-specific operating conditions, a differentiation must be madebetween the intervals to be expected for:

¡ replacing the bearing parts and

¡ replacing the non-rotating components exposed to hot gas.

A decisive role is played by various influencing parameters which, in extreme cases, candrastically reduce the replacement interval of these parts.

During the prescribed periodic service work, the individual parts are examined for wear andreplaced if necessary.

Expected replacement intervals [h]

GAS / MDO HFOGas inlet casing 50000 … 100000 25000 … 50000Gas outlet casing 50000 … 100000 25000 … 100000Nozzle ring 35000 … 50000 25000 … 50000Turbine diffuser / cover ring 35000 … 50000 25000 … 50000Other casings 100000 100000Rotor components See rating plate informationBearing parts See rating plate informationTurbine blades(due to wear)

- - ≥ 12000

Table 4: Expected replacement intervals [h]

GAS = GasMDO = Marine Diesel OilHFO = Heavy Fuel Oil

The specified values are guideline values and are not guaranteed, see influencing paramet-ers.

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Operation Manual / Power2 850-M / 4.2 High-pressure stage3 Expected replacement intervals /


Influencing parameters

The actual values can deviate considerably from the guideline values, for example, due to thefollowing influences:

¡ Fuel quality and fuel treatment

¡ Load profile (thermal cycling, also number of starts/stops, emergency shutdowns)

¡ Gas inlet temperature

¡ Frequency and execution of turbine and compressor cleaning

¡ Specification of the high-pressure stage

¡ System-specific operating conditions (combustion quality, exhaust gas composition)

¡ Atmospheric humidity after the intercooler.

For bearing parts

¡ 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).

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Operation Manual / Power2 850-M / 4.2 High-pressure stage4 Disassembly and assembly / 4.1 Introduction


4 Disassembly and assembly

4.1 Introduction

WARNINGNon-observance of the work steps and further operationsIncorrectly performed work or further operations can cause injury to person-nel or damage to the machine.

u Only perform operations that are described in this document.

u Only perform operations for which you have previously received instruc-tion or training.

u Have further operations carried out only by trained personnel from anABB Turbocharging Service Station.

u Mark the casing position for assembly.

Customer tool set

Before starting work, make sure the required tool set is available (see chapter Tools →35).

Not all tools are marked with a part number. Identification is guaranteed by the tool list. Thislist is enclosed with the tool set.

WARNINGServicing the toolsThe tools must be checked for damage before and after use.

u Visually inspect for corrosion, cracks, deformation and wear.

u Damaged tools must no longer be used and must be replaced.

Customer spare part set

Before starting work, make sure the required customer spare part set is available (seechapter Spare parts →31).

Tightening torques for components

The specified bolted connection tightening torques must be observed (see chapter Table oftightening torques →27).

Tightening torques for assembly devices

Unless described otherwise, the screws and nuts of the assembly devices supplied by ABBmust be tightened so they are tight-fitting.

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Operation Manual / Power2 850-M / 4.2 High-pressure stage4 Disassembly and assembly / 4.1 Introduction


Definition of terms

¡ Suspension pointDefined loading point on a component or an assembly (blind hole thread, eyelet, lug).

¡ Assembly deviceDevices that are fitted on the low-pressure or high-pressure stage in order to obtain asuspension point. Assembly devices are specially constructed and designed for thedefined use; they are not commercially available products. Use assembly devices only forthe described applications.

¡ Lifting gearEquipment for the lifting and transporting of loads (lifting slings, chain block, crane).Lifting gear is not supplied by ABB.

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Operation Manual / Power2 850-M / 4.2 High-pressure stage4 Disassembly and assembly / 4.2 Weights of assemblies


4.2 Weights of assembliesThe specified weights of the individual parts or assemblies are rounded-up standard values.

Fig. 4: Overview of assemblies

Designation Weight [kg]01 Air suction branch 9002 Bellows 4003 Wall insert 6004 Compressor casing 7005 Cartridge group with hood diffuser and nozzle

ring130

Table 5: Weights of the assemblies

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Operation Manual / Power2 850-M / 4.2 High-pressure stage4 Disassembly and assembly / 4.3 Removing the air suction branch to-gether with bellows


4.3 Removing the air suction branch together withbellows

u Disconnect the air line in accordance with the enginebuilder's instructions.

u Dismantle insulation as far as necessary.

u If present: Disconnect supply line for compressor cleaning from air suction branch.

Fig. 5: Removing the air suction branch

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.

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Operation Manual / Power2 850-M / 4.2 High-pressure stage4 Disassembly and assembly / 4.4 Removing the wall insert


4.4 Removing the wall insert


1. Remove three studs (72002) in the upper area.

2. Unplug cable connector (86515) and fix speed measurement cable in wall insert.

3. Use three press-off screws (90900) to press off the wall insert (77000) until the liftingdevice can be fitted.


4. Fit bracket (90030) with screws (90662) and nuts (90415).

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 insertat the bracket.

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Operation Manual / Power2 850-M / 4.2 High-pressure stage4 Disassembly and assembly / 4.4 Removing the wall insert



8. Fit support angle (90450) with screws (90658), washers (72003) and nuts (72004).

9. Put down the wall insert (77000).


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Operation Manual / Power2 850-M / 4.2 High-pressure stage4 Disassembly and assembly / 4.5 Removing the compressor casing


4.5 Removing the compressor casing

Fig. 9: Removing the compressor casing

1. Fit bracket (90030) to compressor casing (72000) with screws (90658).

2. Fit two plates (90031) and secure with plate (90032), screw (90656) and nut (90432).

3. Secure lifting gear to swivel lifting eye (90657) and attach compressor casing to crane.

4. Using press-off nuts (61090) and ring spanner (90426), fully press off 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.

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Operation Manual / Power2 850-M / 4.2 High-pressure stage4 Disassembly and assembly / 4.6 Removing the cartridge group


4.6 Removing the cartridge group




3. Fit bracket (90030) and fit swivel lifting eye (90657) to cartridge group withscrews (90900).

4. Move in three plates (90031).

5. To secure, fit plate (90032) with screw (90656) and nut (90415).



7. Evenly press off cartridge group by screwing three press-off screws (90901) into the des-ignated holes.

8. Carefully move out cartridge group.

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Operation Manual / Power2 850-M / 4.2 High-pressure stage4 Disassembly and assembly / 4.6 Removing the cartridge group


CAUTIONDamage to cartridge group and toolbox coverThe turned-over toolbox cover may only be used for intermediate storage ofthe cartridge group.

u The cover must be on a level surface.

u The cover may not be used to transport the cartridge group.


9. Lower the cartridge group into the holders of the turned-over toolbox cover (90010) andleave it secured to the crane. Pay attention to note concerning aligning the cover.


11. Remove the lamellar rings (64001).

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Operation Manual / Power2 850-M / 4.2 High-pressure stage4 Disassembly and assembly / 4.7 Removing the nozzle ring



12. Remove O-rings (42017 / 42018).

4.7 Removing the nozzle ring

Fig. 14: Removing the nozzle ring

1. Loosen and remove screws (56017) with box spanner insert (90770).

2. Remove nozzle ring (56001).

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Operation Manual / Power2 850-M / 4.2 High-pressure stage4 Disassembly and assembly / 4.8 Measuring axial clearance A


4.8 Measuring axial clearance A




The axial clearance (A) must be measured after removal and before installation of the cart-ridge group.


Axial clearance A[mm]

0.36 ... 0.48Table 6: Axial clearance A

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Operation Manual / Power2 850-M / 4.2 High-pressure stage4 Disassembly and assembly / 4.9 Installing the nozzle ring


4.9 Installing the nozzle ring

Fig. 16: Installing the nozzle ring

Part number Thread and tightening torque56017 M8 Tx40


1. Fit nozzle ring (56001).

2. Coat threads of screws (56017) with high-temperature grease and tighten the screwswith the box spanner insert (90770).

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Operation Manual / Power2 850-M / 4.2 High-pressure stage4 Disassembly and assembly / 4.10 Installing the cartridge group


4.10 Installing the cartridge group

Fig. 17: Installing O-rings

u Fit new O-rings (42017 / 42018).


1. Clean slots for lamellar rings (64001) and fit new lamellar rings. Arrange joints so thatthey are offset by 180°.

2. Fit bracket (90030) and plates (90031).

3. Fit lifting gear to swivel lifting eye (90657).

4. Lift cartridge group and carefully move in.

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5. Fit a screw (42099) as a safeguard.

6. Remove screw (90656), nut (90415) and plates (90031).

7. Remove screws (90900) and bracket (90030).

8. Fit screws (42099). Observe tightening torque.


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Control dimension after installing cartridge group

CAUTIONControl dimension outside the tolerance valueIf the control dimension is out of tolerance, the cartridge group has notbeen correctly installed and can be the cause of serious damage to the ma-chine or property.

u Remove and reinstall the cartridge group.

u Always replace jammed gasket rings with new ones.

u If the control dimension is still out of tolerance, contact an ABB Tur-bocharging Service Station.

Fig. 20: Control dimension X

After installing the cartridge group, the control dimension (X) must be measured.

Control dimension X[mm]

49.0 ±0.2Table 9: Control dimension X

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Operation Manual / Power2 850-M / 4.2 High-pressure stage4 Disassembly and assembly / 4.11 Installing the compressor casing


4.11 Installing the compressor casing

Fig. 21: Installing the compressor casing




Table 10: Tightening torque (61090)

1) Application with adapter 90249 and special key 90250, see below


2. Secure lifting gear to swivel lifting eye (90657) and insert compressor casing.(Installation of bracket and plates (see Fig. 9: Removing the compressor casing →14)).

3. Fit nuts (61090). Observe tightening torque.






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Operation Manual / Power2 850-M / 4.2 High-pressure stage4 Disassembly and assembly / 4.12 Installing the wall insert


4.12 Installing the wall insert


1. Fit bracket (90030). (Installation of bracket (see Fig. 7: Removing wall insert 2 →12))

2. Secure lifting gear to swivel lifting eye (90657) and lift wall insert (77000).

3. Remove support angle (90450).


5. Move in wall insert (77000) until bracket can be removed.

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Operation Manual / Power2 850-M / 4.2 High-pressure stage4 Disassembly and assembly / 4.12 Installing the wall insert





6. Fit a nut (72004) as a safeguard.

7. Remove bracket (90030).

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.

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Operation Manual / Power2 850-M / 4.2 High-pressure stage4 Disassembly and assembly / 4.13 Installing the air suction branch to-gether with bellows


4.13 Installing the air suction branch together withbellows

Fig. 24: Installing the air suction branch



1. Remove lock nut (72004).

2. Loop around air suction branch and secure to air line in such a way that the bellows is notradially pre-tensioned.

3. Fit washers (72003) and nuts (72004) and tighten.

4. Remove the lifting gear.

u Fit all air lines in accordance with the enginebuilder's instructions.

u If present: Connect supply line for compressor cleaning to air suction branch.

u Fit insulation, wherever it has been removed.

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Operation Manual / Power2 850-M / 4.2 High-pressure stage4 Disassembly and assembly / 4.14 Table of tightening torques


4.14 Table of tightening torques

Fig. 25: Tightening torques

The following tightening torques [Nm] must be observed for the designated bolted connec-tions:


80 Nm56017 M8 Tx40

25 Nm61090 M12



72002 M12x9550 Nm

72004 M12120 Nm

82022 M12x45210 Nm

Table 13: Tightening torques

1) Application with adapter 90249 and special key 90250

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Operation Manual / Power2 850-M / 4.2 High-pressure stage5 Taking out of operation at short notice / 5.1 Possible emergency re-pairs


5 Taking out of operation at short notice

5.1 Possible emergency repairs

WARNINGDanger of fire and explosion due to lubricating oil leaksLeaking oil may ignite on hot surfaces. This can result in serious injuries topersonnel or fatal accidents.

u Cordon off danger area.

u Raise the alarm and, depending on the situation, stop the engine.

u Seal the oil leak.

u Soak up oil and dispose of in an environmentally compatible manner.


CAUTIONDirectives for taking out of operationSerious damage to engine or property can be caused by non-compliancewith the directives for blanking off the low-pressure or high-pressure stageon the engine.

u Follow the directives of the enginebuilder.

If damage has occurred to the high-pressure stage and the engine has to be brought backinto operation again as quickly as possible, the following emergency repair option is avail-able:

¡ Attaching the cover plate

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5.1.1 Manufacturing the cover plate

The cover plate and the other parts that are required are not part of the scope of delivery ofABB and must be manufactured by the operator on the basis of the drawing (see Fig. 26:Cover plate / gasket and sleeves →29).

Parts required

¡ 1 cover plate (01) (recommended material: 1.4541 / 1.4571)

¡ 1 gasket (02) (temperature resistant up to 550 °C)

¡ 8 sleeves (03)

Fig. 26: Cover plate / gasket and sleeves

Cover plate (gasket) and sleeves dimensions [mm]

Ø1 Ø2 Ø3 Ø4 Ø5 B1 B2406 376 14 14 20 10 49

Table 14: Cover plate / gasket

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5.1.2 Fitting the cover plate

Fig. 27: Fitting the cover plate



1. Remove air suction branch with bellows, wall insert, compressor casing and cartridgegroup.

2. Close opening in bearing casing with gasket (02) and cover plate (01).

3. Secure cover plate (01) with spacer sleeve (03) and screws (42099).

Fig. 28: Installing the casing

4. Re-fit the compressor casing, the wall insert and air suction branch with bellows.

CAUTIONEscaping lubricating oilComplete sealing of the lubricating oil supply is not guaranteed with thecover plate fitted.

u Close lubricating oil supply to high-pressure stage at engine side.

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Operation Manual / Power2 850-M / 4.2 High-pressure stage6 Spare parts / 6.1 Ordering spare parts


6 Spare parts

6.1 Ordering spare parts

CAUTIONSpare part storageAll spare parts that were ordered together with the low-pressure and/orhigh-pressure stage must be kept intact and ready for use.

u Carefully clean any rusted parts and grease them.

Please quote the following data when making queries and ordering spare parts:

¡ Serial number of Power2 (HT……)

¡ 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.

u If different model variants are not taken into account in this document, contact an ABBTurbocharging Service Station.

u Dispose of placed and unusable parts in an environmentally-friendly and professionalmanner in accordance with the local regulations.

u Dispose of the packaging of new parts in an environmentally-friendly and professionalmanner in accordance with the local regulations.

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Operation Manual / Power2 850-M / 4.2 High-pressure stage6 Spare parts / 6.1 Ordering spare parts


Required customer spare part set (97070) for a high-pressure stage

For the operations described in the Operation Manual, the customer spare part set (97070)is required. These parts are only available in the complete set.

Part number Designation Quantity42010 O-ring 142012 / 77040 O-ring 242017 O-ring 242018 O-ring 442099 Socket screw 856017 Hexalobular-head screw 361090 / 72004 Hex nut 664001 Lamellar ring 272003 Washer 3Table 16: Customer spare part set (97070)

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Operation Manual / Power2 850-M / 4.2 High-pressure stage6 Spare parts / 6.2 View of high-pressure stage with part numbers


6.2 View of high-pressure stage with part numbers

Fig. 29: High-pressure stage with part numbers

(……) only available in customer spare part set (97070).

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Operation Manual / Power2 850-M / 4.2 High-pressure stage6 Spare parts / 6.2 View of high-pressure stage with part numbers


Part number Designation01 Cartridge group with hood diffuser and nozzle ring42001 Bearing casing42010 (in customer spare part set) O-ring42012 (in customer spare part set) O-ring42017 (in customer spare part set) O-ring42018 (in customer spare part set) O-ring42099 (in customer spare part set) Socket screw51001 Gas inlet casing, radial56017 (in customer spare part set) Hexalobular-head screw61001 Gas outlet casing61003 Hexagon-head screw61004 Verbus Ripp®Locking washer61009 Hexagon-head screw61036 Stud61050 Spiral-wound gasket61090 (in customer spare part set) Hexagon nut61300 Support64001 (in customer spare part set) Lamellar ring72000 Compressor casing72003 (in customer spare part set) Washer72004 (in customer spare part set) Hexagon nut77000 Wall insert77040 (in customer spare part set) O-ring81000 Filter silencer82000 Air suction branch82022 Hexagon-head screw82300 Bellows86505 / 86515 Speed sensor / connecting cableTable 17: High-pressure stage part numbers

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Operation Manual / Power2 850-M / 4.2 High-pressure stage7 Tools /


7 ToolsFor the work described in the Operation Manual, the customer tool set 90000 is required.

Part number Designation Quantity90010 Wooden crate 190030 Bracket 190031 Plate 390032 Plate 190770 Box spanner 190450 Support 290426 Ring spanner 190657 Swivel lifting eyes 290900 Press-off screw 390901 Press-off screw 390913 Press-off screw 490658 Hexagon-head screw 490656 Hexagon-head screw 190662 Hexagon-head screw 290415 Hexagon nut 590430 Nut 190161 Protective bag 290250 Special key 190249 Adapter 1Table 18: Customer tool set 90000

This tool set can be ordered from any ABB Turbocharging Service Station. The following spe-cifications must be included in the order:

¡ Equipment type

¡ Designation and part number of the tool set.

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Operation Manual / Power2 850-M / 4.2 High-pressure stage Figures

© Copyright 2020 ABB. All rights reserved. HZTL4063_EN Revision C March 2020

FiguresFig. 1: Swivel lifting eyes ................................................ 3

Fig. 2: Suspension of complete high-pressure stage..4

Fig. 3: Suspension of complete high-pressure stage .5

Fig. 4: Overview of assemblies ................................... 10

Fig. 5: Removing the air suction branch ................... 11

Fig. 6: Removing wall insert 1...................................... 12

Fig. 7: Removing wall insert 2...................................... 12


Fig. 9: Removing the compressor casing ................. 14


Fig. 11: Moving out cartridge group 2........................ 15


Fig. 13: Moving out cartridge group 4....................... 17

Fig. 14: Removing the nozzle ring............................... 17

Fig. 15: Measuring axial clearance A .......................... 18

Fig. 16: Installing the nozzle ring ................................ 19

Fig. 17: Installing O-rings ............................................ 20

Fig. 18: Installing the cartridge group 1 ................... 20

Fig. 19: Installing the cartridge group 2.................... 21

Fig. 20: Control dimension X....................................... 22

Fig. 21: Installing the compressor casing ................. 23


Fig. 23: Installing the wall insert 2............................. 25

Fig. 24: Installing the air suction branch ................. 26

Fig. 25: Tightening torques ......................................... 27

Fig. 26: Cover plate / gasket and sleeves................ 29

Fig. 27: Fitting the cover plate ................................... 30

Fig. 28: Installing the casing....................................... 30

Fig. 29: High-pressure stage with part numbers.... 33

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Operation Manual / Power2 850-M / 4.2 High-pressure stage Tables

© Copyright 2020 ABB. All rights reserved. HZTL4063_EN Revision C March 2020


Table 2: Swivel lifting eyes............................................. 3

Table 3: Transporting the high-pressure stage ........ 3

Table 4: Expected replacement intervals [h]............. 6

Table 5: Weights of the assemblies........................... 10

Table 6: Axial clearance A............................................. 18

Table 7: Tightening torque (56017)............................ 19


Table 9: Control dimension X...................................... 22

Table 10: Tightening torque (61090)......................... 23

Table 11: Tightening torque (72002)......................... 25


Table 13: Tightening torques ...................................... 27

Table 14: Cover plate / gasket ................................... 29

Table 15: Tightening torque (42099)........................ 30

Table 16: Customer spare part set (97070).............. 32

Table 17: High-pressure stage part numbers ......... 34

Table 18: Customer tool set 90000 .......................... 35

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Documents

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