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Operation Manual / 2 Safety / A100-M axial

Table of contents

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HZTL4023_EN

Revision C

January 2017

Safety

Safety.....................................................................................................

1.1

Introduction ................................................................................................

1.2

CE conformity ............................................................................................

1.3

Definition of mandatory signs .....................................................................

1.4

Definition of safety instructions ...................................................................

1.5

Intended use ..............................................................................................

1.6

Deflagration on gas engines ......................................................................

1.7

Warning plates on the turbocharger ...........................................................

1.8

Turbocharger rating plate ...........................................................................

1.9

Periodic check of the pressure vessels ......................................................

1.10

Lifting of loads ............................................................................................ 10

1.11

Prerequisites for operation and maintenance ............................................. 11

1.12

Hazards during operation and maintenance ............................................... 12

1.13

Safe operation ........................................................................................... 14

1.14

Safe maintenance ...................................................................................... 15

Summary of Contents for HT568964

Page 1: ...arging Operation Manual A175 M66 HT568964 English Original Operation Manual Chapter Document ID 1 Introduction HZTL4005_EN_E 2 Safety HZTL4023_EN_C 3 Safety data sheet HT568964 4 Product description HZTL4033_EN_A ...

Page 2: ...als and the corresponding operating limits in chapter 3 are jointly defined with the enginebuilder This information is specific to the product Non observance of the recommended replacement intervals and the operating limits increases the risk of unpre dictable component failures ...

Page 3: ...ents Page 1 8 Copyright 2016 ABB All rights reserved HZTL4005_EN Revision E July 2016 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: ...plains the turbocharger 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 connected to it A...

Page 6: ...rk 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 Turbo Sy...

Page 7: ...eaning 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 wa...

Page 8: ...of the Ordinance on Hazardous Substances Nevertheless the following points must be observed when handling VCI Observe the information in the material safety data sheet Ensure proper space ventilation Do not eat drink or store food at the workplace while working with VCI Clean hands and face after working with VCI For more information see www branopac com Wear safety gloves to protect against mecha...

Page 9: ...y an ABB Turbocharging Service Station Check the package for damage If the package is damaged the turbocharger or cartridge group must be checked and repackaged by an ABB Turbocharging Service Station After every 3 years the following steps must be carried out by an ABB Turbocharging Service Station Checking the component Replacing the desiccant Repackaging the component NOTICE Replacement compone...

Page 10: ...hts reserved HZTL4005_EN Revision E July 2016 1 4 Contact information Contact information of the ABB Turbocharging Service Stations is available online Scan the QR code to access our website ABB Turbo Systems Ltd Bruggerstrasse 71a CH 5401 Baden Switzerland www abb com turbocharging ...

Page 11: ...tion of mandatory signs 4 1 4 Definition of safety instructions 4 1 5 Intended use 5 1 6 Deflagration on gas engines 6 1 7 Warning plates on the turbocharger 7 1 8 Turbocharger rating plate 8 1 9 Periodic check of the pressure vessels 9 1 10 Lifting of loads 10 1 11 Prerequisites for operation and maintenance 11 1 12 Hazards during operation and maintenance 12 1 13 Safe operation 14 1 14 Safe main...

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Page 13: ...equence of insufficient compliance with safety instructions Are a consequence of insufficient or inappropriate performance of maintenance and in spection work The operating company is responsible for defining measures that regulate safe access to and safe handling of the turbocharger All instructions contained in this chapter must be observed for safe and trouble free operation of the turbocharger...

Page 14: ... 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...

Page 15: ... 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 accepts no liability and rejects all warranty claims for any non intended uses 1 Euromot The European Association of Internal Combustion Engine Manufacturers 2 Directive 94 9 EC concerning equipment...

Page 16: ...o charger or improper operation 1 6 Deflagration on gas engines ABB turbochargers can tolerate a deflagration with a transient pressure increase of 12 bar After a deflagration event ABB Turbo Systems recommends verifying the following points on the turbocharger Position of the turbine and compressor casings to the bearing casing Shifting of the bearing casing in relation to the bracket Cracks in c...

Page 17: ...ys be present in the intended locations and must be legible Figure 1 Warning plate If warning plates are not present in the intended locations or are not legible they must be re placed with new warning plates The necessary information can be found in the Operation Manual Chapter 4 Product description Turbochargers supplied to the enginebuilder without insulation must be equipped later with warning...

Page 18: ...erwise agreed with the en ginebuilder 02 Turbocharger operating limits during operation Recommended replacement intervals of turbocharger components 03 Replacement 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 ...

Page 19: ...Mmax is not permitted Non observance of the recommended replacement intervals increases the risk of unpredicta ble component failures Locations of the rating plates The locations of the rating plates are defined in the Operation Manual Chapter 4 Product de scription 1 9 Periodic check of the pressure vessels The pressure vessels used by ABB Turbocharging such as those for wet or dry cleaning are s...

Page 20: ...ct against mechanical hazards Wear safety helmet Figure 3 Attachment of loads 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 des...

Page 21: ...itable working materials and personal protective equipment must be kept in a perfect 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 ...

Page 22: ...ing always wear ear protection Always wear ear protection if the sound pressure level 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 Dang...

Page 23: ...to protect against thermal hazards Hazards due to rotating parts WARNING Physical 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 unin...

Page 24: ... electrical installations Do not carry out any tests with regard to insulation 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 sta...

Page 25: ...hich you have received instruction or train ing Wear safety footwear to protect against 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 ...

Page 26: ...k Safety during disassembly assembly maintenance and repair Observe the procedures 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 engin...

Page 27: ...u have previously received instruc tion or training Hazards due to operating 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 sup...

Page 28: ...mation in the material safety data sheet for the operating materials and supplies 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 co...

Page 29: ...Operation Manual A175 M66 Safety data sheet Page 1 1 Safety data sheet Copyright 2017 ABB All rights reserved HT568964 May 2017 A175 M66 HT568964 A175 M66 HT568964 316 650 302 620 4600 36 50 50 2017 ...

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Page 31: ...urbocharger 10 2 3 Installing the turbocharger 13 3 Commissioning 19 3 1 Oil supply 19 3 2 Inspection procedures 20 3 3 Commissioning after taking out of operation 21 4 Monitoring during operation 23 4 1 Oil pressure oil temperature 23 4 2 Turbocharger speed 25 5 Operation and service 29 5 1 Noise emission 29 5 2 Service work 31 5 3 Expected replacement intervals 34 5 4 Stopping the engine 35 6 Pe...

Page 32: ...ring 73 8 9 Installing the cartridge group 77 8 10 Installing the compressor casing 80 8 11 Axial clearance A after assembly 84 8 12 Removing and installing turbine end nozzle ring 85 8 13 Table of tightening torques 90 9 Taking a turbocharger out of operation 93 9 1 Possible emergency repairs 93 9 2 Locking the rotor 94 9 3 Fitting the cover plate 97 9 4 Blanking off the inlets and outlets 99 9 5...

Page 33: ...ons will be pleased to provide information 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 1 2 Registered trademarks The trademarks of outside companies are used in this document These are marked with the symbol 1 3 Related doc...

Page 34: ...s reserved HZTL4033_EN Revision A July 2016 1 4 Layout and function of the turbocharger Figure 1 Layout and function 01 Filter silencer air suction branch 06 Gas inlet casing 02 Compressor wheel 07 Nozzle ring 03 Diffuser 08 Turbine 04 Bearing bush 09 Bearing casing 05 Gas outlet casing 10 Compressor casing ...

Page 35: ...tral lubricating oil duct which is normally supplied by the lubricating oil circuit of the engine The oil outlet lies at the deepest point of the bearing cas ing 09 The compressor wheel 02 connected to the shaft sucks in fresh air through the filter silencer 01 or the air suction branch The air is compressed further in the compressor and the down stream diffuser 03 and subsequently supplied to the...

Page 36: ...ates 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 Fit new warning plates and remove protective sheets Turbochargers supplied to the enginebuilder without insulation must be fitted late...

Page 37: ...ion A July 2016 1 6 Locations of the rating plates Figure 4 Locations of the rating plates One rating plate each is attached on the left and the right side of the foot of the turbocharger On turbochargers with insulation from ABB Turbo Systems at least one additional rating plate is attached to the insulation of the gas outlet casing ...

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Page 39: ...a sufficient load limit must be used for removing and 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 Figure 5 Turbocharger suspension points Weight of the entire turbocharger Product Weight kg A170 M 3100 A175 M 4600 Ta...

Page 40: ...stallation it may tip over and cause severe injury to personnel or accidents resulting in fatalities Support the turbocharger at a suitable location Secure with lifting gear wherever possible Wear safety helmet If present Loosen cable to speed sensor Disconnect all gas air and lubricating oil pipes Figure 6 Turbocharger suspension points If present Remove insulation segments on bearing casing and ...

Page 41: ...16 Turbocharger with clamping nuts Figure 7 Removing the foot mounting 1 Loosen clamping nuts on compressor end and turbine end foot see Loosening the clamp ing nut 12 2 Fit transport screws 90334 90335 to secure the sliding block 68003 on the left and right on the turbine end foot Lift the turbocharger from the engine and put it down Cover all oil connections ...

Page 42: ...sening the pressure screws Figure 8 Loosening the clamping nut 1 Working in a circle break loose all pressure screws of the clamping nut 2 Working in a circle loosen each of the pressure screws by about of a turn 90 3 Repeat the previous step until all pressure screws are relieved of pressure Unscrew and remove the clamping nut by hand CAUTION Do not clean pressure screws The pressure screws are e...

Page 43: ...ed or not supported at all during removal and installation it may tip over and cause severe injury to personnel or accidents resulting in fatalities Support the turbocharger at a suitable location Secure with lifting gear wherever possible Wear safety helmet Figure 9 Turbocharger suspension points If present Remove insulation segment on the bearing casing Attach lifting gear to the suspension lug ...

Page 44: ...90334 90335 on the left and right side of the foot and place in the toolbox The turbocharger is delivered with a pre installed sliding block 68003 The shipping screws secure the sliding block in the preset position In operation the foot can slip due to thermal expansion Tighten clamping nuts as described in the following sections Connect all gas air and oil pipes If present Re fit the insulation s...

Page 45: ...e end foot Screw dimensions and number of cup springs Product Foot bolt dimension mm Strength class Dimension CE mm Dimension TE mm Number of cup springs a1 b1 c1 a2 a3 b2 c2 c3 X A170 M M30 10 9 82 ø32x23 68 94 124 ø32x11 56 45 9 A175 M M36 10 9 95 ø38x31 85 113 148 ø38x12 66 54 11 Table 3 Foot bolt dimensions Holes b1 b2 are needed to achieve the required clamping length An additional drill hole...

Page 46: ...igure 13 CE foot contact surface Tighten clamping nuts on compressor end CE see Tightening the clamping nut 17 Figure 14 TE foot Handling of cup spring contact surface foot contact surface Coat the contact surface F for the cup springs X see Table 3 at the foot of the turbine end TE with high temperature grease Tighten clamping nuts on turbine end TE see Tightening the clamping nut 17 ...

Page 47: ...cessary tension force is reached Do not clean pressure screws Do not lubricate pressure screws NOTICE Pressure screws d must not protrude from the clamping nut c in the direc tion of the thrust washer b In order to correctly fit the clamping nuts the pressure screws must not pro trude in the direction of the thrust washer Figure 15 Tightening the foot bolts 1 1 Clean bolt thread a and contact surf...

Page 48: ... M M36 85 Table 4 Clamping 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 the tightening torque specified in the table 4 Work in a circle to tighten all pressure screws to 100 of the tightening torque specified in the...

Page 49: ... enginebuilder s specifications on the selection of the lubricating oil and the oil change intervals For more information on the oil supply refer to Chapter Oil pressure oil temperature 23 3 1 2 Pre lubrication and post lubrication The pre lubrication time is at least 2 minutes The post lubrication time is 10 minutes If the engine is operated in idle mode 10 minutes before stopping no additional p...

Page 50: ...taminated oil Serious damage to engine or property can be caused by dirt and solid mate rial 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 ser vice work on the lubricating system Check that the oil filter is clean before commiss...

Page 51: ...bly can liquefy or vaporise and es cape as oily fluids during the initial hours of operation Continuous escape of an oily fluid indicates an oil leak If there is a leak contact an ABB Turbocharging Service Station 3 3 Commissioning after taking out of operation If present Remove cover plates blind flanges on the compressor casing on the gas inlet as well as on the gas outlet General Check the exha...

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Page 53: ...itoring the lubricating oil pressure ABB Turbo Systems recommends installing a ma nometer M If the pressure is controlled electronically the appropriate signals are to be trig gered at the warning and alarm values Figure 17 Lubricating oil pressure measuring point The permitted oil pressure ranges at measuring point M of the turbocharger are listed below Status for operation Pressure at measuring ...

Page 54: ...t 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 spec ified oil outlet temperature is to be considered as alarm value for the turbocharger operation and must be monitored a...

Page 55: ...tant monitoring of the turbocharger speed CAUTION Do not strain cables If you pull the speed measurement cables too hard contacts can be pulled out Do not strain the speed measurement cables by pulling 4 2 2 Layout and overview Figure 18 Speed measurement 86505 Speed sensor 86506 O ring 86515 Cable connector 86526 F I converter 86528 Tachometer 42047 Screw plug 32118 Auxiliary bearing with cams Al...

Page 56: ...ce the engine performance immediately to the point at which the maximum speed of all turbochargers 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 t...

Page 57: ...to idling and then stop the engine Pay attention to post lubrication Stopping the engine 35 Switch off the lubricating oil supply to the turbocharger Disconnect the cable connector from the speed sensor Screw out defective speed sensor Screw in new speed sensor to the stop NOTICE Sealing the speed sensor The speed sensor is designed with a sealing lip and does not require an ad ditional gasket whe...

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Page 59: ...s 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 turbo charger 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 a...

Page 60: ...pyright 2016 ABB All rights reserved HZTL4033_EN Revision A July 2016 Suggestion for noise insulation bellows Figure 19 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 61: ...ty or high system vibrations can lead to untimely machine damage even if the prescribed service intervals are observed Agree on a shortened service interval with ABB Turbo Systems NOTICE 5 year service inspection To prevent machine damage caused by ageing and downtime we recom mend having an inspection carried out by an ABB Turbocharger Service Sta tion no later than 5 years after the last service...

Page 62: ...cks and erosion Check and assess rotor and bearing parts Balancing rotor 5 2 4 Service work every 24000 36000 hours of operation The following work must be carried out by an ABB Turbocharging Service Station Replacement of the bearing parts Checking and assessment of the rotor Disassemble the turbocharger Clearance measurement Clean turbine casing and compressor casing and check for cracks and ero...

Page 63: ...ger The following operating data and measured values must be entered regularly into the engine logbook of the enginebuilder Performance and speed of the engine Speed of the turbocharger Air intake temperature Exhaust gas temperature before and after the turbine Pressure of the charge air Pressure loss in the charge air cooler Lubricating oil pressure and lubricating oil temperature If present Air ...

Page 64: ...osed to hot gas A decisive role is played by various influencing parameters which in extreme cases can dras tically reduce the replacement interval of these parts During the prescribed periodic service work the individual parts are examined for wear and replaced if necessary Influencing parameters for bearing parts Inferior lubricating oil quality lubricating oil filtering lubricating oil conditio...

Page 65: ...e 8 Expected replacement intervals GAS Gas MDO Marine Diesel Oil HFO Heavy Fuel Oil Recommended replacement intervals h Rotor components See rating plate data Bearings See rating plate data Table 9 Recommended replacement intervals The specified values are guideline values and not guaranteed values see Influencing parameters 5 4 Stopping the engine CAUTION Stopping the engine In the turbocharger t...

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Page 67: ...d HZTL4033_EN Revision A July 2016 6 Periodic maintenance 6 1 Foreword to maintenance Maintenance work includes regular visual controls and cleaning operations which are intended to ensure the trouble free functioning of the turbocharger Described maintenance points Filter silencer Diffuser Compressor Turbine and nozzle ring ...

Page 68: ...embly and assembly of the filter silencer 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 wa...

Page 69: ...replaced by an ABB Turbocharging Service Station Fitting the cover grids and absorption segments see Figure 20 CAUTION Penetration of dirt and foreign particles Any penetration of dirt and foreign particles into the compressor can damage it Fit the connecting rods 81269 correctly in the slots on the filter silencer body 81135 It must not be possible to rotate or move the cover grid 81266 after as ...

Page 70: ...with the screws 81272 While tightening the screws 81272 make sure that the connecting rods 81269 lie correctly in the slots on the filter silencer body 81135 Now alternately tighten the screws 81272 up to the following max imum tightening torque Screw Tightening torque Nm 81272 20 Table 10 Tightening torque 81272 Fit lock nuts 81273 on screws 81272 and tighten with the following tightening torque ...

Page 71: ...he slotted diffuser Remove the diffuser see Removing the compressor casing 63 Figure 22 Cleaning the slotted diffuser Clean the diffuser slots S When cleaning please note that this should only take place using compressed air at low pressure a brush and a moist cleaning cloth Have any heavily contaminated or damaged diffusers replaced by an ABB Turbocharging Service Station ...

Page 72: ...w channels if salt oil mist or dust are sucked in with the air Consequences of contamination Impaired compressor efficiency Higher exhaust gas temperatures Increased fuel consumption Increased rotor unbalance Periodic cleaning of the compressor during operation prevents or delays any great increase in the contamination but never replaces the regular service procedures where the turbocharger is com...

Page 73: ...olvent The coating is removed by the mechanical action of the impacting droplets The process is particularly suitable as long as the contamination is not too advanced CAUTION Corrosion and deposits when cleaning Salt water and cooling water treatment substances damage and adversely affect turbocharger parts Never use salt water but only pure water for cleaning CAUTION Volume of water Uncontrolled ...

Page 74: ...rts can be increased No personnel is allowed to be present in the vicinity of the turbocharger during compressor cleaning Compressor cleaning must be activated from the engine control panel Wet cleaning operations for compressor with direct water supply Trigger water injection according to the specifications of the enginebuilder Observe specified water pressure upstream of the connection to the tu...

Page 75: ...creased pressure loss in the charge air cooler and corrected if necessary If surging of the compressor stage continues to occur during compressor cleaning despite correct settings this can be remedied by reducing the engine load further during cleaning of the compressor The reduction of the engine load can lead to a reduction in the effectiveness of the compressor cleaning To avoid a reduction in ...

Page 76: ... ABB Turbo Systems recommends the use of fuels with low ash sulphur sodium and vanadi um contents Consequences of contamination Low turbine efficiency Elevated exhaust gas temperatures Increased charging and ignition pressures with increasing turbocharger speed Lower engine performance Rotor sticking after stopping the engine Periodic cleaning of the turbines during operation prevents or delays an...

Page 77: ...er treatment substances damage and adversely affect turbocharger parts Never use salt water but only pure water for cleaning The influence of the cleaning water on the peripheral units such as the boiler must be clari fied by the operator before commencing wet cleaning The turbine end components are cleaned at reduced engine load The exhaust gas tempera ture must not exceed the value specified in ...

Page 78: ...0 50 so that the turbine inlet temperature is between 380 430 C Figure 23 Turbine and nozzle ring cleaning cycle Once the turbine inlet temperature is stable and has dropped below 430 C wait at least another 10 minutes to allow the turbine end turbocharger parts to cool down Start the cleaning cycle according to the following description Wet cleaning procedure Procedure Figure 24 Procedure Wet cle...

Page 79: ...le volume of water collects in the gas out let casing A drainage system should be installed for the gas outlet casing and opened during cleaning If there is no drainage system the amount of water injected can be monitored with a flowmeter in the water supply The permitted amount of water must be determined with the help of an ABB Turbocharging Service Station To be observed during cleaning The act...

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Page 81: ...charger Rotor unbalance Contact ABB Turbocharging Service Station Turbine or compressor damaged Bearing damaged Table 15 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 This causes the com pre...

Page 82: ...nometer displays incorrectly Replace manometer Turbocharger Axial clearance of the rotor excessive Contact ABB Turbocharging Service Station Table 17 Malfunctions during operation Lubricating oil pressure too low Drop in speed Possible causes Remedy Engine Defects on the connected cylinders in pulse charging Contact enginebuilder Turbocharger Heavy contamination of the turbine and or nozzle ring C...

Page 83: ...h Check clean cooling system Insufficient ventilation Improve ventilation Table 20 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 pipe between engine and tur bine not sealed Injection mistimed Set correctly Valve control...

Page 84: ...o high 7 3 Surging of the turbocharger CAUTION Prolonged or periodic surging If the turbocharger surges continuously or periodically parts of it can be damaged Slowly reduce the engine load Have the cause clarified immediately by an ABB Turbocharging service station and rectified Have components inspected for damage and if necessary replaced by an ABB Turbocharging service station Surging of the t...

Page 85: ...ocharger A surge blow is accompanied by a loud bang and escape of hot air from the filter silencer 7 4 Malfunctions when stopping Noises during run down Possible causes Elimination Turbocharger Turbocharger contaminated Clean it Damaged bearing Contact an ABB Turbocharging Service Station Rubbing rotor Foreign object in turbocharger Table 24 Malfunctions when stopping noises during run down Run do...

Page 86: ...harging Service Station Table 26 Malfunction No speed measurement 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 false triggering For information...

Page 87: ...r assembly ABB Turbo Systems recommends marking the casing positions prior to dis assembly Identification of the assembly devices Not all assembly devices are marked with a part number Identification is guaranteed by the tool list This list is enclosed in the toolbox WARNING Servicing the assembly devices Assembly devices must be checked for damage before and after use Visually inspect for corrosi...

Page 88: ...erly functional lifting gear with sufficient load limit Pay attention to the correct attachment of loads on the crane hook People must not stand under suspended loads Wear safety gloves to protect against mechanical hazards Wear safety helmet Definition of terms Suspension point Defined loading point on a component or an assembly blind hole thread eyelet lug Assembly device Devices that are fitted...

Page 89: ...the individual parts or assemblies are rounded up standard values Figure 25 Assemblies Position Component A170 M kg A175 M kg 01 Filter silencer 260 400 02 Radial air suction branch 120 170 03 Wall insert 210 320 04 Diffuser 30 45 05 Compressor casing 430 620 06 Cartridge group 750 1100 07 Turbine diffuser 80 130 08 Cover ring 40 60 09 Nozzle ring 17 25 10 Gas inlet casing radial 170 230 Table 29 ...

Page 90: ...oving installing the filter silencer 1 Loop lifting gear through the fin on the filter silencer and secure to the eyelets at the rear with shackles 90195 2 Loosen nuts 72027 and remove with washers 72028 Remove and put down filter silencer Installing the filter silencer The installation of the filter silencer is carried out in reverse order Tighten nuts 72027 to the specified tightening torque Par...

Page 91: ...le insulation as far as necessary Figure 27 Removing installing the air suction branch 1 Loop lifting gear around air suction branch 2 Loosen and remove the nuts 72027 with washers 72028 Remove and put down the air suction branch Installing the air suction branch The installation of the air suction branch is carried out in reverse order Tighten nuts 72027 to the specified tightening torque Part nu...

Page 92: ...r safety gloves to protect against mechanical hazards The axial clearance A must be measured prior to removal and after installation of the car tridge group CAUTION Clearances outside the tolerance Serious damage to engines or property can be caused by clearances out side the tolerance and excessively worn parts Have the components assessed and if necessary replaced by an ABB Turbocharging Service...

Page 93: ... wall insert 1 Loosen screws 72011 and remove with washers 72008 2 To secure the wall insert screw in one screw 72011 a third of the way 3 Press off wall insert with three press off screws 90900 until the lifting device 90190 90195 can be fitted 4 Using shackle 90195 and lifting gear fit lifting device 90190 to wall insert 77000 5 Put on shackle 90195 and fasten to lifting gear 6 Remove locking sc...

Page 94: ...033_EN Revision A July 2016 Transporting and turning wall insert Figure 30 Transporting and turning wall insert 1 Fit support angle 90025 with bolts and nuts 2 Carefully turn wall insert over support angle 90025 and place on supports NOTICE Reusing the lifting device Place wall insert such that lifting device 90190 90195 can be removed ...

Page 95: ...sembly Page 65 113 Copyright 2016 ABB All rights reserved HZTL4033_EN Revision A July 2016 Removing the diffuser Figure 31 Removing the diffuser 1 Remove and dispose of the O ring 77040 2 Loosen and remove screws 77015 3 Remove diffuser 79000 with swivel lifting eyes 90235 ...

Page 96: ...vision A July 2016 Remove compressor casing Figure 32 Remove compressor casing 1 Using shackle 90195 and lifting gear fasten lifting device 90190 to compressor casing 72000 and secure to crane 2 Loosen and remove nuts 61037 3 Use press off nuts 61090 to fully press off and remove compressor casing 72000 4 Remove and dispose of the O ring 42012 ...

Page 97: ...d assembly Page 67 113 Copyright 2016 ABB All rights reserved HZTL4033_EN Revision A July 2016 8 6 Removing the cartridge group CAUTION Safety relevant screws The six screws 01 are relevant for containment safety and must not be loosened Figure 33 Safety relevant screws ...

Page 98: ...tes that are specified for the turbocharger have been installed in the two oil inlet channels Check correct installation of oil orifice plates Version with compressor wheel cooling Dismantle air supply line compressor wheel cooling 5 Separate oil inlet and outlet pipes Figure 34 Removing cartridge group 1 1 Unplug cable connector 86515 and unscrew speed sensor 86505 with O ring 86506 Dispose of th...

Page 99: ...ry or property can result from the rubbing or jamming of the blade tips on the casing Check that the blades do not rub on the turbine diffuser during disassem bly assembly by rotating the rotor Figure 35 Removing cartridge group 2 1 Evenly press off cartridge group by screwing three press off screws 90900 into the des ignated holes 2 Using two guide rods 90490 move out cartridge group 3 Fit suppor...

Page 100: ...ng turbine diffuser 1 1 Remove screws 61069 2 Using press off screws 90915 press off turbine diffuser 3 Fit guide plates 90328 with nuts 61037 4 Screw in guide stud 90802 Figure 37 Removing turbine diffuser 2 5 Pull turbine diffuser 63000 out as far as it will go at guide plates 6 Loop around turbine diffuser and secure to lifting gear 7 Remove nuts 61037 and guide plates 90328 8 Completely pull o...

Page 101: ...g cover ring 1 1 Refit guide plates 90328 with nuts 61037 2 Loosen and remove screws 57005 Using press off screws 90916 in the holes provided press off cover ring 3 Pull cover ring 57001 out as far as it will go at guide plates Figure 39 Removing cover ring 2 4 Loop around cover ring and secure to lifting gear 5 Remove guide plates 90328 and nuts 61037 6 Fully pull out and put down cover ring 5700...

Page 102: ...od 90336 into retain ing plate 3 Fit guide plate 90328 with nuts 61037 Figure 41 Removing nozzle ring 2 4 Pull nozzle ring 56001 out as far as it will go at guide plate 5 Loop around nozzle ring 56001 and secure to lifting gear 6 Remove guide plate 90328 and nuts 61037 7 Fully pull out and put down nozzle ring 56001 Blocked areas on nozzle ring If a nozzle ring is blocked in some areas or is cover...

Page 103: ...6 8 8 Installing nozzle ring Figure 42 Installing nozzle ring 1 1 Secure retaining plate 90338 with screws 90339 and hook in guide rod 90336 2 Using lifting gear position nozzle ring 56001 on guide rod 90336 Do not take strain off lifting gear yet 3 Fit guide plate 90328 with nuts 61037 4 Remove the lifting gear 5 Position nozzle ring 56001 in gas outlet casing ...

Page 104: ...0 50 Nm M10 50 Nm Table 33 Tightening torque 56014 6 Undo nuts 61037 and remove guide plate 90328 7 Undo screws 90339 and remove retaining plate 90338 with guide rod 90336 8 Coat the threads of screws 56014 and the contact surface between screw and locking washer with high temperature grease 9 Fit the nozzle ring 56001 on the gas inlet casing 51001 using the screws 56014 and locking washers 56015 ...

Page 105: ...30 Nm M16 200 Nm Table 34 Tightening torque 57005 1 Using lifting gear move in cover ring 57001 over guide studs 90802 with notch V fac ing the gas outlet flange until the lifting gear is on the gas outlet casing 2 Fit guide plates 90328 with nuts 61037 3 Remove the lifting gear 4 Slide in cover ring as far as it will go 5 Remove guide plates 90328 and nuts 61037 6 Coat threads of screws 57005 wit...

Page 106: ...3000 in over guide studs 90802 until the lifting gear is on the gas outlet casing 2 Fit guide plates 90328 with nuts 61037 3 Remove the lifting gear 4 Slide in turbine diffuser as far as it will go 5 Remove nuts 61037 guide plates 90328 and guide studs 90802 Figure 46 Installing turbine diffuser 2 Part number A170 M A175 M 61069 M14 130 Nm M16 200 Nm Table 35 Tightening torque 61069 6 Coat threads...

Page 107: ...Serious damage to machinery or property can result from the rubbing or jamming of the blade tips on the casing Check that the blades do not rub on the turbine diffuser during disassem bly assembly by rotating the rotor Figure 47 Installing the cartridge group 1 1 Fasten lifting gear to bearing casing and lift cartridge group slightly 2 Remove support 90450 3 Using two guide rods 90490 carefully mo...

Page 108: ...90 Nm 86505 M18x1 5 150 Nm M18x1 5 150 Nm 25013 M8 20 Nm M10 40 Nm Table 36 Tightening torque 61059 42128 86505 25013 1 Coat thread of screw 61059 and two bolts for the nuts 42128 with high temperature grease 2 Secure cartridge group with screw 61059 and nuts 42128 3 Fit spinner nose cone 25012 with screw 25013 and washer 25014 and tighten 4 Remove the lifting gear 5 Screw in and tighten speed sen...

Page 109: ...els in the bearing casing When the cartridge group the bearing casing or the turbocharger is fitted to the engine it must be ensured that the orifice plates that are specified for the turbocharger have been installed in the two oil inlet channels Check correct installation of oil orifice plates Remove temporary covers on oil connections Fit all oil pipes according to instructions of enginebuilder ...

Page 110: ... Pre tightening torque 40 Nm Tightening angle 45 5 61090 M22 50 Nm M24 50 Nm Table 37 Tightening torque 61037 61090 1 Distributed evenly around the circumference screw the press off nuts 61090 onto the studs of the bearing casing and turn them by hand until they are at the end of the thread 2 Grease the new O ring 42012 and fit it 3 Fasten lifting device 90190 90195 to compressor casing 72000 and ...

Page 111: ...served HZTL4033_EN Revision A July 2016 Installing diffuser Figure 50 Installing diffuser Part number A170 M A175 M 77015 M5 6 Nm M6 10 Nm Table 38 Tightening torque 77015 1 Position diffuser 79000 with swivel lifting eye 90235 on wall insert 77000 2 Attach diffuser with screws 77015 3 Grease the new O ring 77040 and fit it ...

Page 112: ...ert Figure 51 Turning and moving in wall insert 1 Fasten lifting device 90190 90195 to front of flange Carefully turn wall insert 77000 with fitted diffuser over the support angle 90025 and pull up vertically 2 Remove support angle 90025 bolts and nuts 3 Fit guide studs 90319 4 Carefully install the wall insert 77000 in the compressor casing Make sure both markings are in the correct position ...

Page 113: ...igure 52 Fitting the wall insert Part number A170 M A175 M 72011 M20 580 Nm M24 1000 Nm Table 39 Tightening torque 72011 1 Remove lifting device 90190 90195 2 Slide wall insert 77000 into compressor casing up to stop and remove guide stud 90319 3 Secure wall insert with screws 72011 and washers 72008 For assembly of the alternative air inlet see section Removing Installing air inlets 60 ...

Page 114: ...safety gloves to protect against mechanical hazards The axial clearance A must be measured prior to removal and after installation of the car tridge group CAUTION Clearances outside the tolerance Serious damage to engines or property can be caused by clearances out side the tolerance and excessively worn parts Have the components assessed and if necessary replaced by an ABB Turbocharging Service S...

Page 115: ...ctions Spiral wound gaskets may only be used once Provide new spiral wound gasket 61050 NOTICE Blocked areas on nozzle ring If a nozzle ring is blocked in some areas or is covered by loose parts we would recommend appointing an ABB Turbocharging Service Station to in spect the turbine blades and carry out a crack inspection In order to access the fixing screws and loop round and transport the gas ...

Page 116: ...ving the nozzle ring at the turbine end 1 If present Remove connecting pipe for turbine cleaning 2 Loop around gas inlet casing 51001 and secure with lifting gear 3 Loosen screws 61009 and move out gas inlet casing with nozzle ring 4 Bend open locking washers 56015 undo and remove screws 56014 5 Pull out nozzle ring 56001 6 Remove spiral wound gasket 61050 and provide new one ...

Page 117: ... 56014 with high temperature grease Secure nozzle ring 56001 with screws 56014 and new locking washers 56015 at gas inlet casing 51001 Bend over locking washers 2 Fix new spiral wound gasket 61050 in groove of gas outlet casing 61001 at three evenly distributed points with a little superglue such as Loctite 454 Gel 3 Fit two guide studs 90321 in the upper part of the gas outlet casing 61001 4 Coat...

Page 118: ... 8 Disassembly and assembly Page 88 113 Copyright 2016 ABB All rights reserved HZTL4033_EN Revision A July 2016 7 Fit remaining screws 61009 then tighten all screws 61009 8 If present Fit connecting pipe for turbine cleaning Refit dismantled insulation ...

Page 120: ...escription A100 M axial 8 Disassembly and assembly Page 90 113 Copyright 2016 ABB All rights reserved HZTL4033_EN Revision A July 2016 8 13 Table of tightening torques Figure 56 Tightening torques 1 Figure 57 Tightening torques 2 ...

Page 121: ...M5 6 M6 10 03 61036 M22 60 M24 80 04 61037 M22 415 M24 490 05 61090 M22 50 M24 50 06 61059 42128 M22 415 M24 490 07 61069 M14 130 M16 200 08 63001 M14 170 M18 240 09 56014 M10 50 M10 50 10 61009 M18 2801 M20 3801 11 57005 M14 130 M16 200 12 42059 M16 200 M16 200 13 72011 M20 580 M24 1000 14 72027 M18 170 M20 220 15 72026 M18 40 M20 50 16 25013 M8 20 M10 40 17 86505 M18x1 5 150 M18x1 5 150 Table 42...

Page 122: ...113 Copyright 2016 ABB All rights reserved HZTL4033_EN Revision A July 2016 Tightening sequence Figure 58 Flange tightening sequence Product Tightening torque 61009 Nm Step 1 Step 2 Step 3 Step 4 A170 M hand tight 80 170 280 A175 M hand tight 100 240 380 Table 43 Tightening torques 61009 ...

Page 123: ...r WARNING Danger of fire and explosion due to lubricating oil leaks Leaking oil may ignite on hot surfaces This can cause severe personal injury or fatal accidents can result Cordon off danger area Sound an alarm and depending on the situation stop the engine Seal oil leaks Soak up oil and dispose of in an environmentally compatible manner Wear safety gloves to protect against thermal hazards If d...

Page 124: ...h locked rotor If there is a lubricating oil leak on the turbocharger stop the oil supply A locked rotor must be removed after emergency operation and checked for unbalance see chapter Removing the cartridge group 67 The unbalance check must be carried out by an ABB Turbocharging Service Station Exception The exception concerns customer requirements for test bed runs of new engines at a maxi mum e...

Page 125: ...Fitting the locking device Product Part number 72011 Part number 94006 94007 A170 M 170 Nm 25 Nm A175 M 220 Nm 50 Nm Table 44 Locking device tightening torque 1 Press off the spinner nose cone 25012 with the press off screw 90917 2 Remove two studs 72026 and three screws 72011 in the upper area 3 Insert lifting spigot 90427 into compressor wheel Screw screws 94007 into the free threaded holes of t...

Page 126: ...peeds Observe the speeds of the undamaged turbochargers Reduce the engine load if necessary If the engine is equipped with a common air receiver and separate exhaust gas receivers the bellows on the compressor outlet of the damaged turbocharger must always be removed and the air line on the engine side must be blanked off Otherwise the undamaged turbocharger can spin empty without load and run at ...

Page 127: ...EN 10025 2 must be manufactured according to the drawing from the operator Figure 60 Cover plate dimensions Cover plate spacer sleeve dimensions mm Product B1 B2 B3 B4 B5 B6 B7 B8 A170 M 13 470 50 50 9 12 8 82 A175 M 13 550 50 50 9 12 8 100 Table 45 Cover plate dimensions 1 Product Ø 1 Ø 2 Ø 3 Ø 4 Ø 5 Ø 6 A170 M 915 990 950 20 28 20 A175 M 1045 1165 1117 24 32 20 Table 46 Cover plate dimensions 2 ...

Page 128: ...sleeves and nuts 61037 Close the lubricating oil supply to the turbocharger 9 3 1 Further measures and information for the operation of 4 stroke engines with a cover plate of the turbocharger 4 stroke engine with a turbocharger No further measures are necessary The engine can be operated as a suction engine accord ing to the instructions of the enginebuilder 4 stroke engine with several turbocharg...

Page 129: ...aged turbochargers build up a receiver pressure 9 4 Blanking off the inlets and outlets The chapter is only applicable for engines with several turbochargers and joint air and exhaust gas receivers Close the lubricating oil supply to the turbocharger Blank off flange from compressor casing outlet gas inlet and gas outlet by the installation of cover plates Observe specifications from enginebuilder...

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Page 131: ...operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or con tact 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 Wear personal protective equipment PPE according to the mater...

Page 132: ...arately The turbocharger has been completely 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 ...

Page 133: ...r safety goggles Wear a respiratory mask to protect against dusts Wear safety gloves to protect against mechanical hazards 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 alu minium and bearing brass Further components are Non metallic materials fi...

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Page 135: ... data when making queries and ordering spare parts Locations of the rating plates 7 Turbocharger type Serial number HT Designation and part number Spare parts can be ordered from any ABB Turbocharging Service Station If different model variants are not taken into account in this document contact an ABB Turbocharging Service Station Dispose of placed and unusable parts in an environmentally friendl...

Page 136: ...l the customer spare part set 97070 is required These parts are only available as part of the complete set Part number Designation Quantity 42012 O ring 1 42041 Gasket 1 42045 Gasket 2 42059 42064 Hexagon head screw 2 56014 Hexagon head screw 2 56015 Locking washer 2 57005 Hexagon head screw 5 61037 Hexagon nut 3 61069 Hexagon head screw 3 77015 Socket screw 3 77040 O ring 1 86506 O ring speed sen...

Page 138: ...4 Product description A100 M axial 12 Spare parts Page 108 113 Copyright 2016 ABB All rights reserved HZTL4033_EN Revision A July 2016 12 2 View of turbocharger with part numbers Figure 62 Turbocharger with part numbers ...

Page 139: ...her 57001 Cover ring 57005 in customer spare part set Hexagon head screw 61001 Gas outlet casing 61037 in customer spare part set Hexagon nut 61050 Gasket 61069 in customer spare part set Hexagon head screw 63000 Turbine diffuser 68001 Foot compressor end 68002 Foot turbine end 68003 Sliding block 72000 Compressor casing 77015 in customer spare part set Socket screw 77000 Wall insert 77040 in cust...

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Page 141: ...g installing the filter silencer 60 Fig 27 Removing installing the air suction branch 61 Fig 28 Axial clearance 62 Fig 29 Removing wall insert 63 Fig 30 Transporting and turning wall insert 64 Fig 31 Removing the diffuser 65 Fig 32 Remove compressor casing 66 Fig 33 Safety relevant screws 67 Fig 34 Removing cartridge group 1 68 Fig 35 Removing cartridge group 2 69 Fig 36 Removing turbine diffuser ...

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Page 143: ...as temperature too high 53 Table 21 Malfunctions during operation Charge air pressure too low 53 Table 22 Malfunctions during operation Charge air pressure too high 54 Table 23 Surging of the turbocharger 54 Table 24 Malfunctions when stopping noises during run down 55 Table 25 Malfunctions when stopping run down time shortened 55 Table 26 Malfunction No speed meas urement signal or poor signal am...

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ABB HT568964, Operation Manual

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