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ABB Power2 550-M Operation Manual
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ABB Power2 550-M Operation Manual

ABB Power2 550-M Operation Manual

High-pressure stage
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Operation Manual / Power2 550-M / High-pressure stage

Table of contents

Power2 550-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 .................................................................................................... 41
4.1
Oil supply ....................................................................................................................... 41
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
Speeds........................................................................................................................... 47
6
Operation and service ......................................................................................... 50
6.1
Noise emission ............................................................................................................ 50
© Copyright 2022 ABB. All rights reserved.
HZTL4058_EN
Rev.F
March 2022

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  • Page 1: Table Of Contents

    Operation Manual / Power2 550-M / High-pressure stage Table of contents Power2 550-M / High-pressure stage Introduction......................4 Purpose of the manual....................4 Contact information..................... 4 Essential information....................5 Power2 layout and function ..................7 Layout and function of the high-pressure stage............ 8 Symbols, definitions....................
  • Page 2 Operation Manual / Power2 550-M / High-pressure stage Table of contents Service work ......................... 52 Expected replacement intervals ................54 Stopping the engine....................56 Periodic maintenance..................57 Foreword to maintenance..................57 Cleaning the compressor during operation ............58 Cleaning the high-pressure stage bellows (if present)........60 Cleaning turbines and nozzle rings during operation .........
  • Page 3 Operation Manual / Power2 550-M / High-pressure stage Table of contents Spare parts ......................102 13.1 Ordering spare parts....................102 13.2 Spare part – Illustrations ..................104 Tools ........................115 Gas piping (option).................... 116   Figures........................117   Tables ........................118 ©...

  • Page 4: Introduction

    Operation Manual / Power2 550-M / High-pressure stage 1 Introduction / 1.1 Purpose of the manual Introduction Purpose of the manual Operation Manual The Operation Manual explains the two-stage turbocharging (Power2) from Turbo Systems and contains instructions for safe operation.

  • Page 5: Essential Information

    Operation Manual / Power2 550-M / High-pressure stage 1 Introduction / 1.3 Essential information 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.
  • Page 6 Operation Manual / Power2 550-M / High-pressure stage 1 Introduction / 1.3 Essential information © Copyright 2022 ABB. All rights reserved. HZTL4058_EN Rev.F March 2022...

  • Page 7: Power2 Layout And Function

    Operation Manual / Power2 550-M / High-pressure stage 1 Introduction / 1.4 Power2 layout and function Power2 layout and function Fig. 1: Layout and function Power2 Two-stage turbocharging HP compressor Power2 LP Low-pressure stage HP turbine Power2 HP High-pressure stage Gas piping (bellows)

  • Page 8: Layout And Function Of The High-Pressure Stage

    Operation Manual / Power2 550-M / High-pressure stage 1 Introduction / 1.5 Layout and function of the high-pressure stage Layout and function of the high-pressure stage Fig. 2: Layout of the high-pressure stage 01 Air suction branch Gas outlet flange 02 Bellows...

  • Page 9: Fig. 3: Function Of The High-Pressure Stage

    Operation Manual / Power2 550-M / High-pressure stage 1 Introduction / 1.5 Layout and function of the high-pressure stage Mode of operation of the high-pressure stage (Power2 HP) Fig. 3: Function of the high-pressure stage Power2 Two-stage turbocharging HP compressor Power2 LP...

  • Page 10: Symbols, Definitions

    Operation Manual / Power2 550-M / High-pressure stage 1 Introduction / 1.6 Symbols, definitions Symbols, definitions Symbols The following symbols are used in this document: Indicates an action step. 1. Indicates a numbered action step. →   Refers to a page number...

  • Page 11: Registered Trademarks

    Operation Manual / Power2 550-M / High-pressure stage 1 Introduction / 1.7 Registered trademarks Definition of pictograms The following pictograms can occur in this document. These point out actions that must be taken in accordance with the meaning of the relevant pictogram.

  • Page 12: Storage Of New Low-Pressure And High-Pressure Stages

    Operation Manual / Power2 550-M / High-pressure stage 1 Introduction / 1.8 Storage of new low-pressure and high-pressure stages Storage of new low-pressure and high-pressure stages Storage for up to 6 months New low-pressure and high-pressure stages and spare parts from Turbo Systems can be stored in their closed packages for 6 months from the date of delivery without additional...

  • Page 13: Fig. 5: Package With Hygrometer

    Operation Manual / Power2 550-M / High-pressure stage 1 Introduction / 1.8 Storage of new low-pressure and high-pressure stages Long-term storage of low-pressure and high-pressure stages The low-pressure and high-pressure stages will be prepared for long-term storage if reques- ted in the purchase order. The package is equipped with a hygrometer (see illustration).

  • Page 14: Safety

    Operation Manual / Power2 550-M / High-pressure stage 2 Safety / 2.1 Introduction Safety Introduction The two-stage turbocharging system (Power2) manufactured by Turbo Systems is state of the art and complies with the respective health and safety standards in effect at the time the system was built.

  • Page 15: Definition Of Mandatory Signs

    Operation Manual / Power2 550-M / High-pressure stage 2 Safety / 2.3 Definition of mandatory signs Definition of mandatory signs To be worn at all times Protective clothing Safety footwear to protect against mechanical hazard and risk of falling Table 2: Personal protective equipment to be worn at all times...

  • Page 16: Intended Use

    Operation Manual / Power2 550-M / High-pressure stage 2 Safety / 2.5 Intended use Intended use Use on internal combustion engines Power2 from Turbo Systems is intended for charging internal combustion engines. To ensure compliance with the machinery directive 2006/42/EC when using on gas engines, the Power2 must be operated in an engine room classified as "not at risk of explosion".

  • Page 17: Deflagration On Gas Engines

    Operation Manual / Power2 550-M / High-pressure stage 2 Safety / 2.6 Deflagration on gas engines 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).

  • Page 18: Warning Plates On The High-Pressure Stage

    Operation Manual / Power2 550-M / High-pressure stage 2 Safety / 2.7 Warning plates on the high-pressure stage Warning plates on the high-pressure stage Warning plates are affixed at the following locations: Fig. 6 High-pressure stage If warning plates are not present in the designated locations or not readable, proceed as fol- lows: Order new warning plates from Turbo Systems service stations.

  • Page 19: Rating Plate Of The High-Pressure Stage

    Operation Manual / Power2 550-M / High-pressure stage 2 Safety / 2.8 Rating plate of the high-pressure stage Rating plate of the high-pressure stage Fig. 7: Rating plate Operating limits Operating limits at engine overload (110%). In test rig operation only, unless otherwise agreed with the enginebuilder.

  • Page 20: Periodic Check Of The Pressure Vessels

    Operation Manual / Power2 550-M / High-pressure stage 2 Safety / 2.9 Periodic check of the pressure vessels Explanations of the rating plate The recommended replacement intervals and the corresponding operating limits are jointly defined with the enginebuilder. This information is specific to the system.

  • Page 21: Lifting Of Loads

    Operation Manual / Power2 550-M / High-pressure stage 2 Safety / 2.10 Lifting of loads 2.10 Lifting of loads WARNING Suspended loads Loads that are not attached according to regulations can cause injury to personnel or fatal accidents. Loads must always be fastened to properly functional lifting gear with a sufficient load limit.

  • Page 22: Prerequisites For Operation And Maintenance

    Operation Manual / Power2 550-M / High-pressure stage 2 Safety / 2.11 Prerequisites for operation and maintenance 2.11 Prerequisites for operation and maintenance Responsibility of the operating company In awareness of its responsibility, the operating company must ensure that only authorised personnel work on the Power2, who: ¡...

  • Page 23: Hazards During Operation And Maintenance

    Operation Manual / Power2 550-M / High-pressure stage 2 Safety / 2.12 Hazards during operation and maintenance 2.12 Hazards during operation and maintenance Noise hazards The turbocharger's noise emission is influenced by its installation and operating conditions. A noise level exceeding 85 dB(A) is harmful.
  • Page 24 Operation Manual / Power2 550-M / High-pressure stage 2 Safety / 2.12 Hazards during operation and maintenance WARNING Hot surfaces on the non-insulated low-pressure and high-pressure stage Non-insulated low-pressure and high-pressure stages can cause serious in- juries to personnel (burns).

  • Page 25: Safe Operation

    Operation Manual / Power2 550-M / High-pressure stage 2 Safety / 2.13 Safe operation 2.13 Safe operation Mechanical hazards during operation During standard operation, no mechanical hazards are caused by the low-pressure and high- pressure stage, provided that it has been properly installed.

  • Page 26: Safe Maintenance

    Operation Manual / Power2 550-M / High-pressure stage 2 Safety / 2.14 Safe maintenance 2.14 Safe maintenance Occupational safety WARNING Injuries to persons Severe injuries to personnel or fatal accidents can be caused by mechanical influences as a consequence of hazardous and inadequate operational pro- cedures or non-compliance with safety and health standards.
  • Page 27 Operation Manual / Power2 550-M / High-pressure stage 2 Safety / 2.14 Safe maintenance Welding work Wear personal protective equipment (PPE) for welding operations. When performing welding work in the vicinity of the low-pressure stage, always cover the filter silencer to prevent the filter mat from being damaged.
  • Page 28 Operation Manual / Power2 550-M / High-pressure stage 2 Safety / 2.14 Safe maintenance Mechanical hazards when working on the low-pressure and high-pressure stage WARNING Physical hazards due to rotating parts The rotor can rotate due to the stack draught alone. Contact with rotating parts can cause severe injury.
  • Page 29 Operation Manual / Power2 550-M / High-pressure stage 2 Safety / 2.14 Safe maintenance CAUTION Environmental hazard Improper handling of operating materials and supplies can lead to environ- mental damage. Observe the information in the material safety data sheet for the operat- ing materials and supplies.

  • Page 30: Removal And Installation

    Operation Manual / Power2 550-M / High-pressure stage 3 Removal and installation / 3.1 Transport / weight Removal and installation Transport / weight Swivel lifting eyes to be used Swivel lifting eyes are required for the safe lifting of loads, which are not supplied by Turbo Systems.

  • Page 31: Removing The High-Pressure Stage

    Operation Manual / Power2 550-M / High-pressure stage 3 Removal and installation / 3.2 Removing the high-pressure stage Removing the high-pressure stage Preparing for removal Disconnect all pipes according to the instructions of the enginebuilder. Fig. 13: Removing the high-pressure stage 1.

  • Page 32: Fig. 14: Loosening The Clamping Nut

    Operation Manual / Power2 550-M / High-pressure stage 3 Removal and installation / 3.2 Removing the high-pressure stage CAUTION Do not clean pressure screws The pressure screws are equipped with a permanent sliding layer that must not be removed. In case of non-compliance, it cannot be ensured that the necessary tension force is reached.

  • Page 33: Fig. 15: Removing The High-Pressure Stage

    Operation Manual / Power2 550-M / High-pressure stage 3 Removal and installation / 3.2 Removing the high-pressure stage Removing the high-pressure stage Fig. 15: Removing the high-pressure stage 1. Unscrew the threaded rods (42191) until they have been completely removed from the en- gine support and the centering bush (42193).

  • Page 34: Installing The High-Pressure Stage

    Operation Manual / Power2 550-M / High-pressure stage 3 Removal and installation / 3.3 Installing the high-pressure stage Installing the high-pressure stage 3.3.1 Inserting gaskets CAUTION Inserting the gaskets Gaskets that are forgotten, damaged or improperly inserted will lead to oil leaks.

  • Page 35: Fig. 17: Preparing The Fastening Elements Of The High-Pressure Stage

    Operation Manual / Power2 550-M / High-pressure stage 3 Removal and installation / 3.3 Installing the high-pressure stage 3.3.2 Placing the high-pressure stage on the bracket Fig. 17: Preparing the fastening elements of the high-pressure stage 1. Insert expansion bush (42190) into bearing casing.

  • Page 36: Fig. 18: Placing The High-Pressure Stage On The Bracket

    Operation Manual / Power2 550-M / High-pressure stage 3 Removal and installation / 3.3 Installing the high-pressure stage Fig. 18: Placing the high-pressure stage on the bracket 1. Lightly lubricate hole into which centering bush (42193) is inserted with screw grease.

  • Page 37: Fig. 19: Steps For Fastening The High-Pressure Stage

    Operation Manual / Power2 550-M / High-pressure stage 3 Removal and installation / 3.3 Installing the high-pressure stage 3.3.3 Steps for fastening the high-pressure stage Fig. 19: Steps for fastening the high-pressure stage 1. Tighten the clamping nuts (42201) (see section Tightening the clamping nut).

  • Page 38: Fig. 20: Steps For Fastening The High-Pressure Stage

    Operation Manual / Power2 550-M / High-pressure stage 3 Removal and installation / 3.3 Installing the high-pressure stage WARNING Support (61300) In radial gas outlet casings, the gas forces cause high torques to act on the high-pressure stage. If the high-pressure stage is fastened improperly, this can damage the high-pressure stage and cause serious injuries to persons or even fatal accidents.

  • Page 39: Fig. 21: Preparing The Clamping Nut For The Tightening Procedure

    Operation Manual / Power2 550-M / High-pressure stage 3 Removal and installation / 3.3 Installing the high-pressure stage 3.3.4 Tightening the clamping nut Preparations for tightening the clamping nut CAUTION Do not clean pressure screws (04) The pressure screws are equipped with a permanent sliding layer that must not be removed.

  • Page 40: Fig. 22: Tightening Pressure Screws

    Operation Manual / Power2 550-M / High-pressure stage 3 Removal and installation / 3.3 Installing the high-pressure stage Tightening pressure screws Fig. 22: Tightening pressure screws Fixing screw [mm] Tightening torques [Nm] 43 Nm Table 11 1. Screw in pressure screws crosswise by hand until reaching the stop.

  • Page 41: Commissioning

    Operation Manual / Power2 550-M / High-pressure stage 4 Commissioning / 4.1 Oil supply Commissioning Oil supply 4.1.1 Introduction In all operating states, a functioning and carefully executed oil supply is an important pre- requisite for trouble-free operation of the low-pressure and high-pressure stage.

  • Page 42: Inspection Procedures

    Operation Manual / Power2 550-M / High-pressure stage 4 Commissioning / 4.2 Inspection procedures Inspection procedures 4.2.1 Introduction Inspection procedures include preventative visual controls, monitoring and measuring work before and during commissioning. Inspection procedures enable changes to the low and high-pressure stage to be detected.
  • Page 43 Operation Manual / Power2 550-M / High-pressure stage 4 Commissioning / 4.2 Inspection procedures 4.2.3 Checks after commissioning (engine in idle mode) Lubricating system Check the oil pressure in the oil supply pipes. Check oil inlet temperature. The admissible values are specified in chapter Monitoring during operation →45.

  • Page 44: Commissioning After Taking Out Of Operation

    Operation Manual / Power2 550-M / High-pressure stage 4 Commissioning / 4.3 Commissioning after taking out of operation Commissioning after taking out of operation If present Remove cover plates (blind flanges) from the compressor casing, the gas inlet and the gas outlet.

  • Page 45: Monitoring During Operation

    Operation Manual / Power2 550-M / High-pressure stage 5 Monitoring during operation / 5.1 Lubricating oil pressure Monitoring during operation Lubricating oil pressure CAUTION Assuring lubricating oil pressure Serious damage to the engine or property can result from a missing or insuf- ficient lubricating oil supply.

  • Page 46: Lubricating Oil Temperature

    Operation Manual / Power2 550-M / High-pressure stage 5 Monitoring during operation / 5.2 Lubricating oil temperature Lubricating oil temperature Lubricating oil temperature at the inlet CAUTION Machine damage If the oil temperature at the oil inlet exceeds the admissible range, this may lead to engine damage.

  • Page 47: Speeds

    Operation Manual / Power2 550-M / High-pressure stage 5 Monitoring during operation / 5.3 Speeds Speeds 5.3.1 Introduction Speed measurement systems enable the constant monitoring of the speeds of the low-pres- sure and the high-pressure stage. 5.3.2 Layout and overview Fig. 24: Overview: speed measurement on high-pressure stage...
  • Page 48 Operation Manual / Power2 550-M / High-pressure stage 5 Monitoring during operation / 5.3 Speeds 5.3.3 Differences in speed between the low-pressure or high- pressure stages The speeds of the low-pressure stages differ significantly from the speeds of the high-pres- sure stages.
  • Page 49 Operation Manual / Power2 550-M / High-pressure stage 5 Monitoring during operation / 5.3 Speeds 5.3.4 Replacing the speed sensor WARNING Hot cable connector and hot speed sensor Danger of burns. The cable connector and speed sensor can reach temperat- ures in excess of 100 °C during operation.

  • Page 50: Operation And Service

    Operation Manual / Power2 550-M / High-pressure stage 6 Operation and service / 6.1 Noise emission Operation and service Noise emission WARNING Noise hazards Exposure to noise can harm the hearing system, impair health and the psy- chological state and may lead to lack of attention and irritation.

  • Page 51: Fig. 25: Noise Insulation, Bellows

    Operation Manual / Power2 550-M / High-pressure stage 6 Operation and service / 6.1 Noise emission Suggestion for noise insulation, bellows Fig. 25: Noise insulation, bellows Compressor casing Bellows Charge air duct / scavenging air duct Insulation cushion Insulation mat (at least 15 mm) Sheet metal cover ©...

  • Page 52: Service Work

    Operation Manual / Power2 550-M / High-pressure stage 6 Operation and service / 6.2 Service work Service work Service work includes visual controls, monitoring, measuring and inspection as well as func- tional checks. Service work enables the detection and rectification of changes to the low and high-pressure stage and ensures full operability of the low and high-pressure stage.
  • Page 53 Operation Manual / Power2 550-M / High-pressure stage 6 Operation and service / 6.2 Service work 6.2.4 Service work every 12000 ... 15000 operating hours The rotor and bearing parts must be checked and assessed by a Turbo Systems service sta- tion.

  • Page 54: Expected Replacement Intervals

    Operation Manual / Power2 550-M / High-pressure stage 6 Operation and service / 6.3 Expected replacement intervals Expected replacement intervals Rotating components The recommended replacement intervals of the compressor and turbine wheels are spe- cified with the aid of the safety concept for rotating parts (SIKO) and dependent on the op- erating conditions.
  • Page 55 Operation Manual / Power2 550-M / High-pressure stage 6 Operation and service / 6.3 Expected replacement intervals Influencing parameters The actual values can deviate considerably from the guideline values, for example, due to the following influences: ¡ Fuel quality and fuel treatment ¡...

  • Page 56: Stopping The Engine

    Operation Manual / Power2 550-M / High-pressure stage 6 Operation and service / 6.4 Stopping the engine Stopping the engine CAUTION Residual heat in the low-pressure and high-pressure stage If the residual heat in the low-pressure and high-pressure stage is not suffi- ciently dissipated by the circulating lubricating oil, machine damage could occur.

  • Page 57: Periodic Maintenance

    Operation Manual / Power2 550-M / High-pressure stage 7 Periodic maintenance / 7.1 Foreword to maintenance Periodic maintenance Foreword to maintenance Maintenance work includes regular visual controls and cleaning operations which are inten- ded to ensure the trouble-free functioning of the low-pressure and high-pressure stage.

  • Page 58: Cleaning The Compressor During Operation

    Operation Manual / Power2 550-M / High-pressure stage 7 Periodic maintenance / 7.2 Cleaning the compressor during operation Cleaning the compressor during operation 7.2.1 Prerequisite ¡ The enginebuilder approves the cleaning process and its specifications are adhered to. ¡ Instructions from Turbo Systems are followed.

  • Page 59: Table 18: Cleaning Parameters

    Operation Manual / Power2 550-M / High-pressure stage 7 Periodic maintenance / 7.2 Cleaning the compressor during operation 7.2.3 Prerequisites for wet cleaning of compressor ¡ Engine load of 50 ... 85% CAUTION Volume of water Uncontrolled volumes of water can damage the pressure stages and the en- gine.

  • Page 60: Cleaning The High-Pressure Stage Bellows (If Present)

    Operation Manual / Power2 550-M / High-pressure stage 7 Periodic maintenance / 7.3 Cleaning the high-pressure stage bellows (if present) Cleaning the high-pressure stage bellows (if present) The disassembly and assembly of the bellows (82300) is described in chapter "Disassembly and assembly".
  • Page 61 Operation Manual / Power2 550-M / High-pressure stage 7 Periodic maintenance / 7.4 Cleaning turbines and nozzle rings during operation Turbo Systems recommends using fuels with a mass ratio of vanadium to sodium of less than 3:1 so that the melting temperature of the sodium vanadyl vanadate is as high as pos- sible.
  • Page 62 Operation Manual / Power2 550-M / High-pressure stage 7 Periodic maintenance / 7.4 Cleaning turbines and nozzle rings during operation 7.4.2 Cleaning method and principle Cleaning of the turbine and the nozzle ring during operation is carried out by the cleaning method described in the following and is tested and approved by Turbo Systems: ¡...

  • Page 63: Fig. 27: Load/Time Chart

    Operation Manual / Power2 550-M / High-pressure stage 7 Periodic maintenance / 7.4 Cleaning turbines and nozzle rings during operation 7.4.3 Wet cleaning of turbine blades and nozzle ring Prerequisites The following operating state and the following prerequisites have been tested and ap- proved by Turbo Systems for cleaning operations: Set the engine load between 20 … 50% so that the turbine inlet temperature is between...

  • Page 64: Fig. 28: Wet Cleaning Operation

    Operation Manual / Power2 550-M / High-pressure stage 7 Periodic maintenance / 7.4 Cleaning turbines and nozzle rings during operation Procedure The prerequisites and operating state must be fulfilled prior to cleaning. Fig. 28: Wet cleaning operation Make sure that the water supply (01) is connected, switched on and safeguarded.
  • Page 65 Operation Manual / Power2 550-M / High-pressure stage 7 Periodic maintenance / 7.4 Cleaning turbines and nozzle rings during operation Repetitions of wet cleaning The repetition of cleaning cycles one immediately after the other must be avoided as this can lead to excessive mechanical stress and thus to a reduction in the operating life of the components.

  • Page 66: Table 20: Cleaning Parameters

    Operation Manual / Power2 550-M / High-pressure stage 7 Periodic maintenance / 7.4 Cleaning turbines and nozzle rings during operation Cleaning parameters for wet cleaning of the turbines Power2 Max. temper- Lead time Injection Drying Water flow rate Overpres- ature when...

  • Page 67: Troubleshooting

    Operation Manual / Power2 550-M / High-pressure stage 8 Troubleshooting / 8.1 Malfunctions when starting Troubleshooting Malfunctions when starting Delayed start-up Possible causes Remedy Low-pressure Pressure stage contaminated Clean Bearing damaged Contact a Turbo Systems service sta- high-pressure tion Rotor rubbing...

  • Page 68: Malfunctions During Operation

    Operation Manual / Power2 550-M / High-pressure stage 8 Troubleshooting / 8.2 Malfunctions during operation Malfunctions during operation Lubricating oil pressure too low Possible causes Remedy Engine Oil filter heavily contaminated Clean Oil pump in lubricating system de- Check/replace fective...

  • Page 69: Table 30: Malfunctions During Operation - Power2 Hp Speed Increases

    Operation Manual / Power2 550-M / High-pressure stage 8 Troubleshooting / 8.2 Malfunctions during operation Increase in high-pressure stage speed Possible causes Remedy High-pressure Heavy contamination of the nozzle Contact a Turbo Systems service sta- stage ring tion Low-pressure stage defective...

  • Page 70: Table 32: Malfunctions During Operation - Charge Air Pressure Too Low

    Operation Manual / Power2 550-M / High-pressure stage 8 Troubleshooting / 8.2 Malfunctions during operation Charge air pressure too low Engine performance and engine speed unchanged, suction condition normal Possible causes Remedy Engine Air receiver not sealed Repair Gas piping between engine and tur-...

  • Page 71: Table 34: Malfunctions During Operation - Compressor 1 Contamination

    Operation Manual / Power2 550-M / High-pressure stage 8 Troubleshooting / 8.2 Malfunctions during operation Contamination of the compressor Reduced compressor performance/efficiency and therefore engine performance losses Possible causes Remedy Low-pressure Heavy contamination of the com- Clean the compressor pressor components due to the in-...

  • Page 72: Surging Of The Low-Pressure Or High-Pressure Stage

    Operation Manual / Power2 550-M / High-pressure stage 8 Troubleshooting / 8.3 Surging of the low-pressure or high-pressure stage Surging of the low-pressure or high-pressure stage Possible causes Remedy Engine Protective grating downstream of Clean/replace high-pressure stage contaminated or damaged...

  • Page 73: Malfunctions When Stopping

    Operation Manual / Power2 550-M / High-pressure stage 8 Troubleshooting / 8.4 Malfunctions when stopping Malfunctions when stopping Runout noises Possible causes Remedy Low-pressure Pressure stage contaminated Clean Bearing damaged Contact a Turbo Systems service sta- high-pressure tion Rotor rubbing...

  • Page 74: Speed Measurement System

    Operation Manual / Power2 550-M / High-pressure stage 8 Troubleshooting / 8.5 Speed measurement system Speed measurement system No signal or poor signal amplitude of the speed measurement Possible causes Remedy Low-pres- The speed sensor was acci- The screw plug for the sensor is fitted with an ad-...

  • Page 75: Disassembly And Assembly

    Operation Manual / Power2 550-M / High-pressure stage 9 Disassembly and assembly / 9.1 Introduction Disassembly and assembly Introduction The precondition for the work described in the following is a high-pressure stage that has been removed from the engine (see chapter Removal and installation →30).

  • Page 76: Material Required

    Operation Manual / Power2 550-M / High-pressure stage 9 Disassembly and assembly / 9.2 Material required WARNING Suspended loads Loads that are not attached according to regulations can cause injury to personnel or fatal accidents. Loads must always be fastened to properly functional lifting gear with a sufficient load limit.

  • Page 77: Fig. 29: Swivel Lifting Eye (Example)

    Operation Manual / Power2 550-M / High-pressure stage 9 Disassembly and assembly / 9.2 Material required WARNING Servicing the assembly devices Assembly devices must be checked for damage before and after use. Visually inspect for corrosion, cracks, deformation and wear.

  • Page 78: Weights Of Assemblies

    Operation Manual / Power2 550-M / High-pressure stage 9 Disassembly and assembly / 9.3 Weights of assemblies Weights of assemblies The specified weights of the individual parts or assemblies are rounded-up standard values. Fig. 30: Weights of the assemblies Designation Weight...

  • Page 79: Removing The Gas Outlet Casing

    Operation Manual / Power2 550-M / High-pressure stage 9 Disassembly and assembly / 9.4 Removing the gas outlet casing Removing the gas outlet casing Mark the casing position for assembly. Fig. 31: Removing the gas outlet casing 1. Loop the lifting gear around the gas outlet casing (61001).

  • Page 80: Removing Air Inlets

    Operation Manual / Power2 550-M / High-pressure stage 9 Disassembly and assembly / 9.5 Removing air inlets Removing air inlets Mark the casing position for assembly. Fig. 32: Removing the air inlets 1. Loop the lifting gear around the radial air suction branch (82000).

  • Page 81: Removing The Compressor Casing

    Operation Manual / Power2 550-M / High-pressure stage 9 Disassembly and assembly / 9.6 Removing the compressor casing Removing the compressor casing Mark the casing position for assembly. Measure radial clearance N before removing the compressor casing (72000) (see Measur- ing radial clearances N and R →91).

  • Page 82: Removing The Cartridge Group

    Operation Manual / Power2 550-M / High-pressure stage 9 Disassembly and assembly / 9.7 Removing the cartridge group Removing the cartridge group Mark the casing position for assembly. Do not remove oil orifice (if present) To limit the oil flow rate through the bearing casing during operation (engine under load) to the admissible values, an oil orifice is mandatory at the oil inlet of the bearing casing if the oil inlet pressure is > 3 bar (overpressure).

  • Page 83: Fig. 34: Removing The Cartridge Group

    Operation Manual / Power2 550-M / High-pressure stage 9 Disassembly and assembly / 9.7 Removing the cartridge group WARNING Looping the lifting gear around the cartridge group The looped lifting gear can slip off and lead to serious injuries to persons or even to fatal accidents.

  • Page 84: Fig. 35: Removing The Gas Outlet Flange / Nozzle Ring

    Operation Manual / Power2 550-M / High-pressure stage 9 Disassembly and assembly / 9.7 Removing the cartridge group Removing the gas outlet flange / nozzle ring Fig. 35: Removing the gas outlet flange / nozzle ring 1. Pull out the nozzle ring (56001) by hand. If the nozzle ring does not loosen, the gas outlet flange (57002) must be removed first.

  • Page 85: Installing The Cartridge Group

    Operation Manual / Power2 550-M / High-pressure stage 9 Disassembly and assembly / 9.8 Installing the cartridge group Installing the cartridge group Nozzle ring compression In order for the nozzle ring (56001) to be fixed during operation, it must be clamped between the heat shield (43001) and the turbine casing (51000).

  • Page 86: Fig. 37: Installing The Gas Outlet Flange / Nozzle Ring

    Operation Manual / Power2 550-M / High-pressure stage 9 Disassembly and assembly / 9.8 Installing the cartridge group Installing the gas outlet flange / nozzle ring The nozzle ring (56001) can only be fitted into the turbine casing (51000) if both of the chamferings (02) on diameter D are aligned with one another.

  • Page 87: Fig. 38: Installing The Cartridge Group

    Operation Manual / Power2 550-M / High-pressure stage 9 Disassembly and assembly / 9.8 Installing the cartridge group Installing the cartridge group WARNING Looping the lifting gear around the cartridge group The looped lifting gear can slip off and lead to serious injuries to persons or even to fatal accidents.

  • Page 88: Installing The Compressor Casing

    Operation Manual / Power2 550-M / High-pressure stage 9 Disassembly and assembly / 9.9 Installing the compressor casing Installing the compressor casing Always replace the O-rings (42012 and 77005) with new ones (see Ordering spare parts →102). Fig. 39: Installing the compressor casing...

  • Page 89: Installing The Air Inlets

    Operation Manual / Power2 550-M / High-pressure stage 9 Disassembly and assembly / 9.10 Installing the air inlets 9.10 Installing the air inlets Always replace the O-ring (82010) with a new one (see Ordering spare parts →102). Measure clearance N (see Measuring radial clearances N and R →91).

  • Page 90: Installing The Gas Outlet Casing

    Operation Manual / Power2 550-M / High-pressure stage 9 Disassembly and assembly / 9.11 Installing the gas outlet casing 9.11 Installing the gas outlet casing Measure clearance R (see chapter Measuring radial clearances N and R →91). Fig. 41: Installing the gas outlet casing...

  • Page 91: Measuring Radial Clearances N And R

    Operation Manual / Power2 550-M / High-pressure stage 9 Disassembly and assembly / 9.12 Measuring radial clearances N and R 9.12 Measuring radial clearances N and R Fig. 42: Measuring clearances N and R Clearance N Clearance R 0.50 ... 0.80 mm 0.65 ...

  • Page 92: Measuring Clearance A And B

    Operation Manual / Power2 550-M / High-pressure stage 9 Disassembly and assembly / 9.13 Measuring clearance A and B 9.13 Measuring clearance A and B Measure and record clearances A and B after the removal and before the installation of the cartridge group.

  • Page 93: Table Of Tightening Torques

    Operation Manual / Power2 550-M / High-pressure stage 9 Disassembly and assembly / 9.14 Table of tightening torques 9.14 Table of tightening torques Fig. 44: Overview of tightening torques The following tightening torques [Nm] must be observed for the designated bolted connec-...

  • Page 94: Taking Out Of Operation At Short Notice

    Operation Manual / Power2 550-M / High-pressure stage 10 Taking out of operation at short notice / 10.1 Possible emergency re- pairs Taking out of operation at short notice 10.1 Possible emergency repairs WARNING Danger of fire and explosion due to lubricating oil leaks Leaking oil may ignite on hot surfaces.

  • Page 95: Installing A Replacement Cartridge Group

    Operation Manual / Power2 550-M / High-pressure stage 10 Taking out of operation at short notice / 10.2 Installing a replace- ment cartridge group 10.2 Installing a replacement cartridge group The repair of a cartridge group requires special tools and the expertise of a Turbo Systems service station.

  • Page 96: Fitting The Cover Plate

    Operation Manual / Power2 550-M / High-pressure stage 10 Taking out of operation at short notice / 10.3 Fitting the cover plate 10.3 Fitting the cover plate The cover plate has two functions. It seals the turbine casing from exhaust gas and the bracket from oil leaks.

  • Page 97: Cover Plate Drawing

    Operation Manual / Power2 550-M / High-pressure stage 10 Taking out of operation at short notice / 10.4 Cover plate drawing 10.4 Cover plate drawing The cover plate is not included in the Turbo Systems scope of delivery and must be manufac- tured by the operating company according to the following drawing.

  • Page 98: Fig. 47: Figure For Cover Plate, Slots For O-Rings

    Operation Manual / Power2 550-M / High-pressure stage 10 Taking out of operation at short notice / 10.4 Cover plate drawing Slots for O-rings in cover plate Fig. 47: Figure for cover plate, slots for O-rings 125.5 31.5 Table 55: Dimensions of cover plate, slots for O-rings [mm] ©...

  • Page 99: Taking Out Of Operation For A Long Period

    Operation Manual / Power2 550-M / High-pressure stage 11 Taking out of operation for a long period / 11.1 General Taking out of operation for a long period 11.1 General When 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.

  • Page 100: Material And Disposal

    Operation Manual / Power2 550-M / High-pressure stage 12 Material and Disposal / 12.1 REACH and RoHS Compliance Declara- tion For Products Material and Disposal 12.1 REACH and RoHS Compliance Declaration For Products Turbo Systems hereby confirms that all genuine products, parts and components supplied...

  • Page 101: Disposing Of Low-Pressure And High-Pressure Stage Components

    Operation Manual / Power2 550-M / High-pressure stage 12 Material and Disposal / 12.2 Disposing of low-pressure and high- pressure stage components 12.2 Disposing of low-pressure and high-pressure stage components Disposal must be environmentally compatible, professional, and in compliance with locally applicable regulations.

  • Page 102: Spare Parts

    Operation Manual / Power2 550-M / High-pressure stage 13 Spare parts / 13.1 Ordering spare parts Spare parts 13.1 Ordering spare parts CAUTION Spare part storage All spare parts that were ordered together with the low-pressure and/or high-pressure stage must be kept intact and ready for use.

  • Page 103: Table 56: Customer Spare Part Set (97070)

    Operation Manual / Power2 550-M / High-pressure stage 13 Spare parts / 13.1 Ordering spare parts Required customer spare part set (97070) For the work described in the Operation Manual, the customer spare part set (97070) is re- quired. These parts are only available in the complete set.

  • Page 104: Spare Part - Illustrations

    Operation Manual / Power2 550-M / High-pressure stage 13 Spare parts / 13.2 Spare part – Illustrations 13.2 Spare part – Illustrations The spare parts lists shown below are only available in English. Cartridge 42201 42009 42191 42010* 10900 42012*...

  • Page 105: Table 58

    Operation Manual / Power2 550-M / High-pressure stage 13 Spare parts / 13.2 Spare part – Illustrations Bearing casing 42400 42009 42402 42005 42010* 42006 42001 42304* 42301 42004* 42003* 79000 42188 42197 42189 42196 42007 42008 * = Available within the spare part set HZTL443281 Mod.

  • Page 106: Table 59

    Operation Manual / Power2 550-M / High-pressure stage 13 Spare parts / 13.2 Spare part – Illustrations Rotor and Bearing parts 21000 21011 32102* 21002* 21006* 25000 32115 32116 32108* 32112 32110 32114* 32101* 32107* 32167* 32175* 42302* 32109* 42002...

  • Page 107: Table 60

    Operation Manual / Power2 550-M / High-pressure stage 13 Spare parts / 13.2 Spare part – Illustrations Turbine casing 51009 51015 51005* 57002 51028 THV03 51004 51008 51026* 57004* 61072 51028 Turbine cleaning** 51002 51000 56005* 56001 51105* 51006 THV05...

  • Page 108: Table 61

    Operation Manual / Power2 550-M / High-pressure stage 13 Spare parts / 13.2 Spare part – Illustrations Turbine cleaning 52155 52150 52145 52140 52135 52130 52110 52160 52115 52125 52120 52100 HZTL443585 Mod. A Part no. Designation 52100 Cleaning unit...

  • Page 109: Table 62

    Operation Manual / Power2 550-M / High-pressure stage 13 Spare parts / 13.2 Spare part – Illustrations Gas outlet casing axial 61001 61007* 61205 61005 61072 61007* 61001 * = Available within the spare part set HZTL443347 Mod. B Part no.

  • Page 110: Table 63

    Operation Manual / Power2 550-M / High-pressure stage 13 Spare parts / 13.2 Spare part – Illustrations Gas outlet casing radial 61003 61205 61004 61300 61001 61005 HZTL443289 Mod. B Part no. Designation 61001 Gas-outlet casing 61003 Hexagon-head screw 61004...

  • Page 111: Table 64

    Operation Manual / Power2 550-M / High-pressure stage 13 Spare parts / 13.2 Spare part – Illustrations Compressor casing 81080 72005 72011 72006 72012 77000 77005* 77022 72000 72013 72014 * = Available within the spare part set HZTL443283 Mod. B Part no.

  • Page 112: Table 65

    Operation Manual / Power2 550-M / High-pressure stage 13 Spare parts / 13.2 Spare part – Illustrations Air suction branch axial 82007 82008 82010* 82000 * = Available within the spare part set HZTL443285 Mod. A Part no. Designation 82000...

  • Page 113: Table 66

    Operation Manual / Power2 550-M / High-pressure stage 13 Spare parts / 13.2 Spare part – Illustrations Air suction branch radial 82300 82130 82000 82022 82021 82008 82007 82145 82140 HZTL443284 Mod. B Part no. Designation 82000 Air suction branch...

  • Page 114: Table 67

    Operation Manual / Power2 550-M / High-pressure stage 13 Spare parts / 13.2 Spare part – Illustrations Speed measurement system 86528** 86526** 86505 86515 ** = if provided HZTL443348 Mod. A Part no. Designation 86505 Speed sensor 86515 Cable connector...

  • Page 115: Tools

    Operation Manual / Power2 550-M / High-pressure stage 14 Tools / ​ Tools For the work described in the Operation Manual, the customer tool set 90000 is required. Part number Designation Quantity 90012 Service support 90056 Toolbox 90070 Extraction device...

  • Page 116: Gas Piping (Option)

    Operation Manual / Power2 550-M / High-pressure stage 15 Gas piping (option) / ​ Gas piping (option) The gas piping documentation can be found in the Operation Manual of the Power2 low- pressure stage. © Copyright 2022 ABB. All rights reserved.

  • Page 117: Figures

    Operation Manual / Power2 550-M / High-pressure stage Figures   Figures Fig. 1: Layout and function ..........7 Fig. 31: Removing the gas outlet casing ....79 Fig. 2: Layout of the high-pressure stage ....8 Fig. 32: Removing the air inlets........80 Fig. 3: Function of the high-pressure stage....9 Fig. 33: Removing the compressor casing....

  • Page 118: Tables

    Operation Manual / Power2 550-M / High-pressure stage Tables Tables Table 1: Definition of pictograms ......11 Table 29: Malfunctions during operation – Power2 LP speed increases............68 Table 2: Personal protective equipment to be worn at all times ..............15 Table 30: Malfunctions during operation – Power2 HP speed increases ............
  • Page 119 Operation Manual / Power2 550-M / High-pressure stage Tables Table 55: Dimensions of cover plate, slots for O- rings [mm] ..............98 Table 56: Customer spare part set (97070) ..103 Table 57 ................ 104 Table 58 ................ 105 Table 59 ................ 106 Table 60................. 107 Table 61 ................

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