ABB PT003901 User manual
Turbo Systems Switzerland Ltd
Operation Manual / Power2 340-H44
High-pressure stage PT003901
Document identification
Document number HZTL4054
Revision F
Language English
Original Operation Manual
Product identification
Serial number PT003901
Customer part number 1239301
Delivery date (yyyy-mm-dd) 2022-04-14
Weight 280 kg
Operating limits according to rating plate
Speed limit in test rig operation only nMmax 786 1/s
Speed limit during operation nBmax 785 1/s
Gas inlet temperature limit in test rig operation only tMmax 650 °C
Gas inlet temperature limit during operation tBmax 650 °C
Compressor inlet temperature after intercooler tCmax 50 °C
Operation Manual / Power2 340-H / High-pressure stage
Table of contents
© Copyright 2022 ABB. All rights reserved. HZTL4054_EN Rev.F March 2022
Power2 340-H / 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
Operation Manual / Power2 340-H / High-pressure stage
Table of contents
© Copyright 2022 ABB. All rights reserved. HZTL4054_EN Rev.F March 2022
6.2 Service work................................................................................................................. 52
6.3 Expected replacement intervals .............................................................................. 54
6.4 Stopping the engine................................................................................................... 56
7 Periodic maintenance.......................................................................................... 57
7.1 Foreword to maintenance.......................................................................................... 57
7.2 Cleaning the compressor during operation .......................................................... 58
7.3 Cleaning the high-pressure stage bellows (if present)....................................... 60
7.4 Cleaning turbine and nozzle ring during operation ............................................. 60
8 Troubleshooting................................................................................................... 61
8.1 Malfunctions when starting....................................................................................... 61
8.2 Malfunctions during operation ................................................................................ 62
8.3 Surging of the low-pressure or high-pressure stage .......................................... 66
8.4 Malfunctions when stopping.................................................................................... 67
8.5 Speed measurement system.................................................................................... 68
9 Disassembly and assembly................................................................................. 69
9.1 Introduction ................................................................................................................. 69
9.2 Material required......................................................................................................... 70
9.3 Weights of assemblies................................................................................................ 72
9.4 Removing the gas outlet casing ............................................................................... 73
9.5 Removing air inlets ..................................................................................................... 74
9.6 Removing the compressor casing............................................................................ 75
9.7 Removing the cartridge group................................................................................. 76
9.8 Installing the cartridge group .................................................................................. 79
9.9 Installing the compressor casing ............................................................................ 82
9.10 Installing the air inlets ............................................................................................... 83
9.11 Installing the gas outlet casing................................................................................ 84
9.12 Measuring radial clearances N and R ...................................................................... 85
9.13 Measuring clearance A and B.................................................................................... 86
9.14 Table of tightening torques...................................................................................... 87
10 Taking out of operation at short notice ........................................................... 88
10.1 Possible emergency repairs...................................................................................... 88
10.2 Installing a replacement cartridge group .............................................................. 89
10.3 Fitting the cover plate................................................................................................ 90
10.4 Cover plate drawing .................................................................................................... 91
11 Mothballing the high-pressure stage................................................................ 93
11.1 Taking the engine out of operation for up to 12months ................................... 93
11.2 Taking the engine out of operation for more than 12months.......................... 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
13 Spare parts ........................................................................................................... 97
Operation Manual / Power2 340-H / High-pressure stage
Table of contents
© Copyright 2022 ABB. All rights reserved. HZTL4054_EN Rev.F March 2022
13.1 Ordering spare parts.................................................................................................. 97
13.2 Spare part – Illustrations........................................................................................... 99
14 Tools .................................................................................................................... 110
15 Gas piping (option)............................................................................................. 111
Figures.................................................................................................................. 112
Tables ................................................................................................................... 113
Operation Manual / Power2 340-H / High-pressure stage
1 Introduction / 1.1 Purpose of the manual
© Copyright 2022 ABB. All rights reserved. HZTL4054_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 / 114
Operation Manual / Power2 340-H / High-pressure stage
1 Introduction / 1.3 Essential information
© Copyright 2022 ABB. All rights reserved. HZTL4054_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 / 114
Operation Manual / Power2 340-H / High-pressure stage
1 Introduction / 1.3 Essential information
© Copyright 2022 ABB. All rights reserved. HZTL4054_EN Rev.F March 2022
Page 6 / 114
Operation Manual / Power2 340-H / High-pressure stage
1 Introduction / 1.4 Power2 layout and function
© Copyright 2022 ABB. All rights reserved. HZTL4054_EN Rev.F March 2022
1.4 Power2 layout and function
Fig.1: Layout and function
Power2 Two-stage turbocharging 21 HP compressor
Power2 LP Low-pressure stage 22 HP turbine
Power2 HP High-pressure stage 23* Gas piping (bellows)
A Exhaust gas inlet from internal combus-
tion engine 24 LP turbine
B Exhaust gas outlet 25 LP compressor
C Air or air/gas mixture inlet 26 Intercooler
D Air or air/gas mixture outlet and supply
to the charge air cooler - - - Not included in the Turbo Systems
scope of delivery
*) If present
The diagram shows the position of the low-pressure (Power2LP) and high-pressure stage
(Power2HP) 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 subsequently through the bellows (23*) of the gas pipe to the
turbine (24) of the low-pressure stage. The compressor (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 compressor (21) of the high-pressure stage. Here
the air or air/gas mixture is compressed further and leaves the two-stage turbocharging
(Power2) in the direction of the charge air cooler.
Page 7 / 114
Operation Manual / Power2 340-H / High-pressure stage
1 Introduction / 1.5 Layout and function of the high-pressure stage
© Copyright 2022 ABB. All rights reserved. HZTL4054_EN Rev.F March 2022
1.5 Layout and function of the high-pressure stage
Fig.2: Layout of the high-pressure stage
01 Air suction branch 09 Gas outlet flange
02 Bellows 10 Gas outlet flange
03 Compressor casing 11 Nozzle ring
04 Diffuser 12 Support
05 Axial thrust bearing 13 Turbine-end bearing flange
06 Bearing casing 14 Turbine casing
07 Radial plain bearings 15 Compressor-end bearing flange
08 Turbine 16 Compressor wheel
Page 8 / 114
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