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ABB HT843525 Operation Manual Download Page 49

Operation Manual / 4 Product description / A100-L

4  Monitoring during operation / 4.2  Turbocharger speed

© Copyright 2017 ABB. All rights reserved.

HZTL4034_EN

Revision K

June 2017

4.2.5

Malfunction of the speed measurement system

The possible reasons for malfunction of the speed measuring system are described in
chapter Troubleshooting.

Page 

21

 / 

106

Summary of Contents for HT843525

Page 1: ...arging Operation Manual A170 L37 HT843525 English Original Operation Manual Chapter Document ID 1 Introduction HZTL4005_EN_F 2 Safety HZTL4024_EN_D 3 Safety data sheet HT843525 4 Product description HZTL4034_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: ... 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 ...

Page 10: ......

Page 11: ... 2 1 3 Definition of mandatory signs 3 1 4 Definition of safety instructions 3 1 5 Intended use 4 1 6 Warning plates on the turbocharger 5 1 7 Turbocharger rating plate 6 1 8 Periodic check of the pressure vessels 7 1 9 Lifting of loads 8 1 10 Prerequisites for operation and maintenance 9 1 11 Hazards during operation and maintenance 10 1 12 Safe operation 12 1 13 Safe maintenance 13 ...

Page 12: ...ence 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 a...

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: ...e data are given on the rating plate ABB accepts no liability and rejects all warranty claims for any non intended uses WARNING Unapproved operation Any operation of the turbocharger outside of its operating limits can be haz ardous to personnel u Only operate the turbocharger within the operating limits u Only trained personnel must operate the turbocharger The intended use of the turbocharger in...

Page 15: ... 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 16: ...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 17: ...nMmax 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 8 Periodic check of the pressure vessels The pressure vessels used by ABB Turbocharging such as those for wet or dry clea...

Page 18: ... 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 19: ...e 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 tur...

Page 20: ...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 21: ...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 22: ...rical installations u Do not carry out any tests with regard to insulation resistance or voltage on the electrical components 1 12 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 start...

Page 23: ...ou 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 he...

Page 24: ...fety 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 en...

Page 25: ... 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 supp...

Page 26: ...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...

Page 27: ...Operation Manual A170 L37 Safety data sheet Page 1 1 Safety data sheet Copyright 2018 ABB All rights reserved HT843525 April 2018 A170 L37 HT843525 A170 L37 HT843525 306 550 293 520 3300 36 100 100 2018 ...

Page 28: ......

Page 29: ...ssioning after taking out of operation 15 4 Monitoring during operation 16 4 1 Oil pressure oil temperature 16 4 2 Turbocharger speed 18 4 3 Low pressure measurement at the filter silencer 22 5 Operation and service 23 5 1 Noise emission 23 5 2 Service work 24 5 3 Expected replacement intervals 28 5 4 Flexible turbocharger cut out 29 5 5 Stopping the engine 30 6 Periodic maintenance 31 6 1 Forewor...

Page 30: ...e ring and the insulation A175 L and smaller 72 8 11 Fitting the gas inlet casing nozzle ring A180 L and larger 75 8 12 Axial clearance A after assembly 78 8 13 Fitting diffuser wall insert 79 8 14 Fitting the filter silencer 82 8 15 Fitting the filter silencer with noise package 84 8 16 Table of tightening torques 86 9 Taking a turbocharger out of operation 89 9 1 Possible emergency repairs 89 9 ...

Page 31: ...estions 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 documents C...

Page 32: ...June 2017 1 4 Layout and function of the turbocharger Fig 1 Layout and function of the turbocharger 01 Filter silencer 08 Gas inlet casing 02 Thrust bearing 09 Bearing casing 03 Radial plain bearing 10 Diffuser 04 Radial plain bearing 11 Compressor wheel 05 Gas outlet casing 12 Compressor casing 06 Turbine wheel 13 Air outlet silencer option 07 Nozzle ring Page 4 106 ...

Page 33: ...air passes through the filter silencer 01 to the compressor wheel 11 The air then flows through the diffuser 10 and exits the turbocharger through the compressor cas ing 12 An air outlet silencer 13 is optionally available If installed this will reduce the amount of noise generated by the components at the outlet side after the compressor cas ing The rotor runs in two radial plain bearings 03 04 w...

Page 34: ...ates 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 eq...

Page 35: ...f the rating plates Copyright 2017 ABB All rights reserved HZTL4034_EN Revision K June 2017 1 6 Locations of the rating plates Fig 3 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 7 106 ...

Page 36: ... specified here Product Weight kg A165 L 2300 A170 L 3300 A175 L 5600 A180 L 7500 A185 L 10500 A190 L 13500 Table 2 A100 L Weights 2 2 Removing the turbocharger WARNING Risk of tipping If the turbocharger is not sufficiently supported 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 tur...

Page 37: ...turbocharger Copyright 2017 ABB All rights reserved HZTL4034_EN Revision K June 2017 Fig 4 Fitting lifting gear to turbocharger u Loosen fixing screws on compressor end and turbine end foot u Lift turbocharger from engine and put down in a suitable location u Cover oil connections Page 9 106 ...

Page 38: ... turbocharger on the bracket Fig 5 Placing the turbocharger on the bracket u Remove covers from the oil connections u Align turbocharger and place on engine bracket u Tighten fixing screws Steps for fastening the turbocharger 11 while doing this only slightly loosen the lifting gear u Remove lifting gear from suspension eyes of the bearing casing u Connect cable to speed sensor u Connect all gas a...

Page 39: ...ion a compressor end a height of turbocharger foot a Dimension a turbine end a height of turbocharger foot F spacer sleeve D Value b Hole in bracket Dimension c Thread length 1 5 x nominal thread diameter Coefficient of friction 0 12 lightly oiled Table 3 General information about fastening the turbocharger Compressor end foot Fig 6 Compressor end foot u Tighten the foot fixing screws or nuts diag...

Page 40: ... 3100 Table 4 Tightening torques foot screws Angle controlled tightening Product Thread size Height a of foot mm Pre tightening torque Nm Tightening angle for height a DEG Additional tightening angle for every 10 mm of additional screw length b DEG A165 L M22 86 120 30 3 7 A170 L M27 100 220 30 3 1 A175 L M30 120 300 30 2 6 A180 L M33 136 400 35 2 6 A185 L M39 151 600 35 2 4 A190 L M42 167 700 35 ...

Page 41: ...l with a filter mesh width of 0 050 mm is sufficient for the tur bocharger 3 1 3 Oil pressure Comply precisely with the oil pressure before the turbocharger for trouble free operation If the oil pressure at the inlet of the turbocharger is too high it can be reduced with a throttle valve The throttle valve is normally already fitted on the turbocharger and has been correctly set by the enginebuild...

Page 42: ...icating 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 present and legible u Check whether the protective sheets have been removed 3 2 3 Checks after commi...

Page 43: ...mbly can liquefy or vaporise and es cape as oily fluids during the initial hours of operation Continual escape of an oily fluid indicates an oil leak If there is a leak contact an ABB Turbocharging Service Station 3 3 Commissioning after taking out of operation If present u Remove cover plates blind flanges from the compressor casing the gas inlet and the gas outlet General u Check the exhaust gas...

Page 44: ... the inlet of 30 70 C 0 8 2 5 Admissible for normal operation with an oil temperature range at the inlet of 70 85 C 0 8 2 0 Admissible during engine warm up 0 8 4 0 Temporarily admissible 1 h alarm 0 6 0 8 Not admissible emergency stop 0 0 0 6 Admissible during pre lubrication and post lubrication engine stopped 0 2 0 6 Table 6 Lubricating oil pressure oil inlet Lubricating oil temperature at the ...

Page 45: ...l outlet C Admissible 45 110 Admissible 85 130 Temporarily admissible alarm 45 110 Temporarily admissible alarm 85 130 Not admissible stop engine 45 120 Not admissible stop engine 85 140 Table 8 Lubricating oil temperature at the outlet If the turbocharger was operated for a longer period of time outside of the admissible range ABB Turbo Systems recommends to have the turbocharger inspected by an ...

Page 46: ...AUTION Do not use cables as a climbing aid If you pull the speed measurement cables too hard contacts can be pulled out u Do not tension the speed measurement cables 4 2 2 Layout and overview Fig 8 Layout and overview of the speed measurement system 86505 Speed sensor 86528 Tachometer 86506 O ring 42047 Screw plug 86515 Cable connector 32109 Sealing disc with cams 86526 F I converter Alternative m...

Page 47: ...t 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 clear ...

Page 48: ...ned with a sealing lip and does not require a sealing disc for as sembly Fig 9 Replacing the speed sensor Part number A165 L A170 L A175 L A180 L A185 L A190 L 86505 M18x1 5 150 Nm M18x1 5 150 Nm M18x1 5 150 Nm M27x2 320 Nm M27x2 320 Nm M27x2 320 Nm Table 9 Tightening torques 86505 u Reduce the engine performance to idling and then stop the engine Pay attention to post lubrication Stopping the eng...

Page 49: ...ration 4 2 Turbocharger speed Copyright 2017 ABB All rights reserved HZTL4034_EN Revision K June 2017 4 2 5 Malfunction of the speed measurement system The possible reasons for malfunction of the speed measuring system are described in chapter Troubleshooting Page 21 106 ...

Page 50: ...using a filter mat An increased pressure loss indicates an increase in the fouling of the filter material 4 3 2 U tube manometer at the filter silencer Fig 10 U tube manometer at the filter silencer 81000 Filter silencer 81050 U tube manometer A mm H2O Pressure loss pressure difference If the turbocharger is operated at maximum engine power and pressure loss A reaches the value of 200 mm H2O u Cle...

Page 51: ...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 insu...

Page 52: ...ction checks Service work enables to detect and rectify changes to the turbocharger and ensures full operability of the turbocharger CAUTION Service intervals Any service work on the turbocharger that 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 Shortened service intervals Excepti...

Page 53: ...ast service 5 2 1 Service work every 25 50 hours CAUTION Unknown operational changes Impairment to the degree of a possible operating failure can be the con sequence u Have any unknown causes clarified by an ABB Turbocharging Service Sta tion u Visual check for air exhaust gas water and oil leaks u Record operating data and enter in the engine logbook u In case of deviations determine the cause 5 ...

Page 54: ...ing can also be carried out after disassembling the gas inlet casing u Fit the wall insert u Install the filter silencer 5 2 4 Service work on turbocharger every 36000 hours Service work on the rotor and bearing parts must be carried out by an ABB Turbocharging Service Station Damaged and worn out parts must be replaced with original ABB parts u Remove the filter silencer u Clean filter silencer a...

Page 55: ...ing 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 Pressure loss in the filter s...

Page 56: ...ng the non rotating components exposed to hot gas A decisive role is played by various influencing parameters which in extreme cases can drastically shorten the replacement interval of these parts During the prescribed periodic service work the individual parts are examined for wear and replaced if necessary Expected replacement intervals h Turbocharger part Operation with HFO Gas inlet casing 500...

Page 57: ... turbochargers can be operated with one turbocharger switched off The flexible switch on or switch off of a turbocharger is re ferred to as a flexible turbocharger cut out In flexible systems slide valves or flaps are in stalled by the enginebuilder before the gas inlet and after the air outlet of the turbocharger Depending on the version of the system the turbocharger can be switched off or on ma...

Page 58: ... CAUTION Automatic switching of the flaps During automatic flap control there is a risk of the turbocharger rotating opposite the intended direction of rotation if the air outlet flap is open fur ther than the gas inlet flap during the switching process This can lead to damage on the turbocharger u The turbocharger should only be switched on or off below charging pres sures of 0 3 bar u Close the ...

Page 59: ...rved HZTL4034_EN Revision K June 2017 6 Periodic maintenance 6 1 Foreword to maintenance Maintenance work includes regular visual controls and cleaning operations which are inten ded to ensure the trouble free functioning of the turbocharger Described maintenance points Filter silencer Compressor Turbine and nozzle ring Page 31 106 ...

Page 60: ... 2 Cleaning the filter silencer Filter silencer with tension band Fig 12 Layout and overview of filter silencer 81126 Lock 81266 Cover grid 81135 Body of filter silencer 81268 Connecting strip 81136 Absorption segment 81270 Tension band 81137 Sheet metal covering 81271 Lock 81265 Filter ring if present E Insert unit absorption segment sheet metal covering fitted Page 32 106 ...

Page 61: ...and connecting strips 81268 see Fig 12 Layout and overview of fil ter silencer 32 u Pull out insert units E u Bend up the sheet metal coverings 81137 and remove the absorption segments 81136 u Clean the absorption segments 81136 When cleaning note that the absorption segments may only be cleaned lightly with pres surized air with a soft brush or a moist cleaning cloth Otherwise there is a danger o...

Page 62: ...ion K June 2017 6 3 Changing the filter strip on the filter silencer casing This chapter applies only to turbochargers with filter silencer casing The filter ring 81265 is replaced with the filter silencer installed Fig 13 Dismantling filter ring circumferential part u Dismantle circumferential part 9 Fig 14 Opening filter ring lock u Open the lock of the filter ring 81265 Page 34 106 ...

Page 63: ...ig 15 Attaching new filter ring u Attach the new filter ring 81265 on the filter ring to be replaced so they overlap Fig 16 Fitting new filter ring u Pull on the old filter ring until the new filter ring is completely wrapped around the filter silencer u Undo the connection between the new and the old filter ring u Fasten the newly installed filter ring 81265 then fit circumferential part 9 Page 3...

Page 64: ...during operation prevents or delays any major increase in contamination But it never replaces the regular service work where the turbocharger is completely dismantled and the compressor is mechanically cleaned Cleaning interval The interval between the cleaning cycles depends greatly on the operating conditions Cleaning should normally take place about every 50 hours of operation If the specified ...

Page 65: ...cal action of the impacting droplets The procedure is perfectly suitable provided that the contamination has not progressed too far Cleaning several turbochargers If several turbochargers are installed on an engine it is recommended to clean one com pressor after the other CAUTION Volume of water for cleaning the compressor Uncontrolled volumes of water can damage the turbocharger and the en gine ...

Page 66: ... damage u Always wear ear protection when carrying out wet cleaning on the com pressor Wear ear protection Fig 17 Overview of wet cleaning of compressor 81000 Filter silencer A Can 81126 Lock B Filler opening u Remove insulation from flange of filter silencer 81000 if present u Unscrew lock 81126 u Measure volume of water according to the following table u Pour this water into a clean can A u Care...

Page 67: ... A185 L 3 0 A190 L 3 0 Table 12 Volume of water per cleaning process The filling time is 4 15 seconds Checking the filter plug The filter plug only needs to be checked in the turbocharger version with a cast filter silen cer See chapter Design variants 59 Fig 18 Filter plug view Disassembly and checking of the filter plug 81125 is required if 20 seconds after the clean ing process water is still v...

Page 68: ...h level of contamina tion can lead to intolerably high rotor unbalance Despite periodic cleaning during operation experience shows that overhauls during which the turbine and nozzle ring or VTG are mechanically cleaned cannot be omitted Cleaning method The turbine and the nozzle ring are cleaned during operation using the dry cleaning method This cleaning method is tested and approved by ABB Turbo...

Page 69: ...aning device Fig 19 Overview of dry cleaning device 11 Granulate container 51702 16 Protection valve closed 51713 12 Cover cap 51703 17 Pressurised air valve venting 51704 13 Pressurised air supply 4 7 bar 18 Plate 14 Piping 19 Cleaning instructions 51717 15 On Off valve closed 51705 20 Gas inlet casing insulated CAUTION Protecting the pressurised air system u Protect the pressurised air system ag...

Page 70: ... remove the cover cap 12 u Fill the specified amount of granulate into the container 11 u Screw on and tighten the cover cap 12 u Open the combined pressurised air valve pressure release valve 17 down lever posi tion u Open the protection valve 16 u Open the on off valve 15 for cleaning the turbine for 3 4 minutes u Close the on off valve 15 u Close the protection valve 16 u Set the combined press...

Page 71: ...ng Hard granulated materials such as natural core granulates Soft blast media Activated carbon particles The average grain size of the cleaning granulate must be between 1 2 and 2 0 mm The specific weight of the cleaning granulate must not exceed 1 2 kg dm3 Amount of granulate per turbocharger Product Quantity dm3 A165 L 1 0 A170 L 1 5 A175 L 2 0 A180 L 2 5 A185 L 3 0 A190 L 3 5 Table 14 Amount of...

Page 72: ...ater due to other causes the gas outlet casing can be drained Fig 20 Drain pipe diagram 01 Drain pipe A Position 1 02 Drain cock B Position 2 03 Drain 04 Air line from compressor casing u On the drain pipe 01 set the drain cock 02 to position 1 A If the drain pipe 01 is blocked u Set the drain cock 02 to position 2 B and clean the drain pipe 01 with air from the compressor casing 04 If cleaning wi...

Page 73: ...ervice Sta tion Turbine or compressor damaged Bearing damaged Engine Vibrations from engine Contact enginebuilder Table 16 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 compr...

Page 74: ...f in an environmentally compatible manner Wear safety gloves to protect against thermal hazards Possible causes Remedy Turbocharger Axial clearance of the rotor excessive Contact ABB Turbocharging Service Sta tion Engine Oil filter heavily contaminated Clean Oil pump in lubricating system defective Check replace Manometer displays incorrectly Replace manometer Table 18 Malfunctions during operatio...

Page 75: ...high Check clean cooling system Insufficient ventilation Improve ventilation Table 20 Malfunctions during operation Exhaust gas temperature too high Charge air pressure too low Engine performance and engine speed unchanged suction condition normal Possible causes Remedy Turbocharger Manometer display not correct Replace manometer Supply pipe to manometer not sealed Repair leak Filter silencer cont...

Page 76: ...3 Surging of the turbocharger Surging of the turbocharger Possible causes Remedy Turbocharger Filter silencer or diffuser contamin ated Clean Periodic maintenance 31 Heavy dirt deposits in the turbine or in the nozzle ring Engine Protective grating in front of the tur bocharger contaminated or damaged Clean replace Charge air cooler Cooler contaminated Clean Charge air duct blocked Table 23 Surgin...

Page 77: ...ration 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 Turbocharger contaminated Clean Bearing damaged Contact ABB Turbocharging Service Sta tion Rotor rubbing Foreign object in the turbocharger Table 24 Malfunctions when stopping Runout noises Shortened ru...

Page 78: ...uation electronics This problem will be remedied by removing the gasket Sensor defective Contact ABB Turbocharging Service Station Measured speed too high Contamination of the sensor tip As the sensor tip is magnetic it can attract material particles This reduces the distance to the auxiliary bearing which can lead to amplification of the noise component and hence to false trig gering Disassemble ...

Page 79: ... u Mark the casing position for assembly Identification of the assembly devices Not all assembly devices are marked with a part number Identification is guaranteed by the tool list This list is enclosed 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 assem...

Page 80: ...fting gear with sufficient load limit u Pay attention to the correct attachment of loads on the crane hook u People must not stand under suspended loads Wear safety gloves to protect against mechanical hazards Wear safety helmet Definition of terms Suspension point Defined loading point on a component or an assembly blind hole thread eyelet lug Assembly device Devices that are fitted on the turboc...

Page 81: ... L A175 L A180 L A185 L A190 L 01 Filter silencer 240 360 600 800 850 1050 02 Wall insert 240 340 560 820 1090 1500 03 Diffuser 40 60 100 140 200 270 04 Compressor casing 320 450 740 960 1360 1800 05 Cover ring 30 50 75 90 110 150 06 Nozzle ring 10 20 25 50 65 85 07 Gas inlet casing 180 240 380 520 700 810 Table 27 Weights of assemblies kg The total weight of the complete wall insert is made up of...

Page 82: ...mbly Assembly of the filter silencer casing This chapter applies only to turbochargers with filter silencer casing Only the assembly of the filter silencer casing is described in detail The disassembly must be carried out in reverse order of the assembly Fig 22 Overview of filter silencer casing disassembly and assembly 01 02 Bottom part 03 04 07 08 Side part 05 06 09 Circumferential part 10 11 Fl...

Page 83: ... of filter silencer casing assembly Only this way is it possible to fit all the parts u Do not tighten the screws during assembly Fig 23 Fitting filter silencer casing 1 u Fit the bottom part 01 to the filter silencer 81000 with screws A and B NOTICE Screw A The location of screw A serves as a reference for the correct assembly of the filter silencer casing u Before disassembling the bottom part 0...

Page 84: ...evision K June 2017 Fig 24 Fitting filter silencer casing 2 u Fit the bottom part 02 with the screws on the filter silencer Fig 25 Fitting filter silencer casing 3 u Fit the side parts 03 and 04 with the screws on the filter silencer and on the bottom part u Fit the side parts 07 and 08 with the screws on the filter silencer on the bottom part and on the side parts 03 04 Page 56 106 ...

Page 85: ...eserved HZTL4034_EN Revision K June 2017 Fig 26 Fitting filter silencer casing 4 u Insert the flanges 10 and 11 laterally between the side parts and fit the screws Fig 27 Fitting filter silencer casing 5 u Fit the circumferential part 05 with the screws u Fit the circumferential part 06 with the screws u Fit the circumferential part 09 with the screws Page 57 106 ...

Page 86: ...s to the filter silencer Screws for fastening the individual parts M10 30 Nm M8 25 Nm Table 29 Tightening torques filter silencer screws u Tighten all screws of the bottom parts 01 and 02 u Tighten all screws of the side parts 03 04 07 08 and the flanges 10 11 u Tighten all screws of the circumferential parts 05 06 09 Bellows Fig 28 Fitting the bellows u Fit bellows C with frame F screws S and nut...

Page 87: ...ilencers differ in terms of the fixing eyelets for the lifting gear The relevant vari ant must be taken into consideration for disassembly and assembly 8 4 2 Dismantling the filter silencer welded If the turbocharger is also fitted with a noise package chapter Dismantling the filter silencer with noise package 61 must be observed u Dismantle the insulation if necessary Fig 29 Dismantling the filte...

Page 88: ...lencer cast If the turbocharger is also fitted with a noise package chapter Dismantling the filter silencer with noise package 61 must be observed u Dismantle the insulation if necessary Fig 30 Dismantling the filter silencer 1 Attach the lifting gear to the front lug and rear eyelet of the filter silencer 81000 2 Loosen nuts 72004 and remove with washers 72003 3 Remove and put down filter silence...

Page 89: ...silencer u Dismantle the insulation if necessary Fig 31 Dismantling the filter silencer with noise package 1 Loosen and remove the insulation ring 81300 2 Attach the lifting gear to the front lug and rear eyelet of the filter silencer 81000 paying attention to the version of the filter silencer 3 Loosen nuts 72004 and remove with washers 72003 and insulating discs 81302 4 Remove and put down filte...

Page 90: ...1 and leave 2 3 of the thread length screwed into the com pressor casing 72000 2 Loosen and remove the remaining screws 72011 3 Use the press off screws 90900 to press off the wall insert 77000 from the com pressor casing 72000 until the lifting device 90190 can be fitted 4 Fit shackle 90195 with lifting gear on P1 of lifting device 90190 5 Fit lifting device 90190 with crane on upper area of wall...

Page 91: ...34_EN Revision K June 2017 Fig 33 Moving out wall insert 7 Remove screw 72011 8 Carefully move out the wall insert 77000 with diffuser 79000 9 Remove the O ring 77040 Fig 34 Putting down wall insert u Put down wall insert 77000 with diffuser 79000 in horizontal position and use appro priate supports to prevent it from falling over and rolling away Page 63 106 ...

Page 92: ...onnel and even to fatal accidents u Check the position of the support and correct if necessary WARNING Risk of tipping If the wall insert is not tilted it must be put down correctly Tipping of the wall insert may lead to serious injuries to persons or even to fatal accidents u If the wall insert is not tilted ensure that it is fixed correctly see Dis mantling wall insert Fig 35 Putting down wall i...

Page 93: ...tling wall insert and diffuser Copyright 2017 ABB All rights reserved HZTL4034_EN Revision K June 2017 Fig 36 Dismantling the diffuser 4 Loosen and remove screws 77015 5 Remove O rings 79020 79021 6 Attach lifting gear L to the diffuser 79000 7 Remove and put down diffuser Page 65 106 ...

Page 94: ...al hazards Fig 37 Measuring axial clearance A The axial clearance A of the rotor should always be measured before and after service work on the turbocharger u Measure and note axial clearance A Product Axial clearance A mm A165 L 0 32 0 62 A170 L 0 33 0 63 A175 L 0 38 0 68 A180 L 0 41 0 73 A185 L 0 43 0 77 A190 L 0 45 0 80 Table 30 Admissible axial clearance A CAUTION Clearances outside the tolera...

Page 95: ...nlet casing and the nozzle ring A175 L and smaller Dismantling the insulation NOTICE Dry cleaning The dry cleaning does not have to be removed to dismantle the insulation Fig 38 Removing the insulation A175 L and smaller 1 Loosen and remove screws of insulation jackets 51200 from gas outlet casing 61001 2 Loosen and remove all connecting plates of insulation jackets 3 Remove insulation jackets 4 D...

Page 96: ...sing A175 L and smaller 1 Loosen and remove all but two opposite screws 61009 2 Fit two guide studs 90317 in the upper area on the gas outlet casing 3 Loop around the gas inlet casing 51001 with lifting gear 4 Loosen and remove remaining screws 61009 5 Carefully move out gas inlet casing and put down remove guide studs Dismantling the nozzle ring Fig 40 Dismantling the nozzle ring A175 L and small...

Page 97: ... gas inlet casing A180 L and larger 1 Dismantle both halves of the insulation segment 51215 and remove with all fixing ele ments 2 Detach flange connection between gas inlet casing 51001 and bellows 3 Loosen and remove all but two opposite screws 61009 4 Fit two guide studs 90317 in the upper area on the gas outlet casing 61001 5 Loop lifting gear around gas inlet casing 6 Loosen remaining screws ...

Page 98: ...ing nozzle ring A180 L and larger Copyright 2017 ABB All rights reserved HZTL4034_EN Revision K June 2017 Dismantling the nozzle ring Fig 42 Fitting the nozzle ring holder 1 Remove screws B2 2 Fit the nozzle ring holder 90477 with screws B1 at the top of the flange of the gas inlet casing 51001 Page 70 106 ...

Page 99: ...le ring A180 L and larger 1 Loop around the nozzle ring holder 90477 with the lifting gear and secure it to the crane 2 Loosen screws 56014 and remove with washers 56011 3 Pull the nozzle ring 56001 towards the front onto the nozzle ring holder 4 Screw the screws B2 into the nozzle ring holder 5 Remove screws B1 Fig 44 Putting down the nozzle ring A180 L and larger u Use the crane to remove and pu...

Page 100: ...zzle ring and the insulation A175 L and smaller Fitting the nozzle ring u Coat the screw threads with high temperature grease Fig 45 Fitting the nozzle ring A175 L and smaller Part number A165 L A170 L A175 L 56014 M10 35 Nm M10 35 Nm M10 35 Nm Table 31 Tightening torque 56014 1 Align the notch A1 with the flange connection A2 and slide the nozzle ring 56001 into the gas inlet casing 51001 2 Fit s...

Page 101: ... tightening torque of the screws 1 Fit two guide studs 90317 in the upper area on the gas outlet casing 61001 2 Loop around the gas inlet casing 51001 with the lifting gear and secure it to the crane 3 Push gas inlet casing over the guide studs up to the gas outlet casing 4 Screw in two opposite screws 61009 with high temperature grease 5 Remove the guide studs 90317 and fit the remaining screws 6...

Page 102: ...BB All rights reserved HZTL4034_EN Revision K June 2017 Fitting insulation Fig 47 Fit insulation 1 Fit flange connection between gas inlet casing 51001 and bellows 2 Fit the insulation jackets 51200 on the gas inlet casing 51001 with the screws 3 Fit connecting plates of insulation jackets with screws 4 Fit insulation jackets with screws on gas outlet casing 61001 Page 74 106 ...

Page 103: ...ghts reserved HZTL4034_EN Revision K June 2017 8 11 Fitting the gas inlet casing nozzle ring A180 L and larger Fitting the nozzle ring u Coat the screw threads with high temperature grease Fig 48 Looping around the nozzle ring A180 L and larger u Loop around the nozzle ring 56001 with lifting gear on the nozzle ring holder 90477 and fix on the crane Page 75 106 ...

Page 104: ...185 L A190 L 56014 M12 65 Nm M12 65 Nm M16 170 Nm Table 33 Tightening torque 56014 1 Fit the nozzle ring holder 90477 on the flange of the gas inlet casing 51001 with screws B1 2 Remove screws B2 3 Align the notch A1 on the cam of the nozzle ring 56001 with the flange connection A2 and slide the nozzle ring into the gas inlet casing 4 Coat screws 56014 with high temperature grease and fit with was...

Page 105: ...per area on the gas outlet casing 61001 2 Loop around the gas inlet casing 51001 with the lifting gear and secure it to the crane 3 Dismantle and remove support 90451 from the gas inlet casing 51001 4 Push gas inlet casing over the guide studs up to the gas outlet casing 61001 5 Coat two opposite screws 61009 with high temperature grease and screw in 6 Remove the guide studs 90317 7 Coat remaining...

Page 106: ...zards Fig 51 Measuring axial clearance A The axial clearance A of the rotor should always be measured before and after service work on the turbocharger u Measure and note axial clearance A Product Axial clearance A mm A165 L 0 32 0 62 A170 L 0 33 0 63 A175 L 0 38 0 68 A180 L 0 41 0 73 A185 L 0 43 0 77 A190 L 0 45 0 80 Table 35 Admissible axial clearance A CAUTION Clearances outside the tolerance S...

Page 107: ...ffuser Part number A165 L A170 L A175 L A180 L A185 L A190 L 77015 M5 6 Nm M6 10 Nm M8 25 Nm M8 25 Nm M10 45 Nm M10 45 Nm Table 36 Tightening torque 77015 1 Attach lifting gear L to the diffuser 79000 2 Carefully place the diffuser on the wall insert 77000 then remove lifting gear 3 Fit new O rings 79020 79021 on the diffuser 4 Degrease screws 77015 and threaded holes in wall insert 5 Coat threads...

Page 108: ...sembly 8 13 Fitting diffuser wall insert Copyright 2017 ABB All rights reserved HZTL4034_EN Revision K June 2017 Fitting the wall insert Fig 53 Positioning wall insert u Carefully bring wall insert 77000 into vertical position with the lifting device 90190 Page 80 106 ...

Page 109: ...00 2 Fit two guide studs 90320 in the upper area of the compressor casing 72000 3 Align arrow markings of wall insert 77000 and compressor casing to one another 4 Carefully move the wall insert with diffuser 79000 over the guide studs into the com pressor casing 5 Fit a screw 72011 as a safeguard 6 Change the position of the shackle 90195 with the lifting gear to P1 of the lifting device 90190 and...

Page 110: ...t vari ant must be taken into consideration for disassembly and assembly 8 14 2 Fitting the filter silencer welded If the turbocharger is also fitted with a noise package chapter Fitting the filter silencer with noise package 84 must be observed Fig 55 Fitting the filter silencer Part number A165 L A170 L A175 L A180 L A185 L A190 L 72004 M14 130 Nm M16 200 Nm M18 300 Nm M20 420 Nm M22 570 Nm M24 ...

Page 111: ...ng the filter silencer with noise package 84 must be observed Fig 56 Fitting the filter silencer Part number A165 L A170 L A175 L A180 L A185 L A190 L 72004 M14 130 Nm M16 200 Nm M18 300 Nm M20 420 Nm M22 570 Nm M24 710 Nm Table 39 Tightening torque 72004 1 Attach the lifting gear to the front lug and rear eyelet of the filter silencer 81000 2 Position filter silencer on compressor casing 3 Fit nu...

Page 112: ...ed and cast versions of the filter silencer Before fitting ensure that the individual sealing segments of the gasket 81301 and the gas ket 74042 are not damaged and that the contact surfaces are clean Fig 57 Fitting the filter silencer with noise package Part number A165 L A170 L A175 L A180 L A185 L A190 L 72004 M14 130 Nm M16 200 Nm M18 300 Nm M20 420 Nm M22 570 Nm M24 710 Nm 72043 M10 45 Nm M10...

Page 113: ...e compressor cas ing 72000 2 Attach the lifting gear to the front lug and rear eyelet of the filter silencer 81000 paying attention to the version of the filter silencer 3 Position filter silencer on compressor casing 4 Fit nuts 72004 with washers 72003 and insulating discs 81302 and tighten 5 Fit insulation ring 81300 6 Fit air outlet silencer 74040 with gasket 74042 and secure with counter sunk ...

Page 114: ...embly and assembly 8 16 Table of tightening torques Copyright 2017 ABB All rights reserved HZTL4034_EN Revision K June 2017 8 16 Table of tightening torques Fig 58 Overview of tightening torques Fig 59 Overview of speed sensor tightening torque Page 86 106 ...

Page 115: ...27 1300 M30 1700 M33 2300 63 1 72004 M14 130 M16 200 M18 300 M20 420 M22 570 M24 710 63a 72002 M14 40 M16 60 M18 80 M20 100 M22 120 M24 140 64 77015 M5 6 M6 10 M8 25 M8 25 M10 45 M10 45 65 56014 M10 35 M10 35 M10 35 M12 65 M12 65 M16 170 66 81125 G1 2 45 G1 2 45 G1 2 45 G1 2 45 G1 2 45 G1 2 45 67 86505 M18x1 5 150 M18x1 5 150 M18x1 5 150 M27x2 320 M27x2 320 M27x2 320 Table 41 Overview of tightenin...

Page 116: ...Operation Manual 4 Product description A100 L 8 Disassembly and assembly 8 16 Table of tightening torques Copyright 2017 ABB All rights reserved HZTL4034_EN Revision K June 2017 Page 88 106 ...

Page 117: ...Dismantle filter silencer and lock rotor with locking device Fit cover plates to compressor outlet gas in let and gas outlet casing of defective tur bocharger Engines with by pass around the turbocharger Engines without bypass around the turbocharger Open bypass If the nozzle ring is removed not mandatory a higher engine load can be achieved Continue to operate engine in accordance with enginebuil...

Page 118: ... oil supply remains switched on Further information for operation of 2 stroke engines with blocked ro tor u If there is a lubricating oil leak on the turbocharger stop the oil supply CAUTION Locking of the rotor on the compressor wheel Serious damage to engine or property can be caused by excessive vibrations and unbalance values if set screws balancing screws are loosened or un screwed on the com...

Page 119: ...to remove any set screws from the compressor wheel when fitting the locking device 94003 Fitting the locking device Fig 60 Locking the rotor u Dismantle the filter silencer Dismantling the filter silencer 59 1 If present Remove the spinner nose cone 25012 with the press off screw 90024 2 Loosen retaining nuts N and remove with screws B1 3 Turn back the screw B2 until the slot of the locking device...

Page 120: ... have been prepared and the necessary pipe connections have been provided u Close the lubricating oil supply to the turbocharger u Open the bypass around the turbocharger u Observe specifications from enginebuilder 9 3 3 Engines without bypass around the turbocharger If the nozzle ring is removed not mandatory higher engine performance can be achieved More information about dismantling the nozzle ...

Page 121: ... 34 A190 L 4 5 6 0 25 39 Table 45 Required washers 01 Part number A165 L A170 L A175 L A180 L A185 L A190 L 57005 M12 50 Nm M12 50 Nm M16 80 Nm M20 160 Nm M20 160 Nm M24 280 Nm Table 46 Tightening torque 57005 1 Remove screws 57005 2 Fit and tighten screws 57005 with high temperature grease and washers 01 in accord ance with the table 9 3 4 Continuing to operate the engine Continue to operate engi...

Page 122: ...e inlets and outlets The chapter is only applicable for engines with several turbochargers and joint air and ex haust gas receivers The cover plates for the compressor casing outlet gas inlet and gas outlet are not included in the ABB scope of delivery The following figure shows the positions where to fit the cover plates u Stop the engine u Shut off the supply of lubricating oil to the turbocharg...

Page 123: ...aring 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 shee...

Page 124: ...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 to the ...

Page 125: ...ear 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 of...

Page 126: ...Operation Manual 4 Product description A100 L 11 Disposing of turbocharger components Copyright 2017 ABB All rights reserved HZTL4034_EN Revision K June 2017 Page 98 106 ...

Page 127: ...pare parts can be ordered from any ABB Turbocharging Service Station u If different model variants are not taken into account in this document contact an ABB Turbocharging Service Station Required customer spare part set 97070 For the operations described in the Operation Manual the customer spare part set 97070 is required These parts are only available in the complete set Quantity Designation Pa...

Page 128: ...A100 L 12 Spare parts 12 2 View of turbocharger with part numbers Copyright 2017 ABB All rights reserved HZTL4034_EN Revision K June 2017 12 2 View of turbocharger with part numbers Fig 63 View of turbocharger with part numbers Page 100 106 ...

Page 129: ... 68002 Foot turbine end 72000 Compressor casing 72002 Threaded stud 72003 in the customer spare part set Washer 72004 in the customer spare part set Hexagon nut 72011 Hexagon head screw 74040 Air outlet silencer option 74042 Gasket option 77000 Wall insert 77015 in the customer spare part set Hexagon head screw 77040 in the customer spare part set O ring 79000 Diffuser 79020 in the customer spare ...

Page 130: ...ers Copyright 2017 ABB All rights reserved HZTL4034_EN Revision K June 2017 12 3 View of cartridge group with part numbers Fig 64 View of cartridge group with part numbers NOTICE Cartridge group The cartridge group is not delivered as a fitted assembly Spare parts must be ordered individually Page 102 106 ...

Page 131: ...2102 Radial bearing turbine end 32105 Floating disc 32106 Axial bearing 32109 Sealing disc 32159 Locking screw 32174 O ring 42001 Bearing casing 42008 Socket screw 42011 O ring 42015 Sealing cover 42039 Hexagon head screw 42041 Gasket 42059 Hexagon head screw 42064 Hexagon head screw 42185 Socket screw 42186 O ring 42295 Pressure adjusting unit 42300 Partition wall 42305 O ring 42306 O ring 42307 ...

Page 132: ...ig 27 Fitting filter silencer casing 5 57 Fig 28 Fitting the bellows 58 Fig 29 Dismantling the filter silencer 59 Fig 30 Dismantling the filter silencer 60 Fig 31 Dismantling the filter silencer with noise package 61 Fig 32 Pressing off compressor casing 62 Fig 33 Moving out wall insert 63 Fig 34 Putting down wall insert 63 Fig 35 Putting down wall insert 64 Fig 36 Dismantling the diffuser 65 Fig ...

Page 133: ...g 58 Overview of tightening torques 86 Fig 59 Overview of speed sensor tightening torque 86 Fig 60 Locking the rotor 91 Fig 61 Ensuring clamping of the cover ring 92 Fig 62 Position of cover plates 94 Fig 63 View of turbocharger with part numbers 100 Fig 64 View of cartridge group with part numbers 102 Page 105 106 Page 105 106 ...

Page 134: ...as temperature too high 47 Table 21 Malfunctions during operation Charge air pressure too low 47 Table 22 Malfunctions during operation Charge air pressure too high 48 Table 23 Surging of the turbocharger 48 Table 24 Malfunctions when stopping Runout noises 49 Table 25 Malfunctions when stopping Shortened runout time 49 Table 26 Malfunctions of the speed measurement system 50 Table 27 Weights of a...

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