ABB PT004162 User manual

Turbo Systems Switzerland Ltd
Operation Manual / Power2 845-M46
High-pressure stage PT004162
Document identification
Document number HZTL4069
Revision F
Language English
Original Operation Manual
Product identification
Serial number PT004162
Customer part number HZTL53396J
Delivery date (yyyy-mm-dd) 2022-09-02
Weight 500 kg
Operating limits according to rating plate
Speed limit in test rig operation only nMmax 720 1/s
Speed limit during operation nBmax 720 1/s
Gas inlet temperature limit in test rig operation only tMmax 650 °C
Gas inlet temperature limit during operation tBmax 620 °C
Compressor inlet temperature after intercooler tCmax 60 °C

Operation Manual / Power2 845-M / High-pressure stage
Table of contents
© Copyright 2022 ABB. All rights reserved. HZTL4069_EN Rev.F March 2022
Power2 845-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 ........................................................................... 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 845-M / High-pressure stage
Table of contents
© Copyright 2022 ABB. All rights reserved. HZTL4069_EN Rev.F 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
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 air suction branch together with bellows.................................... 69
9.5 Removing the wall insert ........................................................................................... 70
9.6 Removing the compressor casing ............................................................................ 72
9.7 Removing the cartridge group.................................................................................. 73
9.8 Removing the nozzle ring ........................................................................................... 75
9.9 Measuring axial clearance A...................................................................................... 76
9.10 Installing the nozzle ring ............................................................................................ 77
9.11 Installing the cartridge group .................................................................................. 78
9.12 Installing the compressor casing ............................................................................. 81
9.13 Installing the wall insert ............................................................................................ 82
9.14 Installing the air suction branch together with bellows ..................................... 84
9.15 Table of tightening torques...................................................................................... 85
10 Taking out of operation at short notice ........................................................... 86
10.1 Possible emergency repairs...................................................................................... 86
11 Taking out of operation for a long period........................................................ 89
11.1 General .......................................................................................................................... 89
11.2 Lubricating oil.............................................................................................................. 89
11.3 Process for taking out of operation........................................................................ 89
12 Material and Disposal.......................................................................................... 90
12.1 REACH and RoHS Compliance Declaration For Products ................................... 90
12.2 Disposing of low-pressure and high-pressure stage components ................... 91
13 Spare parts ........................................................................................................... 92
13.1 Ordering spare parts.................................................................................................. 92
13.2 Spare part – Illustrations........................................................................................... 93

Operation Manual / Power2 845-M / High-pressure stage
Table of contents
© Copyright 2022 ABB. All rights reserved. HZTL4069_EN Rev.F March 2022
14 Tools .................................................................................................................... 101
Figures................................................................................................................. 102
Tables .................................................................................................................. 103

Operation Manual / Power2 845-M / High-pressure stage
1 Introduction / 1.1 Purpose of the manual
© Copyright 2022 ABB. All rights reserved. HZTL4069_EN Rev.F 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 / 104

Operation Manual / Power2 845-M / High-pressure stage
1 Introduction / 1.3 Essential information
© Copyright 2022 ABB. All rights reserved. HZTL4069_EN Rev.F 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 / 104

Operation Manual / Power2 845-M / High-pressure stage
1 Introduction / 1.3 Essential information
© Copyright 2022 ABB. All rights reserved. HZTL4069_EN Rev.F March 2022
Page 6 / 104

Operation Manual / Power2 845-M / High-pressure stage
1 Introduction / 1.4 Power2 layout and function
© Copyright 2022 ABB. All rights reserved. HZTL4069_EN Rev.F March 2022
1.4 Power2 layout and function
Fig.1: Power2 layout and function
Power2 Two-stage turbocharging 21 HP compressor
Power2 LP Low-pressure stage 22 HP turbine
Power2 HP High-pressure stage 24 LP turbine
A Exhaust gas inlet from internal combus-
tion engine
25 LP compressor
B Exhaust gas outlet 26 Intercooler
C Air or air/gas mixture inlet
D Air or air/gas mixture outlet and supply
to the charge air cooler
- - - Not included in the Turbo Systems
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) of
the 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 air
cooler.
Page 7 / 104

Operation Manual / Power2 845-M / High-pressure stage
1 Introduction / 1.5 Layout and function of the high-pressure stage
© Copyright 2022 ABB. All rights reserved. HZTL4069_EN Rev.F March 2022
1.5 Layout and function of the high-pressure stage
Fig.2: Layout and function of the high-pressure stage
01 Air suction branch 08 Radial plain bearing
02 Bellows 09 Turbine
03 Compressor casing 10 Support
04 Diffuser 11 Gas inlet casing
05 Bearing casing 12 Nozzle ring
06 Gas outlet casing 13 Bearing bush
07 Axial bearing 14 Compressor wheel
Page 8 / 104

Operation Manual / Power2 845-M / High-pressure stage
1 Introduction / 1.5 Layout and function of the high-pressure stage
© Copyright 2022 ABB. All rights reserved. HZTL4069_EN Rev.F March 2022
Mode of operation of the high-pressure stage (Power2 HP)
Fig.3: Power2 HP diagram
Power2 Two-stage turbocharging 21 HP compressor
Power2 LP Low-pressure stage 22 HP turbine
Power2 HP High-pressure stage 24 LP turbine
A Exhaust gas inlet from internal combus-
tion engine
25 LP compressor
B Exhaust gas outlet 26 Intercooler
C Air or air/gas mixture inlet
D Air or air/gas mixture outlet and supply
to the charge air cooler
- - - Not included in the Turbo Systems
scope of 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.2: Layout and
function of the high-pressure stage →8), the exhaust gas flows through the gas inlet casing
(11) and the nozzle ring (12) and reaches the turbine (09). The HP turbine uses the energy
contained in the exhaust gas to drive the rotor. The exhaust gases then flow through the gas
outlet casing (06) and the exhaust gas pipe connected to it before reaching the turbine of
the low-pressure stage (Power2 LP).
The rotor runs in two radial plain bearings (08). These are located between the compressor
and turbine and are guided in the bearing bush (13) and axial bearing (07). The plain bearings
are connected to a central lubricating oil duct which is normally supplied by the lubricating
oil circuit of the engine. The oil outlet lies at the deepest point of the bearing casing (05).
The HP compressor wheel (14) connected to the shaft sucks in the precompressed air or an
air/gas mixture from the low-pressure stage (25) through the air suction branch (01). The air
is compressed further in the HP compressor (21) and the downstream diffuser (04) and sub-
sequently supplied to the charge air cooler via the compressor casing (03).
Page 9 / 104

Operation Manual / Power2 845-M / High-pressure stage
1 Introduction / 1.6 Symbols, definitions
© Copyright 2022 ABB. All rights reserved. HZTL4069_EN Rev.F March 2022
1.6 Symbols, definitions
Symbols
The following symbols are used in this document:
uIndicates an action step.
1. Indicates a numbered action step.
→Refers to a page number
Definition of mandatory signs
Mandatory signs show the protective equipment to be worn for a task. The mandatory signs
are described in chapter Safety and must be complied with.
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
Turbo Systems
Turbo Systems Switzerland Ltd is referred to in this document as Turbo Systems.
Official service stations of Turbo Systems
Official service stations are identified in this document as Turbo Systems service stations.
These Turbo Systems service stations are regularly audited and certified by Turbo Systems
Switzerland Ltd. See also chapter Contact information →4.
Page 10 / 104

Operation Manual / Power2 845-M / High-pressure stage
1 Introduction / 1.7 Registered trademarks
© Copyright 2022 ABB. All rights reserved. HZTL4069_EN Rev.F March 2022
Definition of pictograms
The following pictograms can occur in this document. These point out actions that must be
taken in accordance with the meaning of the relevant pictogram.
Pictogram Meaning
Tighten with specified torque
Tighten over specified tightening angle
Hand-tight, tighten without tools
Oil
Apply screw locking paste (e.g. Loctite)
Apply high-temperature grease
Apply other paste in accordance with specifications
Oil free, grease free and dry
Affix
Measure
Note
Visually inspect
Please note text for numbered work step.
See document
Dispose of in an environmentally compatible, professional way and in compliance
with locally applicable regulations.
Table1: Definition of pictograms
1.7 Registered trademarks
The trademarks of outside companies are used in this document. These are marked with the
® symbol.
Page 11 / 104

Operation Manual / Power2 845-M / High-pressure stage
1 Introduction / 1.8 Storage of new low-pressure and high-pressure
stages
© Copyright 2022 ABB. All rights reserved. HZTL4069_EN Rev.F March 2022
1.8 Storage of new low-pressure and high-pressure
stages
Storage of new low-pressure and high-pressure stages and spare parts for up to 6
months
New low-pressure and high-pressure stages and spare parts from Turbo Systems can be
stored in their closed packages for 6months from the date of delivery without additional
mothballing measures.
Only dry rooms in which the relative humidity is between 40…70% and condensation cannot
form are suitable for storage.
Storage of new low-pressure and high-pressure stages and spare parts for more than
6 months (VCI)
As the contents of the package are adapted as required, turbochargers may also be de-
livered without a VCI label.
For parts with a VCI label on the package, the following instructions must be observed.
Fig.4: Volatile Corrosion Inhibitor (VCI)
WARNING
Health protection when handling VCI
VCI products are not hazardous in terms of the Ordinance on Hazardous
Substances. Nevertheless, the following points must be observed when
handling VCI:
uObserve information in material safety data sheet
uEnsure proper space ventilation.
uDo not eat, drink or store food at the workplace while working with VCI.
uClean hands and face after working with VCI.
uFor more information, see www.branopac.com.
Wear safety gloves to protect against mechanical hazards.
Every 6months, the following mothballing measures are required:
uOpen package.
uRemove 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 be
obtained from www.branopac.com.
uOld VCI corrosion protection emitters must be disposed of in an environmentally compat-
ible, professional way and in compliance with locally applicable regulations.
Page 12 / 104

Operation Manual / Power2 845-M / High-pressure stage
1 Introduction / 1.8 Storage of new low-pressure and high-pressure
stages
© Copyright 2022 ABB. All rights reserved. HZTL4069_EN Rev.F March 2022
uClose the package. The more tightly the package is sealed, the longer the protection will
last.
Long-term storage of low-pressure and high-pressure stages
The low-pressure and high-pressure stages will be prepared for long-term storage if reques-
ted in the purchase order. The package is equipped with a hygrometer (see illustration).
Fig.5: Package with hygrometer
Every 6months, the following measures are required:
uCheck the hygrometer(02) in the sight-glass. There is an opening(01) in the wooden
crate which allows this check to be carried out. When the display field has changed colour
at the 70% level, the maximum permissible humidity has been exceeded. In this case, the
low-pressure or high-pressure stage or the cartridge group must be checked and repack-
aged by a Turbo Systems service station.
uInspect the package for damage. If the package is damaged, the low or high-pressure
stage or the cartridge group must be checked and repackaged by a Turbo Systems ser-
vice station.
After every 3 years the following work steps must be performed by a Turbo Systems service
station:
¡Inspect the component
¡Replace the desiccant agent
¡Repackage the component.
NOTICE
70% field of the hygrometer has not changed colour
If the 70% field of the hygrometer(02) has not changed colour and the pack-
age is not damaged, the low-pressure or high-pressure stage can be put into
operation without previously having been checked by a Turbo Systems ser-
vice station.
Unpacking the turbochargers
The corrosion protection effect ends after the material is unpacked from the VCI package.
To avoid the formation of condensation, the surroundings and the content of the package
must have the same temperature during unpacking.
Page 13 / 104

Operation Manual / Power2 845-M / High-pressure stage
2 Safety / 2.1 Introduction
© Copyright 2022 ABB. All rights reserved. HZTL4069_EN Rev.F March 2022
2 Safety
2.1 Introduction
The two-stage turbocharging system(Power2) manufactured by Turbo Systems is state of
the art and complies with the respective health and safety standards in effect at the time
the system was built. 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 to
and 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 this
document (see section Definition of safety instructions) must also be observed.
2.2 CE conformity
Information
Low-pressure and high-pressure stages from Turbo Systems comply with the machinery dir-
ective 2006/42/EC and are partly completed machinery as defined by Article2g.
Page 14 / 104

Operation Manual / Power2 845-M / High-pressure stage
2 Safety / 2.3 Definition of mandatory signs
© Copyright 2022 ABB. All rights reserved. HZTL4069_EN Rev.F March 2022
2.3 Definition of mandatory signs
To be worn at all times
Protective clothing Safety footwear to protect
against mechanical hazard and
risk of falling
Table2: Personal protective equipment to be worn at all times
To be worn specific to the respective task
Safety glasses Safety goggles
Safety gloves to protect
against
- Mechanical hazard
- Chemical hazard
- Thermal hazard
- Electrical hazard
Respiratory mask to protect
against
- Dusts
- Gases
Safety helmet Ear protection
Table3: Personal protective equipment to be worn specific to the respective task
2.4 Definition of safety instructions
WARNING
Definition of Warning
Non-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.
uWarning signs must always be observed.
CAUTION
Definition of Caution
Non-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.
uCaution signs must always be observed.
Page 15 / 104

Operation Manual / Power2 845-M / High-pressure stage
2 Safety / 2.5 Intended use
© Copyright 2022 ABB. All rights reserved. HZTL4069_EN Rev.F March 2022
2.5 Intended use
Use on internal combustion engines
Power2 from Turbo Systems is intended for charging internal combustion engines.
To ensure compliance with the machinery directive 2006/42/EC when using on gas engines,
the Power2 must be operated in an engine room classified as "not at risk of explosion". This
is 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 from
the 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.
The use of Power2 is limited to the specific application released at the time of delivery.
Turbo Systems accepts no liability and rejects all warranty claims for any non-intended ap-
plications.
[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, ATEX
Euromot Position 191103
WARNING
Unapproved operation
Operation of the Power2 outside of the operating limits can be hazardous to
personnel.
uPower2 must only be operated within the operating limits.
uPower2 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.
Turbo Systems excludes any liability for damage resulting from unauthorized modifications
to the Power2 or improper operation.
Page 16 / 104

Operation Manual / Power2 845-M / High-pressure stage
2 Safety / 2.6 Deflagration on gas engines
© Copyright 2022 ABB. All rights reserved. HZTL4069_EN Rev.F March 2022
2.6 Deflagration on gas engines
Low-pressure stages from Turbo Systems can tolerate a deflagration with a transient pres-
sure increase of 12bar (guideline value).
High-pressure stages from Turbo Systems can tolerate a deflagration with a transient pres-
sure increase of 15bar (guideline value).
After a deflagration event, Turbo Systems recommends verifying the following points on the
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 deflagration
event has taken place, it is also recommended to check the bearings of the low-pressure and
high-pressure stages before the next start. This inspection and evaluation must be carried
out by a Turbo Systems service station.
Page 17 / 104

Operation Manual / Power2 845-M / High-pressure stage
2 Safety / 2.7 Warning plates on the high-pressure stage
© Copyright 2022 ABB. All rights reserved. HZTL4069_EN Rev.F March 2022
2.7 Warning plates on the high-pressure stage
Warning plates are affixed at the following locations:
Fig.6: Locations of Power2 HP warning plates
If warning plates are not present in the designated locations or not readable, proceed as fol-
lows:
uOrder new warning plates from Turbo Systems service stations.
uRemove any warning plates that have become unreadable.
uClean and degrease the areas designated for the warning plates.
uFit 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 be
equipped later with warning plates to be attached to the insulation. This is the responsibility
of the enginebuilder.
Page 18 / 104