ABB HT597101 Operation Manual Download Page 143

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Operation Manual / 4 Product description / A130-M.. - A145-M..

Figures

HZTL4031_EN

Revision K

February 2020

Figures

Fig. 1: Layout and function of the turbocharger ....... 5

Fig. 2: Compressor wheel cooling ............................... 6

Fig. 3: Warning plate locations ..................................... 7

Fig. 4: Locations of the rating plates ......................... 8

Fig. 5: Suspension of complete turbocharger unit.. 9

Fig. 6: Turbine cleaning nozzle.................................... 10

Fig. 7: Removing the turbocharger ............................ 11

Fig. 8: Loosening the clamping nut ........................... 13

Fig. 9: Turbocharger centre of gravity ...................... 14

Fig. 10: Inserting gaskets into the bracket .............. 15

Fig. 11: Inserting the threaded rods........................... 16

Fig. 12: Requirements for threaded rods.................. 16

Fig. 13: Placing the turbocharger on the bracket ... 17

Fig. 14: Preparing the clamping nut for the tighten-
ing procedure ................................................................ 19

Fig. 15: Tightening pressure screws ......................... 20

Fig. 16: Connecting the speed sensor ....................... 21

Fig. 17: Connecting the compressor cooling air in-
take .................................................................................. 21

Fig. 18: Attaching the support .................................... 22

Fig. 19: Oil orifice .......................................................... 24

Fig. 20: Layout and overview of speed measurement
system ............................................................................. 31

Fig. 21: Replacing the speed sensor........................... 33

Fig. 22: Noise insulation, bellows .............................. 35

Fig. 23: Replacing the protective grid ...................... 38

Fig. 24: Carrying out wet cleaning of compressor. 46

Fig. 25: Carrying out wet cleaning of turbine ......... 50

Fig. 26: Cleaning the filter silencer............................ 52

Fig. 27: Compressor-end, non-rotating parts......... 54

Fig. 28: Turbine end, non-rotating parts ................. 56

Fig. 29: Soaking the turbine end ............................... 58

Fig. 30: Swivel lifting eyes........................................... 69

Fig. 31: Starpoint ring nut VRM.................................. 70

Fig. 32: Weights of assemblies ................................... 71

Fig. 33: Removing the air inlets................................... 72

Fig. 34: Removing the insulation ................................ 73

Fig. 35: Removing the gas outlet casing ................... 74

Fig. 36: Dismantling the gas outlet flange ............... 75

Fig. 37: Removing the gas outlet flange.................... 76

Fig. 38: Removing the compressor casing ............... 77

Fig. 39: Dismantling the wall insert............................ 78

Fig. 40: Press off the casing ........................................ 79

Fig. 41: Removing insulation sheets .......................... 80

Fig. 42: Oil orifice ........................................................... 80

Fig. 43: Removing cartridge group 1.......................... 81

Fig. 44: Removing cartridge group 2 ......................... 81

Fig. 45: Removing the nozzle ring .............................. 82

Fig. 46: Installing the cartridge group on the service
support ............................................................................ 83

Fig. 47: Measuring clearance A and B ........................ 84

Fig. 48: Nozzle ring compression PD ......................... 85

Fig. 49: Installing the nozzle ring................................ 86

Fig. 50: Lifting the cartridge group and rotating it
by 90° ............................................................................... 87

Fig. 51: Installing the cartridge group ....................... 87

Fig. 52: Turbine casing insulation / Burst protection .
89

Fig. 53: Installing the compressor casing ................. 91

Fig. 54: Measuring clearances N and R...................... 92

Fig. 55: Installing the air inlets .................................... 93

Fig. 56: Installing the gas outlet flange..................... 94

Fig. 57: Fitting the insulation ...................................... 95

Fig. 58: Installing the gas outlet casing .................... 96

Fig. 59: Fitting the insulation ...................................... 97

Fig. 60: Tightening torques ........................................ 98

Fig. 61: Tightening torques for insulation ................ 99

Fig. 62: Fitting the cover plate .................................. 102

Fig. 63: Cover plate drawing...................................... 103

Fig. 64: Overview of part numbers........................... 109

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Summary of Contents for HT597101

Page 1: ... Turbocharging Operation Manual A135 M65 HT597101 English Original Operation Manual Chapter Document ID 1 Introduction HZTL4005_EN_G 2 Safety HZTL4022_EN_E 3 Safety data sheet HT597101 4 Product description HZTL4031_EN_K ...

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: ...of contents Copyright 2020 ABB All rights reserved HZTL4005_EN Rev G March 2020 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: ...plains 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 it ...

Page 5: ... the work Definition of mandatory signs Mandatory signs show the protective equipment to be worn for a task The mandatory signs are described in chapter Safety and must be complied with Definition of Caution Warning Caution and warning signs are described in chapter Safety ABB Turbocharging ABB Switzerland Ltd Turbocharging is identified as ABB Turbocharging or as ABB Turbo Sys tems in this docume...

Page 6: ...ictogram Meaning Tighten with specified torque Tighten over specified tightening angle Hand tight tighten without tools Oil Apply screw locking paste e g Loctite Apply high temperature grease Apply other paste in accordance with specifications Oil free grease free and dry Affix Measure Note Visually inspect Please note text for numbered work step See document Dispose of in an environmentally compa...

Page 7: ... the sense of the Hazardous Substances Ordinance Nevertheless the following points are to be observed when handling VCIs u Observe specifications in the safety data sheet u Ensure good room ventilation u Do not eat drink or keep food at the workplace while working with VCIs u Clean hands and face after working with VCIs u For further information refer to www branopac com Wear safety gloves to prot...

Page 8: ... the turbocharger must be inspected by an ABB Turbocharging Service Station and repacked u Inspect the package for damage If the package is damaged the turbocharger must be in spected by an ABB Turbocharging Service Station and repacked After every 3 years the following work steps must be performed by an ABB Turbocharging Service Station Inspect the components Replace the desiccant agent Repackage...

Page 9: ...s reserved HZTL4005_EN Rev G March 2020 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 Switzerland Ltd Turbocharging Bruggerstrasse 71a CH 5401 Baden Switzerland www abb com turbocharging Page 7 7 ...

Page 10: ......

Page 11: ...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 1...

Page 12: ...e 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 and ...

Page 13: ... 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 fata...

Page 14: ...ure required for operation The turbocharger is solely intended to be operated with a clockwise direction of rotation as viewed from the turbine end The specific operating limits of the turbocharger were determined on the basis of 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 i...

Page 15: ...ur 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 i...

Page 16: ...ust 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 war...

Page 17: ...agreed with the en ginebuilder 02 Turbocharger operating limits during operation Recommended inspection and replacement intervals of turbocharger components 03 Inspection interval of plain bearings in 1000 h 04 Replacement interval of compressor in 1000 h 05 Replacement interval of turbine in 1000 h Further data 06 Customer part number 07 Designation for special design 08 Weight of turbocharger in...

Page 18: ...above nMmax and tMmax is not permitted Non observance of the recommended inspection and replacement intervals increases the risk of unpredictable component failures Locations of the rating plates The locations of the rating plates are defined in the Operation Manual Chapter 4 Product description 1 9 Periodic check of the pressure vessels The pressure vessels used by ABB Turbocharging such as those...

Page 19: ...gainst 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 describe...

Page 20: ...hecked 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 turboc...

Page 21: ... 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 WARN...

Page 22: ...oves 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 aga...

Page 23: ...al 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 starting...

Page 24: ...n and insulation can cause serious injuries to per sons or even fatal accidents u Only operate the turbocharger with burst protection fitted and insulation fitted in one of the following permitted variants Fig 5 Variant A Insulation 01 with integrated burst protection from ABB Turbo Systems Variant B Burst protection 03 and insulation 02 from ABB Turbo Systems Variant C Burst protection 03 from AB...

Page 25: ...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 heigh...

Page 26: ...y 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 engin...

Page 27: ...ve 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 supplie...

Page 28: ... 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 com...

Page 29: ...tion Manual A135 M65 Safety data sheet Page 1 1 Safety data sheet Copyright 2020 ABB All rights reserved HT597101 August 2020 A135 M65 HT597101 A135 M65 HT597101 893 630 873 600 150634 18023 300 8 50 50 2020 ...

Page 30: ......

Page 31: ... supply 23 3 2 Inspection procedures 25 3 3 Commissioning after taking out of operation 27 4 Monitoring operation 28 4 1 Oil pressure oil temperature 28 4 2 Exhaust gas temperature before turbine 30 4 3 Turbocharger speed 31 5 Operation and service 34 5 1 Noise emission 34 5 2 Service work 36 5 3 Expected replacement intervals 40 5 4 Stopping the engine 42 6 Periodic maintenance work 43 6 1 Forewo...

Page 32: ...ressor casing 90 8 17 Measuring radial clearances N and R 92 8 18 Installing the air inlets 93 8 19 Installing the gas outlet flange 94 8 20 Fitting the insulation of the turbine casing 95 8 21 Installing the gas outlet casing 96 8 22 Table of tightening torques 98 9 Taking out of operation at short notice 100 9 1 Possible emergency repairs 100 9 2 Installing the replacement turbocharger 101 9 3 I...

Page 34: ... 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 document...

Page 35: ...1 4 Layout and function of the turbocharger Fig 1 Layout and function of the turbocharger 01 Filter silencer air suction branch 08 Gas outlet flange 02 Compressor casing 09 Nozzle ring 03 Diffuser 10 Turbine casing 04 Bearing casing 11 Turbine end bearing flange 05 Axial thrust bearing 12 Compressor end bearing flange 06 Radial plain bearing 13 Compressor wheel 07 Turbine Page 5 115 ...

Page 36: ...e engine cylinders The rotor runs in two radial plain bearings 06 which are located in the bearing casing 04 between the compressor and turbine The axial thrust bearing 05 is located between the two radial plain bearings The plain bearings are connected to a central lubricating oil duct which is normally supplied by the lubricating oil circuit of the engine The oil outlet always lies at the deepes...

Page 37: ... 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 must be...

Page 38: ...ns of the rating plates Copyright 2020 ABB All rights reserved HZTL4031_EN Rev K February 2020 1 6 Locations of the rating plates Fig 4 Locations of the rating plates One rating plate 01 each is attached on the left and the right side of the turbocharger bear ing casing Page 8 115 ...

Page 39: ...bocharger The weight specified below applies to the heaviest variant possible Depending on the specifica tion the weight specified on the rating plate may be lower than the standard value specified here Fig 5 Suspension of complete turbocharger unit A Turbocharger with oil cooled bearing casing B Turbocharger with water cooled bearing casing C Complete turbocharger unit with gas outlet casing Prod...

Page 40: ... 2 2 Removing the turbocharger u Disconnect all pipes according to the instructions of the enginebuilder Fig 6 Turbine cleaning nozzle u If present Loosen the turbine cleaning connection The cleaning nozzle 51301 must be replaced after each removal procedure If the clean ing nozzle is not to be replaced the screw connection 01 must not be loosened during disassembly Page 10 115 ...

Page 41: ...nnect the plug to the speed sensor 86505 and secure the rolled up cable on the turbocharger This protects the plug from being crushed Fig 7 Removing the turbocharger A Oil cooled bearing casing D Clamping nut B Water cooled bearing casing E Standard nut C Position of expansion sleeves u Apply penetrating oil to thread of stud 02 and nut and let it work in Do not oil the pressure screws of the clam...

Page 42: ... be chosen to undo the connection Oil cooled bearing casing A u Attach lifting gear to the suspension eye u Loosen and remove nuts E If clamping nut D is present Loosen in accordance with chapter Loosening the clamping nut 13 u Positioning the turbocharger for storage 14 Water cooled bearing casing B u Loosen and remove water connections Close the openings of the water connections with screw plugs...

Page 43: ... Do not clean pressure screws The pressure screws are equipped with a permanent sliding layer that must not be removed In case of non compliance it cannot be ensured that the necessary tension force is reached u Do not clean pressure screws u Do not lubricate pressure screws If a screw jams the previously loosened screw must be tightened again a little Fig 8 Loosening the clamping nut 1 Working in...

Page 44: ... stably it may tip over This can result in serious personal injury u Place the turbocharger on a clean level support u Secure the turbocharger to prevent it from tipping over by using wooden beams and wedges and by taking the centre of gravity into account Fig 9 Turbocharger centre of gravity 01 Centre of gravity u Remove turbocharger from engine support set it down properly in an appropriate plac...

Page 45: ...ary sealing is provided by O rings The O rings are not included in the ABB scope of delivery Fig 10 Inserting gaskets into the bracket 01 Bracket 04 Slot for O ring 02 Oil supply 05 O rings 03 Oil drain 06 Pin optional Pin 06 as installation safety device Turbochargers can have an oil inlet either on their right or left side the oil inlet position can be different for the turbocharger fitted on th...

Page 46: ...n Requirements for the threaded rods Fig 12 Requirements for threaded rods Product Diameter Threaded rod mm Material DIN ISO 898 Part 1 Thread length L1 mm Oil cooled L2 mm Water cooled L2 mm A130 Ø 16 M16 10 9 12 9 30 250 250 A135 Ø 20 M20 10 9 12 9 30 270 325 A140 Ø 24 M24 10 9 12 9 70 350 360 410 420 A145 Ø 30 M30 10 9 12 9 80 415 425 Table 3 Requirements for threaded rods Fastening material sc...

Page 47: ...ushes 42190 4 Attach the lifting gear to the suspension eye of the bearing casing A B and loop around the gas outlet casing 61001 If the gas outlet casing is already fitted in the exhaust gas pipe the attachment of the lifting gear on the bearing casing is sufficient 5 Position the turbocharger on the bracket 04 and align it Pay attention to the position ing pins 05 in the bracket 6 When fixing wi...

Page 48: ...stening the turbocharger with a standard nut u Fit the nuts and tighten them according to variant 1 or 2 in the table below Product Through hole in bearing casing mm Fixing screws mm Variant 1 Tightening torques Nm Variant 2 Hy draulic pre ten sioning forces kN A130 Ø 17 M16 280 110 A135 Ø 21 M20 560 175 A140 Ø 25 M24 960 250 Table 4 Tightening torque for standard nuts When the turbocharger is mou...

Page 49: ...ure screws u Do not lubricate pressure screws In order to correctly fit the clamping nuts the pressure screws 04 must not protrude from the clamping nuts 03 in the direction of the thrust washer 02 u Make sure the pressure screws do not protrude in the direction of the thrust washer Fig 14 Preparing the clamping nut for the tightening procedure 1 Check whether the expansion bushes 42190 with reces...

Page 50: ...que controlled tightening of the pressure screws 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 ta...

Page 51: ...ebuilder Version with water cooled bearing casing u Fit the water pipes according to the instructions of the enginebuilder Version with compressor wheel cooling CAUTION Failure of compressor wheel cooling Any prolonged failure of the compressor wheel cooling will shorten the re placement interval of the compressor wheel u Make sure there is an uninterrupted supply of cooling air during opera tion ...

Page 52: ... and Installing 2 3 Installing the turbocharger Copyright 2020 ABB All rights reserved HZTL4031_EN Rev K February 2020 2 3 7 Attaching the support Fig 18 Attaching the support u If present Attach support 61301 to engine support or to a connecting piece Page 22 115 ...

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

Page 54: ...1_EN Rev K February 2020 3 1 5 Oil orifice in the bearing casing Fig 19 Oil orifice 01 Bearing casing 02 Oil orifice 03 Circlip With an oil inlet pressure of more than 3 bar of overpressure with engine under load up stream of the turbocharger the bearing casings are equipped with an orifice at the oil inlet as standard Page 24 115 ...

Page 55: ... 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 commissioning u Check the oil pressure in the oil supply pipes Warning plates u Check whether warning plates are ...

Page 56: ...sible values Leaktightness of pipes WARNING Risk of burning from hot gas Escaping gases are hot and will lead to serious burns in the event of contact u Check all pipes for leaks in accordance with the enginebuilder s instruc tions 3 2 4 Checks when starting up the engine If present u Measure speed oil pressure and charging pressure at various engine performances u Measure the exhaust gas temperat...

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

Page 58: ...eration Pressure at oil inlet upstream of the turbocharger bar Overpressure Normal operation 2 0 poil 4 5 Engine start Cold oil admissible for a maximum of 15 minutes 8 0 Engine idling admissible for a maximum of 1 hour 0 5 poil 2 5 Pre lubrication and post lubrication engine stopped 0 5 poil 1 0 Warning signal n 0 5 x nBmax 1 25 Alarm signal Not admissible Stop the engine immedi ately 0 6 Table 6...

Page 59: ...e before start preheat oil 30 C Table 7 Lubricating oil temperature at the inlet Lubricating oil temperature at the outlet The oil temperature at the outlet is mainly dependant on Lubricating oil temperature and pressure at the oil inlet Engine load and turbocharger speed Exhaust gas temperature The maximum admissible oil temperature at the outlet is listed in the following table The specified oil...

Page 60: ...replacement intervals Operation above the operating limits defined on the rating plate can shorten the recommended replacement intervals considerably u Measure exhaust gas temperature upstream of turbine u Comply with operating limits on rating plate u Definition and explanations concerning rating plate refer to chapter 2 of Operation Manual Safety u Operating limits refer to chapter 3 of Operatio...

Page 61: ...charger speed 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 3 2 Layout and overview Fig 20 Layout and overview of speed measurement system 86505 Speed sensor 42188 Screw plug 86515 Cable connector 42189 Gasket 86526 F I converter 01 Plug with integrated voltage limiter 86528 Tachom...

Page 62: ... 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 clear deviations of temperature are found the nearest ABB Turbocharging Service Station has to be c...

Page 63: ...O ring No additional gasket is required during assembly Fig 21 Replacing the speed sensor Part number A130 A135 A140 A145 86505 M12 x 1 5 15 Nm M12 x 1 5 15 Nm M12 x 1 5 15 Nm M12 x 1 5 15 Nm Table 9 Tightening torque 86505 u Reduce the engine performance to idling and then stop the engine Pay attention to post lubrication Stopping the engine 42 u Switch off the lubricating oil supply to the turbo...

Page 64: ... 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 i...

Page 65: ...pyright 2020 ABB All rights reserved HZTL4031_EN Rev K February 2020 Suggestion for noise insulation bellows Fig 22 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 35 115 ...

Page 66: ...hat is omitted or performed too late can cause excessive contamination wear and operating failures u Carry out the service work at the specified time intervals CAUTION Specific service interval Exceptional stresses such as a high number of starts and stops harsh envir onmental conditions poor fuel quality or high system vibrations can lead to untimely machine damage even if the prescribed service ...

Page 67: ...hours after commissioning u Clean or replace the oil filter located in the supply pipe to the turbocharger while the en gine is stopped 5 2 3 Service work according to instructions of enginebuilder u Clean or replace the oil filter located in the supply pipe to the turbocharger while the en gine is stopped 5 2 4 Service work according to data on the rating plate Usually after 8000 16000 operating ...

Page 68: ...t 2020 ABB All rights reserved HZTL4031_EN Rev K February 2020 5 2 5 Other service work If a protective grid is installed in the gas outlet casing 61001 by ABB Fig 23 Replacing the protective grid u Remove the protective grid 61205 after 50000 hours and replace it with a new protect ive grid Page 38 115 ...

Page 69: ...er The following operating data and measured values must be entered regularly in the engine logbook of the enginebuilder Rating and speed of the engine Air intake temperature Pressure of the charge air Pressure loss in the charge air cooler Lubricating oil pressure and lubricating oil temperature If present Speed of the turbocharger Air temperature after the compressor and after the charge air coo...

Page 70: ...placing the bearing parts and replacing the non rotating components exposed to hot gas A decisive role is played by various influencing parameters which in extreme cases can drastically reduce the replacement interval of these parts During the prescribed periodic service work the individual parts are examined for wear and replaced if necessary Expected replacement intervals h GAS MDO HFO Turbine c...

Page 71: ...o the following influences Fuel quality and fuel treatment Load profile thermal cycling also number of starts stops emergency shutdowns oper ating point Gas inlet temperature Frequency and execution of cleaning process during operation Turbocharger specification System specific operating conditions combustion quality exhaust gas composition For bearing parts Lubricating oil quality oil filtering o...

Page 72: ...l inlet before turbocharger 28 Post lubricate water cooled bearing casings until the rotors come to a standstill Deac tivate post lubrication as soon as the rotor comes to a standstill Deviating procedures must be coordinated with ABB Turbocharging For oil cooled bearing casings post lubricate for 20 minutes if the turbine inlet temper ature tTE exceeds the following values when the engine is stop...

Page 73: ... ensuring max imum fuel efficiency Maintenance inter val Maintenance work Operating status 24 72 h 1 Cleaning the compressor during operation 44 Engine load 50 85 50 200 h 1 Cleaning the turbine during operation 47 Engine load 20 40 guideline value According to rating plate 2 Cleaning components mechanically 51 Engine stopped Table 11 Maintenance table h Hours of operation 1 If the maintenance int...

Page 74: ... bocharging recommends mechanical cleaning of the contaminated components Periodic cleaning during operation is not a substitute for the service work during which the turbocharger is completely dismantled and cleaned Cause and consequences of contamination The contamination of the compressor stage depends on the degree of purity of the air that is sucked in Deposits can form in the flow channels i...

Page 75: ... operating periods in the lower range of performance that both turbocharger compressors are cleaned 6 2 4 Function and safety of wet cleaning CAUTION Volume of water Uncontrolled volumes of water can damage the turbocharger and the en gine u Never connect the water connection directly to a water pipe or a bigger metering container than the one specified by ABB Turbocharging WARNING Danger due to p...

Page 76: ...emoved by the mechanical action of the impacting droplets 6 2 5 Carrying out wet cleaning of the compressor Fig 24 Carrying out wet cleaning of compressor Engine load Filling amount of water pressure vessel dm3 Water temperature C Water injection period s 50 85 0 4 5 30 10 Table 12 Parameters for wet cleaning of compressor u Remove sealing plug 27005 u Fill container with 0 4 dm3 of pure water u S...

Page 77: ...ed Cause and consequences of contamination ABB Turbocharging recommends the use of fuels with low ash sulphur sodium and vana dium contents The combustion of heavy fuel oil HFO in diesel engines causes contamination of the tur bine stage Poor quality fuel in conjunction with high exhaust gas temperatures can lead to extremely hard deposits on turbine components Operating states with incomplete com...

Page 78: ...mmended This cleaning process is faster and reduces the risk of surging of the tur bocharger 6 3 4 Function and safety of wet cleaning 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 To clean the turbine stage during operation water is injected befor...

Page 79: ...st gas tem perature after the cylinder This must be taken into account when setting the operating point before cleaning If necessary the engine performance must be reduced to meet these conditions The clean ing cycle can be started when the above conditions are fulfilled 6 3 6 Carrying out wet cleaning of the turbine CAUTION Inadmissible thermal stress and flooding of the turbine Smaller amounts o...

Page 80: ...volume flow VW on the basis ofthe cleaning parameters in the table see Table 14 Wet cleaning of turbine parameters 50 u Close the stop valve 02 after 10 minutes u Wait for 10 minutes do not change the load during this stabilisation phase If the cleaning result is unsatisfactory or there is water leakage contact an ABB Turbochar ging Service Station Product Temperature be fore turbine before cleani...

Page 81: ...itive and easily sustain mechanical dam age The use of needle descalers for example or other striking tools dam ages the components Depending on the specification nozzle rings or tur bine casings may have protective coatings which can also be damaged u Use only soft tools such as rags brushes or wire brushes u In case of heavy contamination the cleaning methods described in this chapter such as so...

Page 82: ...lter 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 air u Rinse the filter ring 81265 with water and mild detergent or in the case of heavy con tamination soak and carefully push through Rinse ...

Page 83: ...tion segments 81136 must only be cleaned lightly with compressed air a soft brush or a moist cleaning cloth u Have any heavily contaminated absorption segments replaced by an ABB Turbocharging Service Station Fitting the filter silencer see Fig 26 Cleaning the filter silencer 52 u Insert the absorption segments 81136 into the sheet metal coverings 81137 u Bend the sheet metal coverings 81137 back ...

Page 84: ...material safety data sheet u Comply with local legislation Wear safety goggles Wear safety gloves to protect against chemical hazards Wear a respiratory mask to protect against gases The following parts which are relevant in terms of performance can be cleaned in accord ance with the description below Fig 27 Compressor end non rotating parts 72000 Compressor casing 77000 Wall insert 79000 Diffuser...

Page 85: ... avoid contact with the skin u Ensure proper ventilation u Observe the information in the material safety data sheet for the operat ing materials and supplies u Wear personal protective equipment PPE according to the material safety data sheet u Comply with local legislation Wear safety goggles Wear safety gloves to protect against chemical hazards Wear a respiratory mask to protect against gases ...

Page 86: ...s in hot water or in a liquid such as brake cleaner to soften the contamination u Brush away the contamination or remove with a steam cleaner u Repeat the soaking and brushing process if necessary u Use clean water to remove all traces of solvent from parts u Dry components completely u Spray cleaned surfaces with penetrating oil Do not spray exterior surfaces of the tur bocharger u Dispose of dir...

Page 87: ...ording to the following description 6 4 6 Cleaning the cartridge group on compressor end CAUTION Selection of the cleaning agent Cleaning agents which contain chlorine attack metals u Use only pH neutral cleaning agents which do not attack metals u Observe safety data sheet CAUTION Water and contamination in the cartridge group If water or contamination penetrates the cartridge group this can impa...

Page 88: ...d in the following Fig 29 Soaking the turbine end Product A mm B mm C mm A130 108 17 205 A135 128 20 245 A140 157 25 300 A145 187 30 357 Table 15 Value table for soaking To soak the layers of contamination on the turbine the cartridge group can be immersed vertically in a container 02 with fluid u Place the container 02 inside a larger container 03 so that the overflowing fluid can be collected CA...

Page 89: ...ger and damage parts inside the cartridge group u Place the cartridge group on suitable supports 01 made of wood or metal u Observe dimension B for the supports 01 so that the cartridge group is not immersed too deeply u Let the layers of contamination on the turbine soak for four hours Removing dirt WARNING Health hazard due to soot particles If soot particles enter the eyes or respiratory tract ...

Page 90: ...its lead to rotor unbal ance This can result in bearing or turbocharger damage u Remove all traces of contamination from the turbine u After brushing off the dirt fill the container 02 with clean water and not with salt water u Immerse the turbine of the cartridge group in clean water so that any loose dirt comes off u Lift up the cartridge group and align it horizontally u Clamp the partition wal...

Page 91: ...ABB Turbocharging Service Station Turbine or compressor damaged Bearing damaged Engine Vibrations from engine Contact enginebuilder Table 17 Malfunctions when starting Vibrations Rubbing of rotating parts Normal behaviour not a malfunction Turbochar ger A slight amount of uniform wear at the circumference of the rotor components caused by slight local rubbing against adjacent components is permitt...

Page 92: ...tion Engine Oil filter heavily contaminated Clean Oil pump in lubricating system defect ive Check replace Manometer displays incorrectly Replace manometer Table 19 Malfunctions during operation Lubricating oil pressure too low Speed reduces Possible causes Remedy Turbochar ger Turbine and or nozzle ring severely con taminated Clean see chapter Periodic mainten ance work 43 Rotor components or bear...

Page 93: ...ng water too high Check clean cooling system Insufficient ventilation Improve ventilation Table 22 Malfunctions during operation Exhaust gas temperature too high Charge air pressure too low Engine performance and engine speed unchanged suction condition normal Possible causes Remedy Turbochar ger Manometer display not correct Replace manometer Supply pipe to manometer not sealed Repair leak Filter...

Page 94: ...severely contaminated or corroded compressor wheel can reduce the com pressor wheel s fatigue endurance limit and result in the turbocharger being damaged u Rectify malfunction in accordance with the following table Possible causes Remedy Turbochar ger Compressor components severely con taminated by the ventilation gases that have been fed in Clean see chapter Periodic mainten ance work 43 Optimiz...

Page 95: ...the cause clarified and remedied immediately by an ABB Turbochar ging Service Station u Have parts assessed for damage and if necessary replaced by an ABB Turbocharging Service Station Possible causes Remedy Turbocharger Filter silencer or diffuser contamin ated Clean see chapter Periodic mainten ance work 43 Heavy contamination deposits in the turbine or in the nozzle ring Engine Protective grati...

Page 96: ...le 28 Malfunctions when stopping Runout noises Runout time too short The runout time must be noted down as a reference Because the runout time depends on the oil viscosity the runout time must always be measured at the same oil temperature If the runout time is significantly shorter in comparison to a previous measurement the fol lowing table must be observed Possible causes Remedy Turbochar ger T...

Page 97: ...o chapter Ordering spare parts 107 Replacing the speed sensor 33 Table 30 Malfunction of the speed measurement system No signal or poor signal amplitude Measured speed too high Possible causes Remedy Turbochar ger 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 ampli fication of the nois...

Page 98: ...ar safety gloves to protect against thermal hazards WARNING Cutting injuries when working on the turbocharger Some parts on the turbocharger may have sharp edges There is a risk of a cutting injury u Wear safety gloves against mechanical risks when conducting assembly and disassembly work Wear safety gloves to protect against mechanical hazards CAUTION Further work This Operation Manual may be use...

Page 99: ...sure the required tool set is available see chapter Tools 112 Not all tools are marked with a part number Identification is guaranteed by the tool list This list is enclosed with the tool set WARNING Servicing the tools The tools must be checked for damage before and after use u Visually inspect for corrosion cracks deformation and wear u Damaged tools must no longer be used and must be replaced S...

Page 100: ...on to the correct attachment of loads 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 s...

Page 101: ...0 65 02 Radial air suction branch 6 8 13 21 03 Axial air suction branch 4 5 6 9 04 Compressor casing 24 40 60 95 05 Wall insert 6 8 15 24 06 Diffuser 3 4 7 11 07 Cartridge group 40 60 110 180 08 Nozzle ring 2 2 4 6 09 Burst ring 2 3 5 12 10 Turbine casing 1 inlet 50 75 135 210 Turbine casing 2 inlets 45 65 125 190 Turbine casing 3 inlets 125 190 11 Gas outlet flange 7 13 20 23 12 Gas outlet casing...

Page 102: ...Removing the air inlets u Mark the casing position for assembly Fig 33 Removing the air inlets 1 Attach lifting gear to the filter silencer 81000 or air suction branch 82000 2 Loosen and remove V clamp 72020 3 Remove filter silencer 81000 or air suction branch 82000 set it down properly in an appropriate place and secure it 4 Remove and dispose of the O ring 81010 82010 Page 72 115 ...

Page 103: ...tling and fitting 8 5 Removing the gas outlet casing Copyright 2020 ABB All rights reserved HZTL4031_EN Rev K February 2020 8 5 Removing the gas outlet casing Removing the insulation Fig 34 Removing the insulation u Remove gas outlet casing insulation Page 73 115 ...

Page 104: ... 61301 from bracket 4 Remove the gas outlet casing 61001 set it down properly in an appropriate place and secure it 5 Remove and dispose of the gasket 61002 8 6 Removing the gas outlet flange Depending on the way of fixing the gas outlet flange the appropriate Working Instruction has to be consulted pressing off using 3 or 6 press off screws If the following Working Instructions are not observed t...

Page 105: ...ecessary for service work u If necessary Treat the centering seat with rust remover through the press off threads and the clearance holes u Mark the casing position for assembly Fig 36 Dismantling the gas outlet flange Product Press off screws strength 8 8 Tightening torque A130 3 x M 8 x 20 20 Nm A135 3 x M10 x 25 40 Nm A140 3 x M12 x 30 65 Nm A145 3 x M12 x 30 65 Nm Table 35 3 press off screws n...

Page 106: ...ecessary for service work u If necessary Treat the centering seat with rust remover through the press off threads and the clearance holes u Mark the casing position for assembly Fig 37 Removing the gas outlet flange Product Press off screws strength 8 8 Tightening torque A130 6x M6 x 20 10 Nm A135 6x M8 x 25 20 Nm A140 6x M10 x 30 40 Nm A145 6x M12 x 30 65 Nm Table 36 6 press off screws not includ...

Page 107: ...ing 1 Loosen screws 72011 and remove together with fastening strips 72012 2 Attach swivel lifting eye S to the compressor casing and the lifting gear 3 Remove the compressor casing 72000 and turn it 180 4 Remove and dispose of the O ring 42012 5 Undo screws 79041 and remove from the compressor casing 72000 with fixing discs 79040 and diffuser 79000 If the compressor casing cannot be loosened it ca...

Page 108: ...TL4031_EN Rev K February 2020 Dismantling the wall insert Fig 39 Dismantling the wall insert 1 Knock the wall insert 77000 out of the compressor casing 72000 with a plastic tip hammer 2 Attach swivel lifting eye S to the compressor casing 72000 and the lifting gear 3 Lift up the compressor casing 72000 4 Remove and dispose of the O ring 77005 Page 78 115 ...

Page 109: ...2020 8 8 Pressing off the casing CAUTION Axial force of the press off tool Using the press off tool 90042 a high level of axial force can be generated If the casing is pressed off with too much force on one side the rotor can be damaged u Use the tool on both sides in alternation and make sure not to press off too hard on either side Fig 40 Press off the casing Page 79 115 ...

Page 110: ...sheets 01 02 03 u Mark the casing position for assembly Do not remove oil orifice if present To limit the oil flow rate through the bearing casing during operation engine under load to the admissible values an oil orifice is mandatory at the oil inlet of the bearing casing if the oil inlet pressure is 3 bar overpressure If an oil orifice is fitted in the oil inlet of the bearing casing it must not...

Page 111: ...rbus Ripp washers 51003 together with fastening strips 51002 Fig 44 Removing cartridge group 2 3 Insert screws from service support into cartridge group 4 Secure ring nuts VRM onto the screws with washers 5 Secure the lifting gear to the ring nuts and suspension eye as shown 6 Remove the cartridge group vertically from the turbine casing 7 Turn the cartridge group into the horizontal rotor axis If...

Page 112: ... Rev K February 2020 8 10 Removing the nozzle ring Fig 45 Removing the nozzle ring 1 If present Remove the metal C ring 51105 2 Position the fastening strips 51002 in place 3 Pull out the nozzle ring 56001 with the two extraction devices 90070 and the service support base 90012 4 Remove the lamellar sealing ring 56005 5 Remove the burst ring 57210 Page 82 115 ...

Page 113: ...2020 ABB All rights reserved HZTL4031_EN Rev K February 2020 8 11 Installing the cartridge group on the service support Fig 46 Installing the cartridge group on the service support 1 Remove ring nuts VRM 2 Remove service support screws 3 Fit service support 90012 according to the illustration 4 Insert the cartridge group 5 Fit the nuts Page 83 115 ...

Page 114: ...0 70 1 37 A145 M 0 15 0 25 0 88 1 56 Table 37 Permissible clearances A and B 1 Move the rotor to and fro up to the stop In order to obtain a correct measurement elev ate the turbine a little 2 Measure clearance A and compare it with the permissible values in the table 3 Raise the compressor and push the turbine down at the same time 4 Raise the turbine and push the compressor down at the same time...

Page 115: ...n the heat shield 42400 and the turbine casing 51000 Fig 48 Nozzle ring compression PD 42001 Bearing casing 51000 Turbine casing 42400 Heat shield 56001 Nozzle ring Product Nozzle ring compression PD mm A130 M 0 15 0 15 A135 M 0 16 0 16 A140 M 0 16 0 16 A145 M 0 16 0 16 Table 38 Nozzle ring compression PD 1 Measure dimensions A B and S on cleaned surfaces 2 Calculate compression PD u If the calcul...

Page 116: ...g ring 56005 in the correct slot see detail A1 A2 When doing this pay attention to correct winding of the lamellar sealing ring see detail B 2 Secure the lamellar sealing ring 56005 with adhesive tape 01 3 Place the burst ring 57210 in the turbine casing 4 Insert the nozzle ring 56001 with the cams facing downwards into the turbine casing as far as it will go Align the cams on the nozzle ring with...

Page 117: ...ing it by 90 Fig 50 Lifting the cartridge group and rotating it by 90 1 Loosen and remove nuts 2 Lift the cartridge group out of the service support 90012 3 Insert the screws of the service support from above and fit ring nuts VRM with washers 4 Attach lifting gear to the ring nuts VRM 5 Lift cartridge group at the side of the ring nuts VRM and turn it into a vertical position Installing the cartr...

Page 118: ... Nm A130 M8 25 A135 M10 45 A140 M12 75 A145 M12 75 Table 39 Tightening torque 51007 1 Coat thread of studs 51006 with high temperature grease 2 Align the casing position of the cartridge group to the marking 3 Lower the cartridge group into the turbine casing 4 Remove ring nuts and screws 5 Fit fastening strips 51002 with Verbus Ripp washers 51003 and hexagon nuts 51007 6 Tighten the hexagon nuts ...

Page 119: ...BB is removed A burst protection is in tegrated into this turbine casing insulation supplied by ABB For turbochargers which were ordered from ABB without insulation or which are equipped with the insulation 02 separate burst protection 03 is fit ted If the insulation from ABB 01 is not installed the separate burst protec tion 03 plus either the insulation 02 or an appropriate insulation supplied b...

Page 120: ...79041 u Always replace the O ring 77005 see section Spare parts A130 A140 1 Fit new O ring 77005 2 Install the wall insert 77000 in the compressor casing 3 Fit diffuser 79000 with fixing discs 79040 and screws 79041 Observe the tightening torque A145 1 Fit the lifting beam 90258 to the wall insert 77000 2 Fit the swivel lifting eye S to the lifting beam Secure lifting gear to the swivel lifting ey...

Page 121: ... M8 35 A135 M10 70 A140 M12 105 A145 M14 170 Table 41 Tightening torque 72011 1 Fit new O ring 42012 2 Thoroughly clean the fastening strips 72012 before assembly 3 Attach swivel lifting eyes S to compressor casing 72000 Secure lifting gear to the swivel lifting eyes 4 Install the compressor casing 72000 5 Install the fastening strips 72012 with screws 72011 Observe the tightening torque If these ...

Page 122: ... Push the feeler gauges 01 into the gap without clearance simultaneously at the top N1 and the bottom N2 2 Calculate clearance N and compare it with the permissible values in the table 3 Push the feeler gauges 01 into the gap without clearance simultaneously at the top R2 and the bottom R1 4 Calculate clearance R and compare it with the permissible values in the table CAUTION Clearances outside th...

Page 123: ...nstalling the air inlets Product Size Tightening torque Nm A130 M12 60 A135 M12 60 A140 M12 60 A145 M12 60 Table 43 Tightening torque 72020 1 Secure lifting gear to filter silencer 81000 2 Fit a new O ring 81010 to the filter silencer 81000 or a new O ring 82010 to the air suction branch 82000 3 Fit the filter silencer 81000 or air suction branch 82000 with the V clamp 72020 4 Observe the tighteni...

Page 124: ... HZTL4031_EN Rev K February 2020 8 19 Installing the gas outlet flange Fig 56 Installing the gas outlet flange 1 If present Insert the metal C ring 57003 into the turbine casing 51000 and secure with high vacuum grease 2 Install the gas outlet flange 57002 in the turbine casing 3 Measure radial clearance R see chapter Radial clearances N and R Page 94 115 ...

Page 125: ...ation of the turbine casing Copyright 2020 ABB All rights reserved HZTL4031_EN Rev K February 2020 8 20 Fitting the insulation of the turbine casing Fig 57 Fitting the insulation u Fit the insulation according to the illustration Observe tightening torques see Table of tightening torques 98 Page 95 115 ...

Page 126: ...Size Tightening torque Nm A130 M8 20 A135 M10 40 A140 M12 65 A145 M12 65 Table 44 Tightening torque 51009 1 Insert a new gasket 61002 into the gas outlet casing 61001 2 Coat the threads of the studs 51008 with high temperature grease 3 Attach the lifting gear to the gas outlet casing 61001 and position the gas outlet casing in the correct position on the turbine casing 51000 4 If present Fit suppo...

Page 127: ...1 Installing the gas outlet casing Copyright 2020 ABB All rights reserved HZTL4031_EN Rev K February 2020 Fitting the insulation Fig 59 Fitting the insulation u Fit the insulation according to the illustration Observe tightening torques see Table of tightening torques 98 Page 97 115 ...

Page 128: ...ns Position Part number A130 A135 A140 A145 02 72020 M12 60 Nm M12 60 Nm M12 60 Nm M12 60 Nm 04 79041 M6 8 Nm M6 8 Nm M6 8 Nm M6 8 Nm 08 51007 M8 25 Nm M10 45 Nm M12 75 Nm M12 75 Nm 09 51009 M8 20 Nm M10 40 Nm M12 65 Nm M12 65 Nm 11 72011 M8 35 Nm M10 70 Nm M12 105 Nm M14 170 Nm 15 86505 M12 x 1 5 15 Nm M12 x 1 5 15 Nm M12 x 1 5 15 Nm M12 x 1 5 15 Nm 16a M10 40 Nm M10 40 Nm M12 65 Nm M12 65 Nm Tab...

Page 129: ...connections Position Part number A130 A135 A140 A145 16a 16b 1 M10 40 Nm M10 40 Nm M12 65 Nm M12 65 Nm 16b 2 M8 20 Nm M8 20 Nm M10 40 Nm M10 40 Nm 18 M6 10 Nm M6 10 Nm M6 10 Nm M6 10 Nm 19 M8 25 Nm M8 25 Nm M8 25 Nm M8 25 Nm 20 M10 45 Nm M10 45 Nm M10 45 Nm M10 45 Nm Table 46 Tightening torques for insulation 1 Tightening torque for attaching the insulation with integrated burst protection at the ...

Page 130: ...ly compatible manner Wear safety gloves to protect against thermal hazards CAUTION Directives for taking out of operation Serious damage to engine or property can be caused by non compliance with the directives for blanking the turbocharger off the engine u Follow the directives of the enginebuilder If the engine has to be operated again as quickly as possible following a turbocharger de fect then...

Page 131: ...rtridge group Incorrect handling of a cartridge group can damage the turbocharger and cause injuries to persons u Have repairs to the cartridge group carried out by an ABB Turbocharging Service Station only To enable you to quickly put an engine back into operation after a turbocharger has sus tained damage ABB Turbocharging recommends having a replacement cartridge group available in storage The ...

Page 132: ...lowing section Gas outlet casing not removed u Fit the turbine casing into the gas pipe and on the gas outlet casing again u Attach the cover plate see following section Fig 62 Fitting the cover plate u Make sure that the oil connections in the bracket are equipped with gaskets 1 Close opening in turbine casing 51000 with cover plate 01 2 Thoroughly clean the fastening strips 51002 before assembly...

Page 133: ...t be manufactured by the operating company according to the following drawing Material General structural steel in accordance with DIN EN 10025 2 Fig 63 Cover plate drawing Product B1 0 5 B2 B3 B4 0 2 B5 B6 B7 ØD1 0 2 ØD2 R1 M A130 65 7 60 130 11 7 1 4 150 35 7 227 7 17 105 M8 A135 79 6 80 155 14 2 1 6 180 39 6 271 7 21 125 M8 A140 98 2 102 190 17 2 2 0 220 48 2 332 5 25 153 M10 A145 116 8 120 226...

Page 134: ... 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 data s...

Page 135: ... 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 ...

Page 136: ...s 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 components...

Page 137: ...ferent model variants are not taken into account 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 12 2 Required cust...

Page 138: ...Operation Manual 4 Product description A130 M A145 M 12 Spare parts 12 2 Required customer spare part set 97070 Copyright 2020 ABB All rights reserved HZTL4031_EN Rev K February 2020 Page 108 115 ...

Page 139: ...re parts 12 3 View of turbocharger with part numbers Copyright 2020 ABB All rights reserved HZTL4031_EN Rev K February 2020 12 3 View of turbocharger with part numbers Fig 64 Overview of part numbers only available in customer spare part set 97070 Page 109 115 ...

Page 140: ...tal C ring 57210 Burst ring 61001 Gas outlet casing 61002 in the customer spare part set Gasket 61200 Burst protection 61205 Protective grid 61301 Support 72000 Compressor casing 72011 Hexagon head screw 72012 Fastening strip 72020 V clamp 77000 Wall insert 77005 in the customer spare part set O ring 79000 Diffuser 79041 in the customer spare part set Counter sunk screw 81000 Filter silencer 81010...

Page 141: ... reserved HZTL4031_EN Rev K February 2020 12 4 View of turbine cleaning device 12 4 1 One cleaning nozzle per turbine inlet Fig 65 Overview of part numbers Part number Designation 51301 1 inlet 1 cleaning nozzle 2 inlets 2 cleaning nozzles 3 inlets 3 cleaning nozzles 51302 Gasket 51303 Screw plug Table 50 Spare parts list Page 111 115 ...

Page 142: ...s required 90000 Designation Quantity 90012 Service support 1 90013 Plastic insert 1 90258 A145 Lifting beam 1 90230 Socket screw 2 90042 Press off tool 1 90070 Extraction device 1 Table 51 Customer tool set 90000 This tool set can be ordered from any ABB Turbocharging Service Station The following spe cifications must be included in the order Turbocharger type Designation and part number of the t...

Page 143: ...ing parts 54 Fig 28 Turbine end non rotating parts 56 Fig 29 Soaking the turbine end 58 Fig 30 Swivel lifting eyes 69 Fig 31 Starpoint ring nut VRM 70 Fig 32 Weights of assemblies 71 Fig 33 Removing the air inlets 72 Fig 34 Removing the insulation 73 Fig 35 Removing the gas outlet casing 74 Fig 36 Dismantling the gas outlet flange 75 Fig 37 Removing the gas outlet flange 76 Fig 38 Removing the com...

Page 144: ...Operation Manual 4 Product description A130 M A145 M Figures Copyright 2020 ABB All rights reserved HZTL4031_EN Revision K February 2020 Fig 65 Overview of part numbers 111 Page 114 115 Page 114 115 ...

Page 145: ...ions during operation Exhaust gas temperature too high 63 Table 23 Malfunctions during operation Charge air pressure too low 63 Table 24 Malfunctions during operation Charge air pressure too high 64 Table 25 Malfunctions during operation Engine performance losses 64 Table 26 Malfunction Turbocharger pumping 65 Table 27 Malfunction Sporadic surge blows 65 Table 28 Malfunctions when stopping Runout ...

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