ABB HT563116 Operation Manual Download

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Operation Manual / 2 Safety / A130 - A155

Safety

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1.3

Definition of mandatory signs

To be worn at all times

Protective clothing

Safety footwear to protect against

mechanical hazard and risk of fall-

ing

Table 1: 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

Respiratory mask to protect against
- Dusts
- Gases

Safety helmet

Ear protection

Table 2: Personal protective equipment to be worn specific to the respective task

1.4

Definition of safety instructions

WARNING

Definition of Warning
Non-compliance or inaccurate compliance with working or operating instruc-

tions indicated by this symbol and the word WARNING can lead to serious

injuries to personnel and even to fatal accidents.



Warning signs must always be observed.

CAUTION

Definition of Caution
Non-compliance or inaccurate compliance with working or operating instruc-

tions indicated by this symbol and the word CAUTION can lead to serious

damage to engine or property with grave consequences.



Caution signs must always be observed.

HZTL4022_EN

Revision C

May 2016

Summary of Contents for HT563116

Page 1: ...Turbo Systems Ltd Operation Manual A135 M55 HT563116 English Original Operation Manual Chapter Document ID 1 Introduction HZTL4005_EN_D 2 Safety HZTL4022_EN_C 3 Safety data sheet HT563116 4 Product description HZTL4031_EN_C ...

Page 2: ...ewith confirm that this Operation Manual has been drawn up in compliance with the EU Product Liability Directive 85 374 EEC as well as with the EU Machinery Directive 2006 42 EC Copyright 2016 ABB All rights reserved Design and specifications are subject to change without notice Printed on naturally white paper bleached free from chlorine and environmentally acceptable The CD is made of polycarbon...

Page 3: ...ts Page 1 8 Copyright 2015 ABB All rights reserved HZTL4005_EN Revision D September 2015 Introduction 1 Introduction 3 1 1 Purpose of the manual 3 1 2 Symbols definitions 4 1 3 Storage of new turbochargers and spare parts 6 1 4 Contact information 8 ...

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Page 5: ...turbocharger from ABB 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 turbocharger conne...

Page 6: ...e work 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 ABB Turbo Systems ABB Turbo Systems Ltd is identified as ABB Turbo Systems in this document Official service stations of ABB Turb...

Page 7: ...m Meaning Pictogram Meaning Tighten with specified torque Affix Tighten over specified tightening angle Measure Hand tight tighten without tools Note Oil Visually inspect Apply screw locking paste e g Loctite Please note text for numbered work step Apply high temperature grease See document Apply other paste in accordance with specifications Dispose of in an environmentally compatible professional...

Page 8: ...e not hazardous in the sense of the Hazardous Substances Ordinance Nevertheless the following points are to be observed when handling VCIs Observe specifications in the safety data sheet Ensure good room ventilation Do not eat drink or keep food at the workplace while working with VCIs Clean hands and face after working with VCIs For further information refer to www branopac com Wear safety gloves...

Page 9: ...bocharging Service Station and repacked Inspect the package for damage If the package is damaged the turbocharger or cartridge group must be inspected by an ABB Turbocharging Service Station and repacked After every 3 years the following work steps must be performed by an ABB Turbocharging Service Station Inspect the components Exchange the desiccant agent Repackage the components NOTICE Replaceme...

Page 10: ...rved HZTL4005_EN Revision D September 2015 1 4 Contact information Contact information for the official service stations of ABB Turbo Systems is available online Scan the QR code to access our website ABB Turbo Systems AG Bruggerstrasse 71a CH 5401 Baden Switzerland www abb com turbocharging ...

Page 11: ...nded use 5 1 6 Deflagration on gas engines 6 1 7 Warning plates on the turbocharger 6 1 8 Turbocharger rating plate 7 1 9 Periodic check of the pressure vessels 8 1 10 Lifting of loads 9 1 11 Prerequisites for operation and maintenance 10 1 12 Hazards during operation and maintenance 11 1 13 Safe operation 13 1 14 Safe maintenance 15 Copyright 2016 ABB All rights reserved HZTL4022_EN Revision C Ma...

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Page 13: ... 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 turbocharger All instructions contained in this chapter must be observed for safe and trouble free operation of the turbocharger and during all work on the turbocharge...

Page 14: ...ersonal protective equipment to be worn specific to the respective task 1 4 Definition of safety instructions WARNING Definition of Warning Non compliance or inaccurate compliance with working or operating instruc tions indicated by this symbol and the word WARNING can lead to serious injuries to personnel and even to fatal accidents Warning signs must always be observed CAUTION Definition of Caut...

Page 15: ...ted with a clockwise direction of rotation as viewed from the turbine end The specific operating limits of the turbocharger were determined on the basis of information from the enginebuilder about the intended use These data are given on the rating plate ABB Turbo Systems accepts no liability and rejects all warranty claims for any non intended uses 1 Euromot The European Association of Internal C...

Page 16: ...to the bearing casing must be checked and the bearing casing must be examined to see if it has shifted in relation to the bracket A crack inspection of the casings and the bellows is also recommended The nearest ABB Turbocharging Service Station should be instructed to carry out this inspection and assessment 1 7 Warning plates on the turbocharger Warning plates that must be observed are attached ...

Page 17: ... during operation Recommended inspection and replacement intervals of turbocharger components 03 Inspection interval of plain bearings in 1000 h 04 Replacement interval of compressor in 1000 h 05 Replacement interval of turbine in 1000 h Further data 06 Customer part number 07 Designation for special design 08 Weight of turbocharger in kg 09 Turbocharger type 10 Serial number 11 Year of constructi...

Page 18: ...n and replacement intervals increases the risk of unpredictable component failures Locations of the rating plates The locations of the rating plates are defined in the Operation Manual Product description 1 9 Periodic check of the pressure vessels The pressure vessels used by ABB Turbo Systems for example in the wet or dry cleaning process are so called simple pressure vessels The locally applicab...

Page 19: ...ds on the crane hook Figure 4 Attachment angle If there are two or more suspension points the attachment angle of 45 must not be exceed ed This prevents excessive loading due to diagonal pull Before looping around the components of the turbocharger let them cool down maximum 80 C Attach components of the turbocharger as described in the respective action steps Use a suitable edge guard if there ar...

Page 20: ...rfect condi tion Only authorised personnel may remain in the vicinity of the turbocharger when the engine is running Competence of personnel The turbocharger must only be operated and serviced by trained and authorised personnel Basic mechanical training is a prerequisite Modifications to the turbocharger Modifications to the turbocharger must be approved by ABB Turbo Systems Original parts and sa...

Page 21: ...el exceeds 85 dB A Wear ear protection Hazards due to hot surfaces Surfaces of the turbocharger attached parts and operating fluids lubricating oil get hot during operation The surface temperature depends on the efficacy of the existing insulation The temperature may rise to a level that can cause burns WARNING Danger of burns Touching hot surfaces or contact with hot operating fluids can cause bu...

Page 22: ...hysical hazards Contact with rotating parts can cause severe injury The turbocharger must never be used without the filter silencer or the air suction branch With the engine stopped the rotor can rotate due to the stack draught alone Operate the turbocharger in compliance with the specifications Secure the rotor against unintentional rotation during maintenance Wear safety gloves to protect agains...

Page 23: ...nsulation resistance or voltage on the electrical components 1 13 Safe operation Mechanical hazards during operation During standard operation no mechanical hazards are caused by the turbocharger itself if it has been properly installed Safety during commissioning and operation Visually inspect your working environment before starting work Remove any obstacles and objects littering the workplace C...

Page 24: ...cidents Only operate the turbocharger with burst protection fitted and insulation fitted in one of the following permitted variants Figure 5 Variant A Insulation 01 with integrated burst protection from ABB Turbo Systems Variant B Burst protection 03 and insulation 02 from ABB Turbo Systems Variant C Burst protection 03 from ABB Turbo Systems with appropriate insulation from the en ginebuilder Cop...

Page 25: ...st mechanical hazard and risk of fall ing Wear protective clothing WARNING Risk of falling When working on the turbocharger there is a risk of falling Do not climb onto the turbocharger or onto attached parts and do not use them as climbing aids Use suitable climbing aids and working platforms for work above body height Comply with the general accident prevention regulations Only perform work on t...

Page 26: ... for set up service and inspection work and the inspection inter vals Inform the operating staff before starting any service or repair work Make sure the engine is not started while work is being conducted on the turbocharger Before taking off any cover or removing any guard from the turbocharger switch off the engine and wait until the turbocharger has come to a standstill Make sure that the oil ...

Page 27: ...ng materials and supplies Operating materials and supplies are substances required for the operation of the turbo charger or for the performance of maintenance work Oils greases coolants detergents and solvents acids and similar substances can be classified as hazardous substances WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies o...

Page 28: ...upplies Comply with local legislation Hazards due to the handling of insulation materials WARNING Danger from insulation materials Dust or fibres from insulation materials can have adverse effects on the health or cause irritations Unsuitable and combustible insulation materials are a fire hazard Only use suitable and non combustible insulation materials Ensure good ventilation at the workplace Av...

Page 29: ...Operation Manual A135 M55 Safety data sheet Page 1 1 Safety data sheet Copyright 2016 ABB All rights reserved HT563116 June 2016 A135 M55 HT563116 A135 M55 HT563116 891 630 864 600 270 12 50 50 2016 ...

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Page 31: ...urbocharger 12 2 3 Installing the turbocharger 16 3 Commissioning 23 3 1 Oil supply 23 3 2 Inspection procedures 25 3 3 Commissioning after taking out of operation 27 4 Monitoring operation 29 4 1 Oil pressure oil temperature 29 4 2 Exhaust gas temperature before turbine 31 4 3 Turbocharger speed 32 5 Operation and service 35 5 1 Noise emission 35 5 2 Service work 37 5 3 Expected replacement inter...

Page 32: ...e group 86 8 11 Axial clearance A and radial clearance B 87 8 12 Nozzle ring compression PD 88 8 13 Installing nozzle ring 89 8 14 Installing the cartridge group 90 8 15 Installing the compressor casing 93 8 16 Radial clearances N and R 95 8 17 Installing air inlets 96 8 18 Installing the gas outlet flange 97 8 19 Installing the gas outlet casing 97 8 20 Table of tightening torques 98 9 Taking out...

Page 33: ... Table of contents Page 3 115 Copyright 2015 ABB All rights reserved HZTL4031_EN Revision C February 2016 12 1 Ordering spare parts 109 12 2 Required customer spare part set 97070 109 12 3 View of turbocharger with part numbers 110 Figures 113 Tables 115 ...

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Page 35: ... on questions regarding a design variant see Operation Manual 1 Introduction Customer Service Accuracy of illustrations The illustrations in this document are general in nature and intended for ease of understanding Differences in detail are therefore possible 1 2 Registered trademarks The trademarks of outside companies are used in this document These are marked with the symbol 1 3 Related docume...

Page 36: ... and function of the turbocharger Figure 1 Layout and function of the turbocharger 01 Filter silencer air suction branch 08 Gas outlet flange 02 Compressor casing 09 Nozzle ring 03 Diffuser 10 Turbine casing 04 Bearing casing 11 Turbine end bearing flange 05 Axial thrust bearing 12 Compressor end bearing flange 06 Radial plain bearing 13 Compressor wheel 07 Turbine ...

Page 37: ...ngine cylinders The rotor runs in two radial plain bearings 06 which are located in the bearing casing 04 between compressor and turbine The axial thrust bearing 05 is located between the two radial plain bearings 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 always lies at the deepest point...

Page 38: ...rning plates are not present in the designated locations or not readable proceed as follows Order new warning plates from ABB Turbocharging Service Stations Remove any warning plates that have become unreadable Clean and degrease the areas designated for the warning plates Attach the new warning plates Turbochargers supplied to the enginebuilder without insulation must be fitted later with warning...

Page 39: ...on Page 9 115 Copyright 2015 ABB All rights reserved HZTL4031_EN Revision C February 2016 1 6 Locations of the rating plates Figure 4 Locations of the rating plates One rating plate 01 each is attached on the left and the right side of the turbocharger bearing casing ...

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Page 41: ... installing the turbocharger The following weight specification applies to the heaviest variant possible Depending on the specification the weight specified on the rating plate may be lower than the standard value specified here Product Weights kg A130 190 A135 270 A140 460 A145 750 Table 2 Turbocharger weights Figure 5 Suspension of complete turbocharger unit A Turbocharger with water cooled bear...

Page 42: ...ping nut B Water cooled bearing casing E Standard nut C Position of expansion sleeves Treat the stud 02 and nut with penetrating oil on the thread and let it work in If present Disconnect the plug to the speed sensor 86505 and secure the rolled up cable on the turbocharger This protects the plug from being crushed If present Loosen support 61301 from engine support and remove NOTICE Safeguard agai...

Page 43: ...ing via one of the two bottom openings of the water connections 2 2 1 Fastening of the turbocharger Depending on the type and version the turbocharger can be fastened in different ways The appropriate procedure must be chosen to undo the connection Oil cooled bearing casing A Attach lifting gear to the suspension eye Loosen and remove nuts E Water cooled bearing casing B Loosen and remove water co...

Page 44: ...teps for loosening the pressure screws CAUTION Do not clean pressure screws The pressure screws are equipped with a permanent sliding layer that must not be removed Do neither clean nor lubricate the pressure screws In case of non compliance it cannot be ensured that the necessary tension force is reached Do not clean pressure screws Do not lubricate pressure screws Figure 7 Loosening the clamping...

Page 45: ...rage WARNING Risk of tipping If the turbocharger is not positioned stably it may tip over and cause personal injury Place the turbocharger on a clean level support Secure the turbocharger to prevent it from tipping over by using wooden beams and wedges and by taking the centre of gravity into account Figure 8 Turbocharger centre of gravity 01 Centre of gravity Close or cover the openings of the tu...

Page 46: ... the bracket The gaskets are not included in the ABB Turbo Systems scope of delivery and must be provided by the enginebuilder Figure 9 Inserting gaskets into the bracket 01 Bracket 04 Slot for gasket 02 Oil supply 05 O rings 03 Oil drain 06 Pin optional NOTICE Pin 06 as installation safety device Turbochargers can have an oil inlet either on their right or left side the oil inlet position can be ...

Page 47: ...nts for threaded rods Product Diameter Threaded rod mm Material DIN ISO 898 Part 1 Thread length L1 mm Length of threaded rod Oil cooled L2 mm Water cooled L2 mm A130 Ø 16 M16 10 9 12 9 30 250 250 A135 Ø 20 M20 10 9 12 9 30 270 325 A140 Ø 24 M24 10 9 12 9 70 350 360 410 420 A145 Ø 30 M30 10 9 12 9 80 415 425 Table 3 Requirements for threaded rods Fixing material scope of delivery The threaded rods...

Page 48: ...ontact surfaces of the expansion bushes 42190 in the bearing casing 3 Clean the expansion bushes 42190 4 Attach the lifting gear to the suspension eye of the bearing casing A B and loop around the gas outlet casing 5 Position the turbocharger on the bracket 04 and align it Pay attention to the positioning pins 05 in the bracket 6 When fixing with a standard nut D fit expansion bushes 42190 in the ...

Page 49: ...19 A130 A140 Fastening the turbocharger with a clamping nut 20 A140 and A145 2 3 4 Fastening the turbocharger with a standard nut Fit the nuts and tighten them according to variant 1 or 2 in the table below When the turbocharger is mounted on the engine support the bolt threads and screw heads must be lightly oiled assumed friction coefficient µ 0 12 for tightening torque Product Through hole in b...

Page 50: ...ured that the necessary tension force is reached Do not clean pressure screws Do not lubricate pressure screws NOTICE Pressure screws 04 must not protrude from the clamping nut 03 in the direction of the thrust washer 02 In order to correctly fit the clamping nut the pressure screws must not protrude in the direction of the thrust washer Figure 13 Preparing the clamping nut for the tightening proc...

Page 51: ...4 35 A145 M30 45 Table 5 Pressure screw tightening torques 1 Screw in pressure screws crosswise by hand until reaching the stop 2 Tighten pressure screws crosswise to 50 of the tightening torque specified in the table 3 Tighten pressure screws crosswise to 100 of tightening torque specified in table 4 Work in a circle to tighten all pressure screws to 100 of the tightening torque specified in the ...

Page 52: ...t the water pipes according to the enginebuilder s instructions Version with compressor wheel cooling CAUTION Failure of compressor wheel cooling Any prolonged failure of the compressor wheel cooling will shorten the replacement interval of the compressor wheel Make sure there is an uninterrupted supply of cooling air during operation Figure 15 Connecting the compressor cooling air intake Remove t...

Page 53: ...ebuilder s specifications on the selection of the lubricating oil and the oil change intervals 3 1 2 Pre lubrication Pre lubrication must be carried out as follows Switch on the oil pump Build up oil pressure see Table 6 Do not exceed a pre lubrication time of 2 minutes Start the engine Let the oil pump run until the pump driven by the engine generates sufficient pressure 3 1 3 Oil filtering Lubri...

Page 54: ...ved HZTL4031_EN Revision C February 2016 3 1 5 Oil orifice in the bearing casing Figure 17 Oil orifice 01 Bearing casing 02 Oil orifice 03 Circlip With an oil inlet pressure of more than 3 bar when engine under load before the turbocharger the bearing casings are equipped as standard with an orifice at the oil inlet ...

Page 55: ...e or property can be caused by dirt and solid material particles in the oil At initial commissioning and after all service work the complete lubricating system must be thoroughly flushed with warm oil Use special running in filters when running in the engine and after all service work on the lubricating system Check that the oil filter is clean before commissioning Check the oil pressure in the oi...

Page 56: ...inlet Keep to the lubricating oil temperature at the inlet Refer to chapter Monitoring operation 29 for admissible values Tightness of pipes Check all the pipes for tightness 3 2 4 Checks when starting up the engine Measure speed oil pressure and charging pressure at various engine performances Measure the exhaust gas temperature before and after the turbine Measure the air temperature before and ...

Page 57: ...ipe Version with compressor wheel cooling Remove the screw plug on the cooling air connection and fit the cooling air line General Check the exhaust gas pipe before and after the turbine for combustion residues or water residues and clean it Remove any foreign objects that may be present Check and clean filter silencer or air supply line and remove any foreign objects that may be present Put engin...

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Page 59: ... signal Stop the engine after 1 minute at the latest 0 6 Table 6 Lubricating oil pressure oil inlet 01 Turbocharger contact surface 02 Oil inlet 03 Oil outlet M Oil pressure measuring point T Oil temperature measuring point For monitoring the lubricating oil pressure ABB Turbo Systems recommends installing an M manometer immediately before the turbocharger If the pressure is controlled electronica...

Page 60: ... the outlet The oil temperature at the outlet is mainly dependant on Lubricating oil temperature and pressure at the oil inlet Engine load and turbocharger speed Exhaust gas temperature The maximum admissible oil temperature at the outlet is listed in the following table The specified oil outlet temperature is to be considered as alarm value for the turbocharger operation and must be monitored acc...

Page 61: ...lacement intervals Operation above the operating limits defined on the rating plate can shorten the recommended replacement intervals considerably Measure exhaust gas temperature upstream of turbine Comply with operating limits on rating plate Definition and explanations concerning rating plate refer to chapter 2 of Operation Manual Safety Operating limits refer to chapter 3 of Operation Manual Sa...

Page 62: ...ger speed CAUTION Do not use cable as climbing aid Contacts can be ripped out by pulling strongly on the speed measurement cables Do not strain the speed measurement cable by pulling 4 3 2 Layout and overview Figure 18 Layout and overview of speed measurement system 86505 Speed sensor 42188 Screw plug 86515 Cable connector 42189 Gasket 86526 F I converter 01 Plug with integrated voltage limiter 86...

Page 63: ...rgers does not exceed 70 of nBmax If the engine cannot be stopped it can continue to be driven at this reduced engine load or turbocharger speed If a turbocharger surges continuously the engine performance must be reduced further Measure the temperatures in the air lines and exhaust gas pipes from and to the turbochargers and compare with normal values Check the pressure loss of the alternative ai...

Page 64: ...an additional O ring and does not need an additional gasket for assembly Figure 19 Replacing the speed sensor Part number A130 A135 A140 A145 86505 M12 x 1 5 15 Nm M12 x 1 5 15 Nm M12 x 1 5 15 Nm M12 x 1 5 15 Nm Table 9 Tightening torque 86505 Reduce the engine performance to idling and then stop the engine Pay attention to post lubrication Stopping the engine 43 Switch off the lubricating oil sup...

Page 65: ...d is measured at a distance of 1 meter from the turbocharger The highest value of the emission sound pressure level1 reaches a maximum of 105 dB A near the filter silencer The following prerequisites must be fulfilled with regard to the turbocharger to observe this limit value Air inlet system has been fitted All standard noise reducing measures2 have been fitted Bellows at the air outlet has been...

Page 66: ...yright 2015 ABB All rights reserved HZTL4031_EN Revision C February 2016 Suggestion for noise insulation bellows Figure 20 Noise insulation bellows 01 Compressor casing 02 Bellows 03 Charge air duct scavenging air duct 04 Insulation cushion 05 Insulation mat at least 15 mm 06 Sheet metal cover ...

Page 67: ...ted or performed too late can cause excessive contamination wear and operating failures Carry out the service work at the specified time intervals CAUTION Shortened service intervals Exceptional stresses such as several starts stops per day harsh environmental conditions poor fuel quality or high system vibrations can lead to untimely machine damage even if the prescribed service intervals are obs...

Page 68: ...hours after commissioning Clean or replace the oil filter located in the supply pipe to the turbocharger while the engine is stopped 5 2 3 Service work according to instructions of enginebuilder Clean or replace the oil filter located in the supply pipe to the turbocharger while the engine is stopped 5 2 4 Service work according to data on the rating plate Usually after 8000 12000 operating hours ...

Page 69: ...t 2015 ABB All rights reserved HZTL4031_EN Revision C February 2016 5 2 5 Other service work If a protective grid is installed in the gas outlet casing 61001 by ABB Turbo Systems Figure 21 Replacing the protective grid Remove the protective grid 61205 after 50000 hours and replace it with a new one ...

Page 70: ...ocharger The following operating data and measured values must be entered regularly in the engine logbook of the enginebuilder Rating and speed of the engine Air intake temperature Pressure of the charge air Pressure loss in the charge air cooler Lubricating oil pressure and lubricating oil temperature If present Speed of the turbocharger Air temperature after the compressor and after the charge a...

Page 71: ...ing the bearing parts and replacing the non rotating components exposed to hot gas A decisive role is played by various influencing parameters which in extreme cases can drastically shorten the replacement interval of these parts During the prescribed periodic service work the individual parts are examined for wear and replaced if necessary Expected replacement intervals h GAS MDO HFO Turbine casi...

Page 72: ...the following influences Fuel quality and fuel treatment Load profile thermal cycling also number of starts stops emergency shutdowns operating point Gas inlet temperature Frequency and execution of turbine and compressor cleaning Turbocharger specification System specific operating conditions combustion quality exhaust gas composition For bearing parts Lubricating oil quality oil filtering oil co...

Page 73: ...ed for engine idling see Table 6 Post lubricate water cooled bearing casings until the rotors come to a standstill Deactivate post lubrication as soon as the rotor comes to a standstill Deviating procedures must be coordinated with ABB Turbo Systems For oil cooled bearing casings post lubricate for 20 minutes if the turbine inlet temperature tTE exceeds the following values when the engine is stop...

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Page 75: ... the engine to be kept low while ensuring maximum fuel efficiency Maintenance interval Maintenance work Operating status 24 72 h 1 Cleaning the compressor during operation 46 Engine load 50 85 50 200 h 1 Cleaning the turbine during operation 50 Engine load 20 40 guideline value Similar to the service interval usually every 8000 12000 h 2 Cleaning components mechanically 54 Engine stopped Table 11 ...

Page 76: ...ems recommends having the contaminated components cleaned mechanically by an ABB Turbocharging Service Station Periodic cleaning in operation is no replacement for service work in which an ABB Turbocharging Service Station completely dismantles and maintains the turbocharger Causes and results of contamination Contamination of the compressor stage depends on the degree of purity of the sucked in a...

Page 77: ...operating periods in the lower range of performance that both turbocharger compressors are cleaned 6 2 4 Function and safety of wet cleaning CAUTION Volume of water Uncontrolled volumes of water can damage the turbocharger and the engine Never connect injection tubes directly to a water pipe or a larger metering container other than that specified by ABB Turbo Systems WARNING Danger due to pressur...

Page 78: ...o filter silencer or air suction branch 02 Pressurized air inlet pipe 03 Valve activator Pressurized air from the compressor casing 72000 of the turbocharger passes through the pipe 02 to the water pressure vessel 27000 As soon as the valve activator 03 is activated water is pressed into the pipe 01 and routed to the filter silencer or air suction branch The water does not act as a solvent The coa...

Page 79: ...in Push the valve activator 03 against the spring and hold for 10 15 seconds until the entire volume of water is injected Continue to operate the engine for at least five minutes to ensure that all of the water is flushed out of the system The process can be repeated up to two times Before repeating the process continue to operate the engine for at least five minutes to ensure that all of the wate...

Page 80: ... in operation is no replacement for service work in which an ABB Turbocharging Service Station completely dismantles and maintains the turbocharger Cause and consequences of contamination ABB Turbo Systems recommends the use of fuels with low ash sulphur sodium and vanadium contents The combustion of heavy fuel oil HFO in diesel engines causes contamination of the turbine stage Poor quality fuel i...

Page 81: ...eaning process with multiple short injection periods A turbine cleaning procedure with multiple short injection periods is recommended only under certain circumstances If such a procedure is to be used this must be coordinated with ABB Turbo Systems Contact ABB Turbo Systems CAUTION Corrosion and deposits when cleaning Salt water and cooling water treatment substances damage and adversely affect t...

Page 82: ...s temperature after the cylinder This must be taken into account when setting the operating point before cleaning If necessary the engine performance must be reduced to meet these conditions The cleaning cycle can be started when the above conditions are fulfilled 6 3 6 Carrying out wet cleaning of the turbine CAUTION Inadmissible thermal stress and flooding of the turbine Smaller amounts of water...

Page 83: ...op valve 02 after 10 minutes Wait for 10 minutes do not change the load during this stabilisation phase If the cleaning result is unsatisfactory or there is water leakage contact an ABB Turbocharging Service Station Product Temperature before turbine before cleaning C Maximum temperature before turbine during cleaning C Water volume flow VW dm3 min 1 Injection time min A130 350 430 530 4 0 10 A135...

Page 84: ...d easily sustain mechanical damage The use of needle descalers for example or other striking tools damages the components Depending on the specification nozzle rings or turbine casings may have protective coatings which can also be damaged Use only soft tools such as rags brushes or wire brushes In case of heavy contamination the cleaning methods described in this chapter such as soaking for examp...

Page 85: ...ncer is described in chapter Disassembly and assembly Cleaning the filter ring if present Remove filter ring 81265 Clean filter ring 81265 as required or every 500 hours of operation and replace after the fifth cleaning process at the latest Contamination of the filter ring depends on the degree of purity of the sucked in air Rinse the filter ring 81265 with water and mild detergent or in the case...

Page 86: ...ion segments 81136 must only be cleaned lightly with compressed air a soft brush or a moist cleaning cloth Have any heavily contaminated absorption segments replaced by an ABB Turbocharging Service Station Fitting the filter silencer see Figure 24 Insert the absorption segments 81136 into the sheet metal coverings 81137 Bend the sheet metal coverings 81137 back to their original shape and insert i...

Page 87: ...lies Comply with local legislation Wear safety goggles Wear safety gloves against mechanical risks Wear a respiratory mask to protect against gases The following parts which are relevant in terms of performance can be cleaned in accordance with the description below Figure 25 Compressor end non rotating parts 72000 Compressor casing 77000 Wall insert 79000 Diffuser Steam clean the above mentioned ...

Page 88: ...risks Wear a respiratory mask to protect against gases Baked layers of contamination for example from heavy fuel oil or coked oil occur at the turbine end The following parts which are relevant in terms of performance can be cleaned in accordance with the description below Figure 26 Turbine end non rotating parts 51000 Turbine casing 56001 Nozzle ring 57002 Gas outlet flange 56005 Lamellar sealing...

Page 89: ...y after cleaning install the cartridge group and put it back into operation There can be severe contamination of the compressor wheels due to badly filtered suction air and of the turbines because of heavy fuel oil operation or carbonized oil Cleaning during operation may not suffice to remove such contamination instead it may need to be cleaned mechanically during standard service intervals see c...

Page 90: ...ntamination penetrates the cartridge group this can impair the function of the turbocharger and damage parts inside the cartridge group Make sure that no water or contamination can enter into the cartridge group Clean the compressor wheel with a rag or soft brush which has been soaked in water with a household cleaning agent Do not use wire brushes Dry the compressor wheel and the gap between the ...

Page 91: ...l as for cleaning the turbine are described in the following Figure 27 Soaking the turbine end Product A mm B mm C mm A130 108 17 205 A135 128 20 245 A140 157 25 300 A145 187 30 357 Table 15 Value table for soaking To soak the layers of dirt on the turbine the cartridge group can be immersed vertically in a container 02 with fluid Set the container 02 inside a larger container 03 so that the overf...

Page 92: ...idge group this can impair the function of the turbocharger and damage parts inside the cartridge group Place the cartridge group on suitable supports 01 made of wood or metal Observe value B for the supports 01 so that the cartridge group is not immersed too deeply Let the layers of dirt on the turbine soak for four hours Removing dirt WARNING Health hazard due to soot particles If soot particles...

Page 93: ...deposits lead to rotor unbalance This can result in bearing or turbocharger damage Remove all traces of contamination from the turbine After brushing off the dirt fill the container 02 with clean water and not with salt water Immerse the turbine of the cartridge group in clean water so that any loose dirt comes off Lift up the cartridge group and align it horizontally Clamp the partition wall to t...

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Page 95: ...t enginebuilder Turbocharger Rotor unbalance Contact ABB Turbocharging Service Station Turbine or compressor damaged Bearing damaged Table 17 Malfunctions when starting Vibrations Rubbing of rotating parts Normal behaviour not a malfunction Turbocharger A minimal and uniform wear at the circumference of the rotor components caused by slight local rubbing against adjacent components is permitted Th...

Page 96: ...nometer displays incorrectly Replace manometer Turbocharger Axial clearance of the rotor excessive Contact ABB Turbocharging Service Station Table 19 Malfunctions during operation Lubricating oil pressure too low Speed reduces Possible causes Remedy Engine Defect on the connected cylinders in pulse charging Contact enginebuilder Turbocharger Turbine and or nozzle ring severely contaminated Clean s...

Page 97: ...ater too high Check clean cooling system Insufficient ventilation Improve ventilation Table 22 Malfunctions during operation Exhaust gas temperature too high 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 turbine not sealed Injection mistimed Set correctly ...

Page 98: ...severely contaminated or corroded compressor wheel can reduce the compressor wheel s fatigue endurance limit and result in the turbocharger being damaged Rectify malfunction in accordance with the following table Possible causes Remedy Turbocharger Compressor components severely contaminated by the ventilation gases that have been fed in Clean see chapter Periodic maintenance work 45 Optimize oil ...

Page 99: ...ause clarified and remedied immediately by an ABB Turbocharging Service Station Have parts assessed for damage and if necessary replaced by an ABB Turbocharging Service Station Possible causes Remedy Engine Protective grating in front of the turbocharger contaminated or damaged Clean replace Turbocharger Filter silencer or diffuser contaminated Clean see chapter Periodic maintenance work 45 Heavy ...

Page 100: ...le 28 Malfunctions when stopping Runout noises Runout time too short The runout time must be noted down as a reference Because the runout time depends on the oil viscosity the runout time must always be measured at the same oil temperature If the runout time is significantly shorter in comparison to a previous measurement the following table must be observed Possible causes Remedy Turbocharger Tur...

Page 101: ...re parts 109 Replacing the speed sensor 34 Table 30 Malfunction of the speed measurement system No signal or poor signal amplitude Measured speed too high Possible causes Remedy Turbocharger Sensor tip contaminated since it is magnetic and can attract metallic particles This reduces the distance to the signal emitting sealing disc which can lead to amplification of the noise component and hence to...

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Page 103: ...e carrying out any work Wear safety gloves against thermal risks WARNING Cutting injuries when working on the turbocharger Some parts on the turbocharger may have sharp edges There is a risk of a cutting injury Wear safety gloves against mechanical risks when conducting assembly and disassembly work Wear safety gloves against mechanical risks CAUTION Further operations This Operation Manual may be...

Page 104: ...d assembly devices must no longer be used and must be replaced Customer spare part set Before starting operations make sure the required customer spare part sets are available See chapter Spare parts 109 Oil orifice When disassembling the turbocharger an oil orifice fitted in the oil inlet must not be removed see also chapter Removing the cartridge group 83 Tightening torques for components of the...

Page 105: ...oint Defined loading point on a component or an assembly blind hole thread eyelet lug Assembly device Devices that are fitted on the turbocharger in order to obtain a suspension point Assembly devices are specially constructed and designed for the defined use they are not trading goods Use assembly devices only for the described applications Lifting gear Equipment for the lifting and transporting ...

Page 106: ...rights reserved HZTL4031_EN Revision C February 2016 Two ring nuts are required for safer lifting of the cartridge group which are not included in the ABB Turbo Systems scope of delivery Ring nuts to be used VRM Product Thread Starpoint ring nut VRM A130 M16 A135 M16 A140 M16 A145 M16 Table 34 Ring nuts to be used ...

Page 107: ...on A130 kg A135 kg A140 kg A145 kg 01 Filter silencer 19 30 40 65 02 Radial air suction branch 6 8 13 21 03 Axial air suction branch 4 5 6 9 04 Compressor casing 24 40 60 95 05 Wall insert 6 8 15 24 06 Diffuser 3 4 7 11 07 Cartridge group 40 60 110 180 08 Nozzle ring 2 2 4 6 09 Burst ring 2 3 5 12 10 Turbine casing 1 inlet 45 65 120 190 Turbine casing 2 inlets 40 60 120 180 Turbine casing 3 inlets...

Page 108: ...Removing air inlets NOTICE Marking casing position for assembly ABB Turbo Systems recommends marking the casing positions prior to disassembly Figure 29 Removing the air inlets 1 Loop around the filter silencer 81000 with lifting gear 2 Loosen the V clamp 72020 3 Remove the filter silencer 81000 with the O ring 81010 or the air suction branch 82000 with the O ring 82010 ...

Page 109: ...ruary 2016 8 4 Removing the gas outlet casing NOTICE Marking casing position for assembly ABB Turbo Systems recommends marking the casing positions prior to disassembly Figure 30 Removing the gas outlet casing 1 Loosen and remove nuts 51009 2 If present Loosen the support 61301 from the bracket 3 Remove the gas outlet casing 61001 4 Remove the gasket 61002 ...

Page 110: ... position for assembly ABB Turbo Systems recommends marking the casing positions prior to disassembly Figure 31 Removing the gas outlet flange Product Press off screws to be used strength 8 8 A130 6x M6 A135 6x M8 A140 6x M10 A145 6x M12 Table 36 Gas outlet flange press off screws Not included in the ABB Turbo Systems scope of delivery 1 Press off and remove the gas outlet flange 57002 with screws...

Page 111: ...e compressor casing with press off tool If the compressor casing cannot be loosened it can be pressed off against the turbine casing with the press off tool 90042 see chapter Pressing off the casing 82 Figure 32 Removing the compressor casing 1 Loosen screws 72011 and remove together with fastening strips 72012 2 Attach swivel lifting eye 01 to the compressor casing and the lifting gear 3 Remove t...

Page 112: ...g 72000 with a nylon hammer 2 Attach swivel lifting eyes 01 to compressor casing 72000 and lifting gear 3 Lift up the compressor casing 72000 4 Remove O ring 77005 8 7 Pressing off the casing CAUTION Axial force of the press off tool Using the press off tool 90042 a high level of axial force can be generated If the casing is pressed off with too much force on one side the rotor can be damaged Use ...

Page 113: ...on for assembly ABB Turbo Systems recommends marking the casing positions prior to disassembly 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 If an oil orifice is fitted in the oil ...

Page 114: ...ssing off the casing 82 Figure 36 Removing cartridge group 1 1 Treat threads of studs 51006 with penetrating oil and leave to take effect 2 Loosen nuts 51007 and remove Verbus Ripp washers 51003 together with the fastening strips 51002 Figure 37 Removing cartridge group 2 3 Insert screws from service support into cartridge group 4 Secure ring nuts VRM onto the screws with washers 5 Secure the lift...

Page 115: ...ZTL4031_EN Revision C February 2016 8 9 Removing the nozzle ring Figure 38 Removing the nozzle ring 1 Place the fastening strips 51002 under the nozzle ring 2 Pull out the nozzle ring 56001 with the two extraction devices 90070 and the service support base 90012 3 Remove the lamellar sealing ring 56005 4 Remove the burst ring 57210 ...

Page 116: ... C February 2016 8 10 Rotating and fixing the cartridge group Figure 39 Rotating and fixing the cartridge group 1 Remove the lifting gear from the ring nuts 2 Remove the ring nuts VRM and screws from the service support 3 Insert the service support 90012 into the cartridge group 4 Fit the nuts 5 Rotate the cartridge group on the service support 90012 ...

Page 117: ...before the installation of the cartridge group Attach the dial indicator and align it for the respective clearance as per the illustration Figure 40 Measuring clearance A and B Product A mm B mm A130 0 08 0 16 0 47 1 00 A135 0 10 0 18 0 58 1 16 A140 0 12 0 21 0 70 1 37 A145 0 15 0 25 0 88 1 56 Table 37 Permissible clearances A and B 1 Move the rotor to and fro up to the stop For an accurate measur...

Page 118: ... the heat shield 42400 and the turbine casing 51000 Figure 41 Nozzle ring compression PD Product Compression PD mm A130 0 15 0 15 A135 0 16 0 16 A140 0 16 0 16 A145 0 16 0 16 Table 38 Permitted nozzle ring compression PD 42001 Bearing casing 51000 Turbine casing 42400 Heat shield 56001 Nozzle ring 1 Measure dimensions A B and S on cleaned surfaces 2 Calculate compression PD If the calculated value...

Page 119: ...g 1 Fit the lamellar sealing ring 56005 and secure it with adhesive tape 01 When doing this pay attention to correct winding of the lamellar sealing ring see detail A 2 Insert the nozzle ring into the turbine casing with the cams facing downwards Align the cams on the nozzle ring with the recesses of the turbine casing 51000 3 Insert the nozzle ring 56001 into the turbine casing up to the stop Do ...

Page 120: ...up by 90 removing the support 1 Rotate the service support 90012 on a soft underlay with the cartridge group 2 Loosen and remove nuts 3 Pull the service support 90012 out of the cartridge group Attach lifting gear to the cartridge group Figure 44 Attach lifting gear to the cartridge group 1 Insert screws from service support into cartridge group 2 Secure ring nuts VRM onto the screws with washers ...

Page 121: ... number A130 A135 A140 A145 51007 M8 25 Nm M10 45 Nm M12 75 Nm M12 75 Nm Table 39 Tightening torque 51007 1 Coat the threads of the studs 51006 with high temperature grease 2 Align the casing position of the cartridge group with the marking 3 Lower the cartridge group into the turbine casing 4 Remove ring nuts and screws 5 Install the fastening strips 51002 with Verbus Ripp discs 51003 and hexagon...

Page 122: ...moved A burst protection is integrated in this turbine casing insulation supplied by ABB Turbo Systems For turbochargers which were ordered from ABB Turbo Systems without insulation or which are equipped with the insulation 02 a separate burst protection 03 is fitted If the insulation from ABB Turbo Systems 01 is not installed the separate burst protection 03 plus either the insulation 02 or an ap...

Page 123: ...Nm M6 8 Nm Table 40 Tightening torque 79041 Always replace the O ring 77005 see section Spare parts A130 A140 1 Fit a new O ring 77005 2 Install the wall insert 77000 in the compressor casing 3 Secure the diffuser 79000 with fixing discs 79040 and screws 79041 A145 1 Attach the lifting beam 90258 to the wall insert 77000 2 Attach swivel lifting eyes 01 to lifting beam 3 Fit a new O ring 77005 4 In...

Page 124: ...he compressor casing Part number A130 A135 A140 A145 72011 M8 35 Nm M10 70 Nm M12 105 Nm M12 105 Nm Table 41 Tightening torque 72011 Always replace the O ring 42012 see chapter Spare parts 1 Thoroughly clean the fastening strips 72012 before assembly 2 Attach swivel lifting eyes 01 to the compressor casing 72000 and lifting gear 3 Install the compressor casing 72000 4 Install the fastening strips ...

Page 125: ...ure 48 Measuring clearances N and R Product N mm R mm A130 0 26 0 60 0 45 0 70 A135 0 34 0 70 0 51 0 85 A140 0 45 0 90 0 64 1 00 A145 0 56 0 95 0 76 1 20 Table 42 Permissible clearances N and R 1 Push the feeler gauges 01 into the gap such that there is no clearance The upper direction N1 and lower direction N2 must be covered simultaneously 2 Calculate clearance N and compare it with the permissi...

Page 126: ...talling air inlets Figure 49 Installing the air inlets Part number A130 A135 A140 A145 72020 M12 60 Nm M12 60 Nm M12 60 Nm M12 60 Nm Table 43 Tightening torque 72020 1 Loop around the filter silencer 81000 with lifting gear 2 Fit the filter silencer 81000 with the O ring 81010 or the air suction branch 82000 with the O ring 82010 and V clamp 72020 3 Tighten the V clamp 72020 ...

Page 127: ...tlet flange 57002 in the turbine casing 3 Measure radial clearance R see chapter Radial clearances N and R 8 19 Installing the gas outlet casing Figure 51 Installing the gas outlet casing Part number A130 A135 A140 A145 51009 M8 20 Nm M10 40 Nm M12 65 Nm M12 65 Nm Table 44 Tightening torque 51009 1 Insert a new gasket 61002 into the gas outlet casing 61001 2 Attach the lifting gear to the gas outl...

Page 128: ...signated screw fittings Position Part number A130 A135 A140 A145 02 72020 M12 60 Nm M12 60 Nm M12 60 Nm M12 60 Nm 04 79041 M6 8 Nm M6 8 Nm M6 8 Nm M6 8 Nm 08 51007 M8 25 Nm M10 45 Nm M12 75 Nm M12 75 Nm 09 51009 M8 20 Nm M10 40 Nm M12 65 Nm M12 65 Nm 11 72011 M8 35 Nm M10 70 Nm M12 105 Nm M12 105 Nm 15 86505 M12 x 1 5 15 Nm M12 x 1 5 15 Nm M12 x 1 5 15 Nm M12 x 1 5 15 Nm 16 51101 51103 51104 61201...

Page 129: ...ure 53 Tightening torques for insulation The following tightening torques must be observed for the designated screw fittings Position Part number A130 A135 A140 A145 16 M10 40 Nm M10 40 Nm M12 65 Nm M12 65 Nm 18 M6 10 Nm M6 10 Nm M6 10 Nm M6 10 Nm 19 M8 25 Nm M8 25 Nm M8 25 Nm M8 25 Nm 20 M10 45 Nm M10 45 Nm M10 45 Nm M10 45 Nm Table 46 Tightening torques for insulation ...

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Page 131: ...entally compatible manner Wear safety gloves against thermal risks CAUTION Directives for taking out of operation Serious damage to engine or property can be caused by non compliance with the directives for blanking the turbocharger off the engine Follow the directives of the enginebuilder If the engine has to be operated again as quickly as possible following a turbocharger defect then the follow...

Page 132: ...correct handling of a cartridge group can damage the turbocharger and cause injuries to persons Have repairs to the cartridge group carried out by an ABB Turbocharging Service Station only NOTICE Quick recommissioning In order to quickly put an engine back into operation after a turbocharger has sustained damage ABB Turbo Systems recommends having a replacement cartridge group available in storage...

Page 133: ...owing section Gas outlet casing not removed Fit the turbine casing into the gas pipe and on the gas outlet casing again Attach the cover plate see following section Figure 54 Fitting the cover plate Make sure that the oil connections in the bracket are equipped with gaskets 1 Close opening in turbine casing 51000 with cover plate 01 2 Thoroughly clean the fastening strips 51002 before assembly 3 C...

Page 134: ...y and must be manufactured by the operating company according to the following drawing Material General structural steel in compliance with DIN EN 10025 2 Figure 55 Cover plate drawing Product B1 0 5 B2 B3 B4 0 2 B5 B6 B7 ØD1 0 2 ØD2 R1 M A130 65 7 60 130 11 7 1 4 150 35 7 227 7 17 105 M8 A135 79 6 80 155 14 2 1 6 180 39 6 271 7 21 125 M8 A140 98 2 102 190 17 2 2 0 220 48 2 332 5 25 153 M10 A145 1...

Page 135: ...andling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or contact with them may be harmful to health Do not breathe in these substances and avoid contact with the skin Ensure proper ventilation Observe the information in the material safety data sheet for the operating materials and supplies Comply with local legislation Wear safety goggles Wear...

Page 136: ...etely removed either as a whole unit or in individual parts For the measures always necessary for preparing the turbocharger parts for mothballing see section Taking out of operation for up to 12 months subsection Preparations for mothballing If the turbocharger remains attached to the engine see section Taking out of operation for up to 12 months subsection Rotation of the rotor in the stack drau...

Page 137: ...ther Wear safety goggles Wear a respiratory mask to protect against particles Wear safety gloves against mechanical risks Disposal must be environmentally compatible professional and in compliance with locally applicable regulations The turbocharger consists largely of metal cast iron materials steel nickel steel alloys aluminium and bearing brass Further components are Non metallic materials filt...

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Page 139: ...iants are not taken into account in this document contact an ABB Turbocharging Service Station Dispose of placed and unusable parts in an environmentally friendly and professional manner in accordance with the local regulations Dispose of the packaging of new parts in an environmentally friendly and professional manner in accordance with the local regulations 12 2 Required customer spare part set ...

Page 140: ...4 Product description A130 M A145 M 12 Spare parts Page 110 115 Copyright 2015 ABB All rights reserved HZTL4031_EN Revision C February 2016 12 3 View of turbocharger with part numbers Figure 56 Overview of part numbers ...

Page 141: ...ring 57210 Burst ring 61001 Gas outlet casing 61002 in the customer spare part set Gasket 61200 Burst protection 61205 Protective grid 61301 Support 72000 Compressor casing 72011 Hexagon head screw 72012 Fastening strip 72020 V clamp 77000 Wall insert 77005 in the customer spare part set O ring 79000 Diffuser 79041 in the customer spare part set Counter sunk screw 81000 Filter silencer 81010 in th...

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Page 143: ...rbines 53 Fig 24 Cleaning the filter silencer 55 Fig 25 Compressor end non rotating parts 57 Fig 26 Turbine end non rotating parts 58 Fig 27 Soaking the turbine end 61 Fig 28 Weights of assemblies 77 Fig 29 Removing the air inlets 78 Fig 30 Removing the gas outlet casing 79 Fig 31 Removing the gas outlet flange 80 Fig 32 Removing the compressor casing 81 Fig 33 Dismantling the wall insert 82 Fig 3...

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Page 145: ...ns during operation Exhaust gas temperature too high 67 Table 23 Malfunctions during operation Charge air pressure too low 67 Table 24 Malfunctions during operation Charge air pressure too high 68 Table 25 Malfunctions during operation Engine performance losses 68 Table 26 Malfunction Turbocharger pumping 69 Table 27 Malfunction Sporadic surge blows 69 Table 28 Malfunctions when stopping Runout no...

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