ABB Power2 650-M User manual

Operation Manual / Power2 650-M / High-pressure stage
Table of contents
© Copyright 2022 ABB. All rights reserved. HZTL4066_EN Rev.C March 2022
Power2 650-M / High-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 high-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 high-pressure stage ........................................................... 18
2.8 Rating plate of the high-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 high-pressure stage.......................................................................... 31
3.3 Installing the high-pressure stage .......................................................................... 34
4 Commissioning .................................................................................................... 40
4.1 Oil supply ...................................................................................................................... 40
4.2 Inspection procedures............................................................................................... 42
4.3 Commissioning after taking out of operation...................................................... 44
5 Monitoring during operation.............................................................................. 45
5.1 Lubricating oil pressure............................................................................................. 45
5.2 Lubricating oil temperature ..................................................................................... 46
5.3 Speed measurement .................................................................................................. 47
6 Operation and service ......................................................................................... 50
6.1 Noise emission ............................................................................................................ 50

Operation Manual / Power2 650-M / High-pressure stage
Table of contents
© Copyright 2022 ABB. All rights reserved. HZTL4066_EN Rev.C March 2022
6.2 Service work.................................................................................................................. 51
6.3 Expected replacement intervals .............................................................................. 53
6.4 Stopping the engine................................................................................................... 54
7 Periodic maintenance.......................................................................................... 55
7.1 Foreword to maintenance......................................................................................... 55
7.2 Cleaning the compressor during operation .......................................................... 56
7.3 Cleaning turbine and nozzle ring during operation ............................................. 58
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............................................................................................... 69
9.4 Removing the compressor casing........................................................................... 70
9.5 Removing the cartridge group.................................................................................. 71
9.6 Installing the cartridge group .................................................................................. 74
9.7 Installing the compressor casing ............................................................................. 77
9.8 Measuring radial clearances N and R ...................................................................... 78
9.9 Measuring clearance A and B.................................................................................... 79
9.10 Table of tightening torques...................................................................................... 80
10 Taking out of operation at short notice ........................................................... 81
10.1 Possible emergency repairs....................................................................................... 81
10.2 Installing a replacement cartridge group .............................................................. 82
10.3 Fitting the cover plate................................................................................................ 83
10.4 Cover plate drawing ................................................................................................... 84
11 Taking out of operation for a long period........................................................ 86
11.1 General .......................................................................................................................... 86
11.2 Lubricating oil.............................................................................................................. 86
11.3 Process for taking out of operation........................................................................ 86
12 Material and Disposal.......................................................................................... 87
12.1 REACH and RoHS Compliance Declaration For Products ................................... 87
12.2 Disposing of low-pressure and high-pressure stage components .................. 88
13 Spare parts ........................................................................................................... 89
13.1 Ordering spare parts.................................................................................................. 89
13.2 Spare part – Illustrations............................................................................................ 91
14 Tools .................................................................................................................... 102

Operation Manual / Power2 650-M / High-pressure stage
Table of contents
© Copyright 2022 ABB. All rights reserved. HZTL4066_EN Rev.C March 2022
15 Gas piping (option)............................................................................................ 103
Figures................................................................................................................. 104
Tables .................................................................................................................. 105

Operation Manual / Power2 650-M / High-pressure stage
1 Introduction / 1.1 Purpose of the manual
© Copyright 2022 ABB. All rights reserved. HZTL4066_EN Rev.C 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 / 106

Operation Manual / Power2 650-M / High-pressure stage
1 Introduction / 1.3 Essential information
© Copyright 2022 ABB. All rights reserved. HZTL4066_EN Rev.C 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 / 106