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ABB HT575442, Operation Manual

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Operating limits and replacement intervals

The recommended replacement intervals 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.

Summary of Contents for HT575442

Page 1: ...arging Operation Manual A175 M62 HT575442 English Original Operation Manual Chapter Document ID 1 Introduction HZTL4005_EN_F 2 Safety HZTL4023_EN_D 3 Safety data sheet HT575442 4 Product description HZTL4033_EN_B ...

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: ... contents Copyright 2017 ABB All rights reserved HZTL4005_EN Revision F May 2017 Introduction 1 Introduction 2 1 1 Purpose of the manual 2 1 2 Symbols definitions 3 1 3 Storage of new turbochargers and spare parts 5 1 4 Contact information 7 ...

Page 4: ...explains the turbocharger and contains instructions for safe opera tion 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 i...

Page 5: ...n 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 Systems Offici...

Page 6: ...Meaning Pictogram Meaning Tighten with specified torque Affix Tighten over specified tighten ing 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 accord ance with specifications Dispose of in an environmentally compatible professional...

Page 7: ...ous in terms of the Ordinance on Hazardous Substances Nevertheless the following points must be observed when handling VCI u Observe information in material safety data sheet u Ensure proper space ventilation u Do not eat drink or store food at the workplace while working with VCI u Clean hands and face after working with VCI u For more information see www branopac com Wear safety gloves to protec...

Page 8: ... repackaged by an ABB Turbocharging Service Station u 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 Repl...

Page 9: ...ights reserved HZTL4005_EN Revision F May 2017 1 4 Contact information Contact information for the ABB Turbocharging Service Stations is available online u Scan the QR code to access our website ABB Turbo Systems Ltd Bruggerstrasse 71a CH 5401 Baden Switzerland www abb com turbocharging Page 7 7 ...

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Page 11: ...f mandatory signs 3 1 4 Definition of safety instructions 3 1 5 Intended use 4 1 6 Deflagration on gas engines 5 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...

Page 12: ...nce 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 opera tion of the turbocharger an...

Page 13: ...ry 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 in structions indicated by this symbol and the word WARNING can lead to seri ous injuries to personnel and even to fa...

Page 14: ...urbine end The specific operating limits of the turbocharger were determined on the basis of informa tion 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 and ...

Page 15: ... tur bocharger 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...

Page 16: ... must always be present in the intended locations and must be legible Fig 1 Warning plate If warning plates are not present in the intended locations or are not legible they must be replaced 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 w...

Page 17: ...therwise 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 0...

Page 18: ...Mmax and tMmax is not permitted Non observance of the recommended replacement intervals increases the risk of unpredict able component failures Locations of the rating plates The locations of the rating plates are defined in the Operation Manual Chapter 4 Product description 1 9 Periodic check of the pressure vessels The pressure vessels used by ABB Turbocharging such as those for wet or dry clean...

Page 19: ... against mechanical hazards Wear safety helmet Fig 3 Attachment of loads on the crane hook Fig 4 Attachment angle If there are two or more suspension points the attachment angle of 45 must not be ex ceeded This prevents excessive loading due to diagonal pull u Before looping around the components of the turbocharger let them cool down max imum 80 C u Attach components of the turbocharger as descri...

Page 20: ... checked periodically Suitable working materials and personal protective equipment must be kept in a perfect condition 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 turb...

Page 21: ...is running always wear ear protection u 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 insula tion The temperature may rise to a level that can cause burns WA...

Page 22: ...gloves 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 u Operate the turbocharger in compliance with the specifications u Secure the rotor a...

Page 23: ...ical installations u 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 u Visually inspect your working environment before starti...

Page 24: ...u 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 u Do not climb onto the turbocharger or onto attached parts and do not use them as climbing aids u Use suitable climbing aids and working platforms for work above body hei...

Page 25: ...ety during disassembly assembly maintenance and repair u Observe the procedures for set up service and inspection work and the inspection inter vals u Inform the operating staff before starting any service or repair work Make sure the en gine is not started while work is being conducted on the turbocharger u Before taking off any cover or removing any guard from the turbocharger switch off the eng...

Page 26: ...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 tur bocharger 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 suppl...

Page 27: ...on in the material safety data sheet for the operat ing materials and supplies u 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 u Only use suitable and non c...

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Page 29: ...ion Manual A175 M62 Safety data sheet Page 1 1 Safety data sheet Copyright 2018 ABB All rights reserved HT575442 February 2018 A175 M62 HT575442 A175 M62 HT575442 320 650 305 620 HZTL53350K 4600 35 50 50 2018 ...

Page 30: ......

Page 31: ...Oil supply 18 3 2 Inspection procedures 19 3 3 Commissioning after taking out of operation 20 4 Monitoring during operation 21 4 1 Oil pressure oil temperature 21 4 2 Turbocharger speed 23 5 Operation and service 26 5 1 Noise emission 26 5 2 Service work 28 5 3 Expected replacement intervals 31 5 4 Stopping the engine 32 6 Periodic maintenance 33 6 1 Foreword to maintenance 33 6 2 Cleaning the fil...

Page 32: ...mpressor casing 74 8 11 Axial clearance A after assembly 78 8 12 Removing and installing turbine end nozzle ring 79 8 13 Table of tightening torques 82 9 Taking a turbocharger out of operation 85 9 1 Possible emergency repairs 85 9 2 Locking the rotor 86 9 3 Fitting the cover plate 89 9 4 Blanking off the inlets and outlets 91 9 5 Engines with bypass around the turbocharger 91 10 Mothballing the t...

Page 33: ...ny questions regarding a design variant see Contact information at www abb com turbocharging Accuracy of illustrations The illustrations in this document are general in nature and intended for ease of understand ing Differences in detail are therefore possible 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 34: ...B All rights reserved HZTL4033_DE Revision B December 2017 1 4 Layout and function of the turbocharger Fig 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 4 99 ...

Page 35: ...gs are connected to a central lubricating oil duct which is normally supplied by the lubricating oil circuit of the engine The oil outlet lies at the deepest point of the bearing casing 09 The compressor wheel 02 connected to the shaft sucks in fresh air through the filter silen cer 01 or the air suction branch The air is compressed further in the compressor and the downstream diffuser 03 and subs...

Page 36: ... warning plates are not present in the designated locations or not readable proceed as fol lows u Order new warning plates from ABB Turbocharging Service Stations u Remove any warning plates that have become unreadable u Clean and degrease the areas designated for the warning plates u Fit new warning plates and remove protective sheets Turbochargers supplied to the enginebuilder without insulation...

Page 37: ... Revision B December 2017 1 6 Locations of the rating plates Fig 4 Locations of the rating plates One rating plate each is attached on the left and the right side of the foot of the turbochar ger On turbochargers with insulation from ABB Turbo Systems at least one additional rating plate is attached to the insulation of the gas outlet casing Page 7 99 ...

Page 38: ...ith a sufficient load limit must be used for removing and installing the tur bocharger The following weight specification applies to the heaviest variant possible De pending on the specification the weight specified on the rating plate may be lower than the standard value specified here Fig 5 Turbocharger suspension points Weight of the entire turbocharger Product Weight kg A170 M 3100 A175 M 4600...

Page 39: ...nstallation it may tip over and cause severe injury to per sonnel or accidents resulting in fatalities u Support the turbocharger at a suitable location u Secure with lifting gear wherever possible Wear safety helmet u If present Loosen cable to speed sensor u Disconnect all gas air and lubricating oil pipes Fig 6 Turbocharger suspension points u If present Remove insulation segments on bearing ca...

Page 40: ...er 2017 Turbocharger with clamping nuts Fig 7 Removing the foot mounting 1 Loosen clamping nuts on compressor end and turbine end foot see Loosening the clamping nut 11 2 Fit transport screws 90334 90335 to secure the sliding block 68003 on the left and right on the turbine end foot u Lift the turbocharger from the engine and put it down u Cover all oil connections Page 10 99 ...

Page 41: ... loosening the pressure screws Fig 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 u Unscrew and remove the clamping nut by hand CAUTION Do not clean pressure screws The pressure screws ar...

Page 42: ...ted or not supported at all dur ing removal and installation it may tip over and cause severe injury to per sonnel or accidents resulting in fatalities u Support the turbocharger at a suitable location u Secure with lifting gear wherever possible Wear safety helmet Fig 9 Turbocharger suspension points u If present Remove insulation segment on the bearing casing u Attach lifting gear to the suspens...

Page 43: ...s 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 u Tighten clamping nuts as described in the following sections u Connect all gas air and oil pipes u If present Re fit the insu...

Page 44: ...bine end foot Screw dimensions and number of cup springs Product Foot bolt di mension 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 ...

Page 45: ...CE foot contact surface u Tighten clamping nuts on compressor end CE see Tightening the clamping nut 16 Fig 14 TE foot Handling of cup spring contact surface foot contact surface u Coat the contact surface F for the cup springs X see Table 3 Foot bolt dimensions 14 at the foot of the turbine end TE with high temperature grease u Tighten clamping nuts on turbine end TE see Tightening the clamping n...

Page 46: ... the necessary tension force is reached u Do not clean pressure screws u Do not lubricate pressure screws NOTICE Pressure screws d must not protrude from the clamping nut c in the dir ection of the thrust washer b In order to correctly fit the clamping nuts the pressure screws must not protrude in the direction of the thrust washer Fig 15 Tightening the foot bolts 1 1 Clean bolt thread a and conta...

Page 47: ... A175 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 i...

Page 48: ... enginebuilder s specifications regarding the selection of lubricating oil and the oil change intervals For more information on the oil supply refer to Chapter Oil pressure oil temperature 21 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 additiona...

Page 49: ...ontaminated oil Serious damage to engine or property can be caused by dirt and solid ma terial particles in the oil u For the initial commissioning phase and after all service work flush the complete lubricating system with warm oil u Use special running in filters when running in the engine and after all ser vice work on the lubricating system u Check that the oil filter is clean before commissio...

Page 50: ...nd after the compressor u Compare the measured values with the values of the acceptance report Different operat ing conditions indicate a malfunction see Chapter Troubleshooting 45 Escape of oily fluids Lubricants and pastes used during assembly can liquefy or vaporise and escape as oily fluids during the initial hours of operation Continual escape of an oily fluid indicates an oil leak u If there...

Page 51: ...controlled electronically the appropriate signals are to be triggered at the warning and alarm values Fig 17 Lubricating oil pressure measuring point The permitted oil pressure ranges at measuring point M of the turbocharger are listed be low Status for operation Pressure at measuring point M Poil in bar Normal operation 1 3 2 5 Engine start Cold oil admissible for max 15 minutes 1 3 5 0 Pre lubri...

Page 52: ...t 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 op eration and must be monitored according to the current regulations Status for operation Oil temperature at the outlet Toil outlet C Admissible ...

Page 53: ... constant monitoring of the turbocharger speeds CAUTION Do not strain cables If you pull the speed measurement cables too hard contacts can be pulled out u Do not strain the speed measurement cables by pulling 4 2 2 Layout and overview Fig 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 ca...

Page 54: ...e point at which the maximum tur bocharger speed does not exceed 70 of nBmax u If the engine cannot be stopped it can continue to be driven at this reduced engine load or turbocharger speed u If a turbocharger surges continuously the engine performance must be reduced further u Measure the temperatures in the air lines and gas piping from and to the turbochargers and compare with normal values If ...

Page 55: ... sensor The speed sensor is designed with a sealing lip and does not require any ad ditional gasket for assembly u Connect cable connector 86515 with the speed sensor 86505 u Switch on lubricating oil supply to the turbocharger 4 2 5 Malfunction of the speed measurement system The possible reasons for malfunction of the speed measurement system are described in chapter Troubleshooting Reasons for ...

Page 56: ...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 tur bocharger 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 acoustically...

Page 57: ...right 2017 ABB All rights reserved HZTL4033_DE Revision B December 2017 Suggestion for noise insulation bellows Fig 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 27 99 ...

Page 58: ...or high system vibrations can lead to untimely machine damage even if the prescribed service intervals are ob served u 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 Turbocharging Service Sta tion no later than 5 years after the last servic...

Page 59: ...sing and blow through oil holes u Clean nozzle ring and check for cracks and erosion u Check and assess rotor and bearing parts u Balancing rotor 5 2 4 Service work every 24000 36000 hours of operation u Disassemble the turbocharger u Clearance measurement u Clean turbine casing and compressor casing and check for cracks and erosion corrosion u Clean bearing casing and blow through oil holes u Cle...

Page 60: ...er 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 t...

Page 61: ...ents exposed to hot gas A decisive role is played by various influencing parameters which in extreme cases can drastically 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 c...

Page 62: ...xpected 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 para meters 5 4 Stopping the engine CAUTION Stopping the engine In the turbocharger the h...

Page 63: ...etal covering 81272 Screw 81265 Filter ring if present 81273 Lock nut E Insert unit absorption segment sheet metal covering Cleaning the filter ring if present u Remove filter ring 81265 u 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 ai...

Page 64: ... rods replaced by an ABB Turbocharging Service Station Fitting the cover grids and absorption segments see Fig 20 Cleaning the filter silencer 1 33 CAUTION Penetration of dirt and foreign particles Any penetration of dirt and foreign particles into the compressor can dam age it u Fit the connecting rods 81269 correctly in the slots on the filter silencer body 81135 u It must not be possible to rot...

Page 65: ...81269 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 u Fit lock nuts 81273 on screws 81272 and tighten with the following tightening...

Page 66: ...ning the slotted diffuser u Remove the diffuser see Removing the compressor casing 55 Fig 22 Cleaning the slotted diffuser u 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 u Have any heavily contaminated or damaged diffusers replaced by an ABB Turbocharging Service Station Page 36 99 ...

Page 67: ...n form in the flow 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 major increase in contamination But it never replaces the regular service work where the turbochar...

Page 68: ... act as a solvent 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 u Never use salt water but only pure water for cleaning CAUTION Volume of water ...

Page 69: ...arger parts can be in creased u No personnel is allowed to be present in the vicinity of the turbocharger during compressor cleaning u Compressor cleaning must be activated from the engine control panel Wet cleaning operations for compressor with direct water supply u Trigger water injection according to the specifications of the enginebuilder u Observe specified water pressure upstream of the con...

Page 70: ...ns e g an increased 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 effective ness of the compressor cleaning u To avoid ...

Page 71: ...omponents ABB Turbo Systems recommends the use of fuels with low ash sulphur sodium and vana dium 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 ...

Page 72: ...damage and adversely affect turbocharger parts u 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 temperat ure must not exceed the value specified in the cleaning instructi...

Page 73: ... inlet temperature is between 380 430 C Fig 23 Turbine and nozzle ring cleaning cycle u 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 u Start the cleaning cycle according to the following description Wet cleaning procedure Procedure Fig 24 Procedure Wet cleaning of turbine and nozzl...

Page 74: ...s important to ensure that no impermissible volume of water collects in the gas outlet 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 mon itored with a flowmeter in the water supply The permitted amount of water must be de termined with the help of an ABB Turbocharging Service Stat...

Page 75: ...ing Service Sta tion Turbine or compressor damaged Bearing damaged Engine Vibrations from engine Contact enginebuilder 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 ...

Page 76: ...Station Engine Oil filter heavily contaminated Clean Oil pump in lubricating system defective Check replace Manometer displays incorrectly Replace manometer Table 17 Malfunctions during operation Lubricating oil pressure too low Drop in speed Possible causes Remedy Turbocharger Heavy contamination of the turbine and or nozzle ring Clean see chapter Periodic maintenance 33 Damaged rotor components ...

Page 77: ...states such as when redu cing the engine load quickly when manoeuvring When this happens the flow direction in the compressor is momentarily reversed Such sporadic surge blows do not impair the safe op eration of the turbocharger A surge blow is accompanied by a loud bang and escape of hot air from the filter silencer 7 4 Malfunctions when stopping Runout noises Possible causes Remedy Turbocharger...

Page 78: ...urbocharging Service Station Table 22 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 amplifica tion of the noise component and hence to false triggering For infor...

Page 79: ... assembly devices are marked with a part number Identification is guaranteed by the tool list This list is enclosed with the toolbox WARNING Servicing the assembly devices Assembly devices must be checked for damage before and after use u Visually inspect for corrosion cracks deformation and wear u Damaged assembly devices must no longer be used and must be re placed Customer spare part set Before...

Page 80: ... on the crane hook u People must not stand beneath 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 on the turbocharger in order to obtain a suspension point As sembly devices are specially construct...

Page 81: ...s of the individual parts or assemblies are rounded up standard values Fig 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 2...

Page 82: ...6 Removing 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 u Remove and put down filter silencer Installing the filter silencer The installation of the filter silencer is carried out in reverse order u Tighten nuts 72027 to the specified tightening t...

Page 83: ... u Dismantle insulation as far as necessary Fig 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 u 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 u Tighten nuts 72027 to the specified tightening tor...

Page 84: ...ty gloves Wear safety gloves to protect against mechanical hazards The axial clearance A must be measured prior to removal and after installation of the cart ridge group CAUTION Clearances outside the tolerance Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts u Have the components assessed and if necessary replaced by an ABB Tur boc...

Page 85: ...emoving 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 loc...

Page 86: ...HZTL4033_DE Revision B December 2017 Transporting and turning wall insert Fig 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 56 99 ...

Page 87: ...ving the compressor casing Copyright 2017 ABB All rights reserved HZTL4033_DE Revision B December 2017 Removing the diffuser Fig 31 Removing the diffuser 1 Remove and dispose of the O ring 77040 2 Loosen and remove screws 77015 3 Loop diffuser 79000 with lifting gear and remove Page 57 99 ...

Page 88: ..._DE Revision B December 2017 Remove compressor casing Fig 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 58 99 ...

Page 89: ...moving the cartridge group Copyright 2017 ABB All rights reserved HZTL4033_DE Revision B December 2017 8 6 Removing the cartridge group CAUTION Safety relevant screws The six screws 01 are relevant for containment safety and must not be loosened Fig 33 Safety relevant screws Page 59 99 ...

Page 90: ...plates that are specified for the turbocharger have been installed in the two oil inlet channels u Check correct installation of oil orifice plates Version with compressor wheel cooling u Dismantle air supply line see Compressor wheel cooling 5 u Separate oil inlet and outlet pipes Fig 34 Removing cartridge group 1 1 Unplug cable connector 86515 and unscrew speed sensor 86505 with O ring 86506 Dis...

Page 91: ... machinery or property can result from the rubbing or jamming of the blade tips on the casing u Check that the blades do not rub on the turbine diffuser during disas sembly assembly by rotating the rotor Fig 35 Removing cartridge group 2 1 Evenly press off cartridge group by screwing three press off screws 90900 into the designated holes 2 Using two guide rods 90490 move out cartridge group 3 Fit ...

Page 92: ...oving 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 Fig 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 93: ...ving 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 Fig 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 94: ...e rod 90336 into re taining plate 3 Fit guide plate 90328 with nuts 61037 Fig 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 95: ...r 2017 8 8 Installing nozzle ring Fig 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 65 99 ...

Page 96: ...M10 50 Nm M10 50 Nm Table 29 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 5601...

Page 97: ... 130 Nm M16 200 Nm Table 30 Tightening torque 57005 1 Using lifting gear move in cover ring 57001 over guide studs 90802 with notch V fa cing 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 w...

Page 98: ...er 63000 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 Fig 46 Installing turbine diffuser 2 Part number A170 M A175 M 61069 M14 130 Nm M16 200 Nm Table 31 Tightening torque 61069 6 Coat thread...

Page 99: ... casing Serious damage to machinery or property can result from the rubbing or jamming of the blade tips on the casing u Check that the blades do not rub on the turbine diffuser during disas sembly assembly by rotating the rotor Fig 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 caref...

Page 100: ...ecember 2017 Fig 48 Installing the cartridge group 2 Part number A170 M A175 M 61059 42128 M22 415 Nm M24 490 Nm 86505 M18x1 5 150 Nm M18x1 5 150 Nm Table 32 Tightening torque 61059 42128 86505 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 Remove the lifting gear Page 70 99 ...

Page 101: ...rger u Follow the assembly instructions u Observe control dimension Z Fig 49 Preparing the threaded stud 25008 Product A170 M A175 M Inner thread size 25008 M8 M10 Table 33 Inner thread size 25008 1 Remove residual glue from the inner thread of the threaded stud 25008 by using a screw tap 2 Clean and degrease the inner thread of the threaded stud and screw 25013 3 Coat the outer contact surface A ...

Page 102: ... M A175 M 25013 M8 20 Nm M10 40 Nm Table 34 Tightening torque 25013 5 Fit the spinner nose cone and secure with washer 25014 and screw Counterhold the compressor wheel 25000 by hand and tighten the screw Observe the tightening torque 6 Measure distance Z between spinner nose cone and compressor wheel at no less than three points around the circumference Permissible distance Z 0 1 0 7 mm Permissibl...

Page 103: ...justing the oil pressure is fitted in each of the two oil inlet channels 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 u Check correct installation of oil orifice plates u Remove temporary covers on oil ...

Page 104: ...e 45 5 Pre tightening torque 40 Nm Tightening angle 45 5 61090 M22 50 Nm M24 50 Nm Table 35 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 7200...

Page 105: ...ghts reserved HZTL4033_DE Revision B December 2017 Installing diffuser Fig 53 Installing diffuser Part number A170 M A175 M 77015 M5 6 Nm M6 10 Nm Table 36 Tightening torque 77015 1 Loop diffuser 79000 with lifting gear and position it on wall insert 77000 2 Attach diffuser with screws 77015 3 Grease the new O ring 77040 and fit it Page 75 99 ...

Page 106: ...n wall insert Fig 54 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 mark ings are in the correct posit...

Page 107: ...ll insert Fig 55 Fitting the wall insert Part number A170 M A175 M 72011 M20 580 Nm M24 1000 Nm Table 37 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 52 Pa...

Page 108: ...oves Wear safety gloves to protect against mechanical hazards The axial clearance A must be measured prior to removal and after installation of the cart ridge group CAUTION Clearances outside the tolerance Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts u Have the components assessed and if necessary replaced by an ABB Tur bochargi...

Page 109: ... leaking con nections Spiral wound gaskets may only be used once u 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 t...

Page 110: ...2017 Fig 57 Removing 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 ...

Page 111: ...01 to the gas inlet casing 51001 using the screws 56014 and new locking washers 56015 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 3 Fit two guide studs 90321 in the upper part of the gas outlet casing 61001 4 Coat threads of screws 61009 with high temperature grease...

Page 112: ... M axial 8 Disassembly and assembly 8 13 Table of tightening torques Copyright 2017 ABB All rights reserved HZTL4033_DE Revision B December 2017 8 13 Table of tightening torques Fig 59 Tightening torques 1 Fig 60 Tightening torques 2 Page 82 99 ...

Page 113: ... 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 40 Tighte...

Page 114: ... torques Copyright 2017 ABB All rights reserved HZTL4033_DE Revision B December 2017 Tightening sequence Fig 61 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 41 Tightening torques 61009 Page 84 99 ...

Page 115: ...er WARNING Danger of fire and explosion due to lubricating oil leaks Leaking oil may ignite on hot surfaces This can result in serious injuries to personnel or fatal accidents u Cordon off danger area u Raise the alarm and depending on the situation stop the engine u Seal the oil leak u Soak up oil and dispose of in an environmentally compatible manner Wear safety gloves to protect against thermal...

Page 116: ...h locked rotor u 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 59 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 max imum...

Page 117: ...62 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 42 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 o...

Page 118: ...eds u Observe the speeds of the undamaged turbochargers u 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 tur bocharger can spin empty without load and run ...

Page 119: ...5 2 must be manufactured according to the drawing from the oper ator Fig 63 Cover plate 01 spacer sleeves 02 dimensions Cover plate 01 spacer sleeves 02 dimensions mm Product B1 B2 B3 B4 B5 B6 B7 B8 A170 M 13 432 50 50 9 12 8 96 A175 M 13 500 50 50 9 12 8 112 Table 43 Cover plate dimensions 1 Product Ø 1 Ø 2 Ø 3 Ø 4 Ø 5 Ø 6 A170 M 835 915 872 4 24 34 20 A175 M 965 1050 1007 5 26 36 20 Table 44 Cov...

Page 120: ...r sleeves 02 and nuts 61037 u 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 tur...

Page 121: ... undamaged 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 ex haust gas receivers u Close the lubricating oil supply to the turbocharger u Blank off flange from compressor casing outlet gas inlet and gas outlet by the installa tion of cover plates u Observe specifications from...

Page 122: ...the bearing parts are largely protected against corrosion Preparations for mothballing WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or con tact with them may be harmful to health u Do not breathe in these substances and avoid contact with the skin u Ensure proper ventilation u Observe the information in the material safety dat...

Page 123: ...parts are dismantled by an ABB Turbocharging Service Station and stored separately The turbocharger is 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 the engine out of operation for up to 12 months subsection Preparations for mothballing If the turbocharger remains attached t...

Page 124: ...gles 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 filter compone...

Page 125: ...ccount in this document contact an ABB Turbocharging Service Station u Dispose of placed and unusable parts in an environmentally friendly and professional manner in accordance with the local regulations u Dispose of the packaging of new parts in an environmentally friendly and professional manner in accordance with the local regulations Required customer spare part set 97070 For the operations de...

Page 126: ...rts 12 2 View of turbocharger with part numbers Copyright 2017 ABB All rights reserved HZTL4033_DE Revision B December 2017 12 2 View of turbocharger with part numbers Fig 65 Turbocharger with part numbers only available in customer spare part set 97070 Page 96 99 ...

Page 127: ... Locking washer 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 7...

Page 128: ...8 Axial clearance 54 Fig 29 Removing wall insert 55 Fig 30 Transporting and turning wall insert 56 Fig 31 Removing the diffuser 57 Fig 32 Remove compressor casing 58 Fig 33 Safety relevant screws 59 Fig 34 Removing cartridge group 1 60 Fig 35 Removing cartridge group 2 61 Fig 36 Removing turbine diffuser 1 62 Fig 37 Removing turbine diffuser 2 62 Fig 38 Removing cover ring 1 63 Fig 39 Removing cov...

Page 129: ... during operation Speed in creases 46 Table 20 Malfunctions when stopping Runout noises 47 Table 21 Malfunctions when stopping Shortened runout time 47 Table 22 Malfunction No speed measurement sig nal or poor signal amplitude 48 Table 23 Malfunction Measured speed too high 48 Table 24 Malfunction Measured speed too low 48 Table 25 Assembly weights 51 Table 26 Tightening torque 27027 52 Table 27 T...

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