ABB Power2 650-M User manual

Operation Manual / Power2 650-M / Low-pressure stage
Table of contents
© Copyright 2022 ABB. All rights reserved. HZTL4065_EN Rev.E March 2022
Power2 650-M / Low-pressure stage
1 Introduction............................................................................................................ 4
1.1 Purpose of the manual................................................................................................. 4
1.2 Contact information..................................................................................................... 4
1.3 Essential information.................................................................................................... 5
1.4 Power2 layout and function......................................................................................... 7
1.5 Layout and function of the low-pressure stage ..................................................... 8
1.6 Symbols, definitions.................................................................................................... 10
1.7 Registered trademarks ............................................................................................... 11
1.8 Storage of new low-pressure and high-pressure stages..................................... 12
2 Safety .................................................................................................................... 14
2.1 Introduction .................................................................................................................. 14
2.2 CE conformity............................................................................................................... 14
2.3 Definition of mandatory signs .................................................................................. 15
2.4 Definition of safety instructions .............................................................................. 15
2.5 Intended use ................................................................................................................. 16
2.6 Deflagration on gas engines ..................................................................................... 17
2.7 Warning plates on the low-pressure stage............................................................. 18
2.8 Rating plate of the low-pressure stage................................................................... 19
2.9 Periodic check of the pressure vessels................................................................... 20
2.10 Lifting of loads ............................................................................................................. 21
2.11 Prerequisites for operation and maintenance....................................................... 22
2.12 Hazards during operation and maintenance ......................................................... 23
2.13 Safe operation............................................................................................................. 25
2.14 Safe maintenance ....................................................................................................... 26
3 Removal and installation.................................................................................... 30
3.1 Transport / weight ..................................................................................................... 30
3.2 Removing the low-pressure stage............................................................................ 31
3.3 Installing the low-pressure stage ............................................................................. 32
4 Commissioning .................................................................................................... 33
4.1 Oil supply ...................................................................................................................... 33
4.2 Inspection procedures............................................................................................... 35
4.3 Commissioning after taking out of operation....................................................... 37
5 Monitoring during operation.............................................................................. 38
5.1 Lubricating oil pressure............................................................................................. 38
5.2 Lubricating oil temperature ..................................................................................... 39
5.3 Speed measurement .................................................................................................. 40
6 Operation and service ......................................................................................... 45
6.1 Noise emission ............................................................................................................ 45

Operation Manual / Power2 650-M / Low-pressure stage
Table of contents
© Copyright 2022 ABB. All rights reserved. HZTL4065_EN Rev.E March 2022
6.2 Service work................................................................................................................. 46
6.3 Expected replacement intervals .............................................................................. 48
6.4 Stopping the engine................................................................................................... 49
7 Periodic maintenance.......................................................................................... 50
7.1 Foreword to maintenance......................................................................................... 50
7.2 Cleaning the compressor during operation ........................................................... 51
7.3 Cleaning turbine and nozzle ring during operation ............................................. 54
7.4 Cleaning the filter silencer ........................................................................................ 54
8 Troubleshooting................................................................................................... 59
8.1 Malfunctions when starting...................................................................................... 59
8.2 Malfunctions during operation ................................................................................ 60
8.3 Surging of the low-pressure or high-pressure stage .......................................... 64
8.4 Malfunctions when stopping.................................................................................... 65
8.5 Speed measurement system.................................................................................... 65
9 Disassembly and assembly ................................................................................ 66
9.1 Introduction ................................................................................................................. 66
9.2 Material required......................................................................................................... 67
9.3 Weights of assemblies............................................................................................... 68
9.4 Removing the filter silencer and injection ring..................................................... 69
9.5 Removing the air suction branch and injection ring............................................ 70
9.6 Axial clearance A prior to disassembly .................................................................... 71
9.7 Removing the wall insert ............................................................................................ 72
9.8 Removing the compressor casing ........................................................................... 74
9.9 Removing the cartridge group.................................................................................. 75
9.10 Removing turbine diffuser and nozzle ring ............................................................ 77
9.11 Installing turbine diffuser and nozzle ring............................................................. 79
9.12 Installing the cartridge group ................................................................................... 81
9.13 Installing the compressor casing ............................................................................ 84
9.14 Installing the wall insert ............................................................................................ 85
9.15 Axial clearance A after assembly.............................................................................. 87
9.16 Installing the air suction branch and injection ring ............................................. 88
9.17 Installing the filter silencer and injection ring ...................................................... 89
9.18 Table of tightening torques...................................................................................... 90
10 Taking out of operation at short notice ........................................................... 91
10.1 Possible emergency repairs....................................................................................... 91
11 Taking out of operation for a long period........................................................ 94
11.1 General .......................................................................................................................... 94
11.2 Lubricating oil.............................................................................................................. 94
11.3 Process for taking out of operation........................................................................ 94
12 Material and Disposal.......................................................................................... 95
12.1 REACH and RoHS Compliance Declaration For Products ................................... 95
12.2 Disposing of low-pressure and high-pressure stage components .................. 96

Operation Manual / Power2 650-M / Low-pressure stage
Table of contents
© Copyright 2022 ABB. All rights reserved. HZTL4065_EN Rev.E March 2022
13 Spare parts ........................................................................................................... 97
13.1 Ordering spare parts.................................................................................................. 97
13.2 Spare part – Illustrations........................................................................................... 99
14 Tools ..................................................................................................................... 111
15 Gas piping (option) ............................................................................................ 112
15.1 Commissioning and operating .............................................................................. 112
15.2 Periodic maintenance .............................................................................................. 112
15.3 Removal and installation .......................................................................................... 113
15.4 Storage and disposal ................................................................................................ 115
15.5 Spare parts.................................................................................................................. 115
Figures.................................................................................................................. 117
Tables .................................................................................................................. 118

Operation Manual / Power2 650-M / Low-pressure stage
1 Introduction / 1.1 Purpose of the manual
© Copyright 2022 ABB. All rights reserved. HZTL4065_EN Rev.E March 2022
1 Introduction
1.1 Purpose of the manual
Operation Manual
The Operation Manual explains the two-stage turbocharging (Power2) from Turbo Systems
and contains instructions for safe operation.
The Operation Manual is a complement to and expansion of existing national regulations for
occupational safety, accident prevention and environmental protection.
Target group
The Operation Manual is aimed at engineers and trained mechanics responsible for the
proper 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 the
Operation Manual.
1.2 Contact information
Contact information for the Turbo Systems service stations is available online.
uScan the QR code to access our website.
Turbo Systems Switzerland Ltd
Bruggerstrasse 71a
CH-5401 Baden
Switzerland
www.abb.com/turbocharging
Page 4 / 119

Operation Manual / Power2 650-M / Low-pressure stage
1 Introduction / 1.3 Essential information
© Copyright 2022 ABB. All rights reserved. HZTL4065_EN Rev.E March 2022
1.3 Essential information
Design variants
This document is valid for different design variants of Power2 high-pressure stages. This
may result in sections and descriptions of components that are not relevant for a specific
Power2 high-pressure stage.
Please contact a Turbo Systems service station if you have any questions regarding a design
variant (see Contact information at www.abb.com/turbocharging).
Accuracy of illustrations
The illustrations in this document are general in nature and intended for ease of understand-
ing. Differences in detail are therefore possible.
Page 5 / 119