ABB HT609938, Operation Manual

Page 1: ...ion Serial number HT609938 Customer part number X00074674 Delivery date yyyy mm dd 2022 07 15 Weight 270 kg Operating limits according to rating plate Speed limit in test rig operation only nMmax 908...

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Page 3: ...n on gas engines 15 2 7 Periodic check of the pressure vessels 15 2 8 Warning plates on the turbocharger 16 2 9 Turbocharger rating plate 17 2 10 Lifting of loads 19 2 11 Prerequisites for operation a...

Page 4: ...ssor casing 86 9 7 Pressing off the casing 88 9 8 Removing the cartridge group 89 9 9 Removing the nozzle ring 91 9 10 Installing the cartridge group on the service support 92 9 11 Measuring clearance...

Page 5: ...y 2021 12 Material and Disposal 108 12 1 REACH and RoHS Compliance Declaration For Products 108 12 2 Disposing of turbocharger components 109 13 Spare parts 110 13 1 Ordering spare parts 110 13 2 Requ...

Page 6: ...lains 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...

Page 7: ...s document is valid for different design variants of turbochargers There may be sections and descriptions of components that are not relevant for a specific turbocharger variant Please contact an ABB...

Page 8: ...nction of the turbocharger Fig 2 Layout and function of the turbocharger 01 Air suction branch 08 Turbine 02 Compressor casing 09 Gas outlet flange 03 Diffuser 10 Nozzle ring 04 Bearing casing 11 Turb...

Page 9: ...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...

Page 10: ...cilitates 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 Defin...

Page 11: ...ogram 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...

Page 12: ...NING Health protection when handling VCI VCI products are not hazardous in terms of the Ordinance on Hazardous Substances Nevertheless the following points must be observed when handling VCI u Observe...

Page 13: ...spected 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...

Page 14: ...are a consequence of insufficient compliance with safety instructions are a consequence of insufficient or inappropriate performance of maintenance and in spection work The operating company is respon...

Page 15: ...ry mask to protect against Dusts Gases Safety helmet Ear protection Table 3 Personal protective equipment to be worn specific to the respective task 2 4 Definition of safety instructions WARNING Defin...

Page 16: ...volume or air gas mixture and the associ ated charging pressure required for operation The turbocharger is solely intended to be operated with a clockwise direction of rotation as viewed from the turb...

Page 17: ...during external inspection anomalies are found or if a particularly strong deflagration event has taken place it is also recommended to check the bearings of the turbochargers before the next start A...

Page 18: ...resent 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 Clea...

Page 19: ...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...

Page 20: ...tacting the nearest ABB Turbochar ging Service Station nMmax tMmax normally apply only when running at overload 110 during trials on the engine test bed These limit values can also be permitted during...

Page 21: ...mechanical hazards Wear safety helmet Fig 9 Attachment of loads on the crane hook Fig 10 Attachment angle If there are two or more suspension points the attachment angle of 45 must not be ex ceeded T...

Page 22: ...tion Manual must be 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 tu...

Page 23: ...ar 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 flu...

Page 24: ...iding protection against contact with hot surfaces u Compliance with the instructions and specifications given by the en ginebuilder to protect against hot turbocharger surfaces is compulsory Wear saf...

Page 25: ...efore commission ing u Check turbocharger for recognisable damage or defects every 12 hours of operation or at least once a day u Report any damage and any alterations of operational characteristics t...

Page 26: ...perations for which you have received instruction or train ing Wear safety footwear to protect against mechanical hazard and risk of fall ing Wear protective clothing WARNING Risk of falling When work...

Page 27: ...Observe the material safety data sheet for the cleaning agent or solvent u Wear personal protective equipment PPE according to the material safety data sheet u Inspect the electric cables for abrasion...

Page 28: ...s for which you 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...

Page 29: ...e 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...

Page 30: ...a sufficient load limit must be used for removing installing and transport ing the turbocharger The weight specified below applies to the heaviest variant possible Depending on the specification the...

Page 31: ...work in Do not apply penetrating oil to the pressure screws of the clamping nut B u If present Disconnect the plug to the speed sensor 86505 and secure the rolled up cable on the turbocharger This pro...

Page 32: ...perty can be the consequence if the cooling water freezes in the pipes and in the bearing casing u For transport and storage of the turbocharger drain the cooling water in the bearing casing via two o...

Page 33: ...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...

Page 34: ...t 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 a...

Page 35: ...ealing is provided by O rings The O rings are not included in the ABB scope of delivery Fig 15 Inserting gaskets into the bracket 01 Bracket 04 Slot for O ring 02 Oil supply 05 O rings 03 Oil drain 06...

Page 36: ...3 Remove nuts 01 again Requirements for the threaded rods Fig 17 Requirements for threaded rods Product Diameter Threaded rod mm Material DIN ISO 898 Part 1 Thread length L1 mm Length of threaded rod...

Page 37: ...the bearing casing 42001 and loop around the gas outlet casing 4 Position the turbocharger on the bracket 04 and align it If present pay attention to the positioning pin 05 in the bracket 5 When fixin...

Page 38: ...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 17 M16 280 110 A135 21 M20 560 175 A...

Page 39: ...ricate 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...

Page 40: ...ening 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 pr...

Page 41: ...sor 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...

Page 42: ...width of 0 034 mm is sufficient for this tur bocharger 4 1 3 Oil pressure Comply precisely with the oil pressure before the turbocharger for trouble free operation Different oil pressures must be tak...

Page 43: ..._EN Rev G July 2021 4 1 5 Oil orifice in the bearing casing Fig 23 Oil orifice 01 Bearing casing 02 Oil orifice 03 Circlip With an oil inlet pressure of more than 3 bar of overpressure with engine und...

Page 44: ...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 wo...

Page 45: ...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 Wear safety glove...

Page 46: ...r 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 co...

Page 47: ...ne 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 sign...

Page 48: ...he 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 admi...

Page 49: ...age or the rating plate on the turbocharger 5 3 Turbocharger speed 5 3 1 Introduction A speed measuring system enables the constant monitoring of the turbocharger speed CAUTION Do not put the speed me...

Page 50: ...N Rev G July 2021 5 3 2 Layout and overview Fig 24 Layout and overview of speed measurement system 86505 Speed sensor 42188 Screw plug 86515 Cable connector 42189 Gasket 86526 F I converter 01 Plug wi...

Page 51: ...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 ai...

Page 52: ...a sealing lip and an O ring No additional gasket is required during assembly Fig 25 Replacing the speed sensor Part number Thread size Tightening torque 86505 M12 x 1 5 15 Nm Table 11 Tightening torq...

Page 53: ...1 meter from the turbocharger The highest value of the emission sound pressure level1 reaches a maximum of 105 dB A near the air inlet The following prerequisites must be fulfilled with regard to the...

Page 54: ...21 ABB All rights reserved HZTL4030_EN Rev G July 2021 Suggestion for noise insulation bellows Fig 26 Noise insulation bellows 01 Compressor casing 02 Bellows 03 Charge air duct scavenging air duct 04...

Page 55: ...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...

Page 56: ...in accordance with the instructions of the enginebuilder 6 2 4 Service work according to data on the rating plate Usually after 8000 12000 operating hours The rotor and bearing parts must be checked...

Page 57: ...tective grid 61205 after 50000 hours and replace it with a new one Pre mix gas engines CAUTION Replace the protective grid of pre mix gas engines after 20000 hours Applications on pre mix gas engines...

Page 58: ...regularly into the engine logbook of the enginebuilder Number of times the engine is started successfully possible aborted start cycles do not need to be recorded Performance and speed of the engine...

Page 59: ...start stop cycles or after reaching the number of operating hours specified on the rating plate Non rotating components Depending on the system specific operating conditions a differentiation must be...

Page 60: ...ervals The specified values are guideline values and not guaranteed values see Influencing para meters Influencing parameters The specified values are guideline values and are not guaranteed The actua...

Page 61: ...adequately dissipated it may damage the engine u Adequate cooling of the turbocharger must be ensured after stopping the engine Water cooled turbocharger variant u Post lubricate as long as the rotor...

Page 62: ...d cleaning operations which are inten ded to ensure the trouble free functioning of the turbocharger Maintenance interval Maintenance work Operating status Similar to the service interval usually ever...

Page 63: ...y 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...

Page 64: ...sent 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 The contamination of the filter ring de...

Page 65: ...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 Fitti...

Page 66: ...y 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 r...

Page 67: ...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 Baked layers of contamination for exam...

Page 68: ...dge group is not put back into operation immediately after clean ing parts may corrode u Immediately after cleaning install the cartridge group and put it back into operation Compressor wheels can be...

Page 69: ...idge group this can impair the function of the turbocharger and damage parts inside the cartridge group u Make sure that no water or contamination can enter into the cartridge group u Cleaning procedu...

Page 70: ...B mm C mm A130 108 17 205 A135 128 20 245 A140 157 25 300 Table 14 Value table for soaking To soak the layers of contamination on the turbine the cartridge group can be immersed vertically in a conta...

Page 71: ...side 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 Le...

Page 72: ...uted residual contamination deposits 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 contamina...

Page 73: ...ing Service Station Turbine or compressor damaged Bearing damaged Engine Vibrations from engine Contact enginebuilder Table 16 Malfunctions when starting Vibrations Rubbing of rotating parts Normal be...

Page 74: ...l filter heavily contaminated Clean Oil pump in lubricating system defect ive Check replace Manometer displays incorrectly Replace manometer Table 18 Malfunctions during operation Lubricating oil pres...

Page 75: ...igh Check clean cooling system Insufficient ventilation Improve ventilation Table 21 Malfunctions during operation Exhaust gas temperature too high Charge air pressure too low Engine performance and e...

Page 76: ...minated 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 tabl...

Page 77: ...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 Fi...

Page 78: ...ions 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...

Page 79: ...ing Service Station Replacing the speed sensor 50 Table 29 Malfunction of the speed measurement system No signal or poor signal amplitude Measured speed too high Possible causes Remedy Turbochar ger S...

Page 80: ...g 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 wor...

Page 81: ...r components of the turbocharger The specified tightening torques of the screw fittings must be observed Table of tightening torques Tightening torques for assembly devices Unless otherwise described...

Page 82: ...f loads ropes chain block crane Lifting gear is not supplied by ABB Swivel lifting eyes to be used Swivel lifting eyes are required for the safe lifting of loads which are not supplied by ABB Fig 32 S...

Page 83: ...5 kg A140 kg 01 Filter silencer 19 30 40 02 Radial air suction branch 6 8 13 03 Axial air suction branch 4 5 6 04 Compressor casing 24 40 60 05 Wall insert 6 8 15 06 Diffuser 3 4 7 07 Cartridge group...

Page 84: ...ir inlets u Mark the casing position for assembly Fig 35 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 Remo...

Page 85: ...ort 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 9 5 Removing the gas outlet flange Depen...

Page 86: ...essary 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 Dismantling the g...

Page 87: ...essary 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 38 Removing the gas...

Page 88: ...chapter Spare parts 110 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 casin...

Page 89: ...Rev G July 2021 Dismantling the wall insert Fig 40 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...

Page 90: ...ing 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 th...

Page 91: ...ation 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 o...

Page 92: ...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...

Page 93: ...y 2021 9 9 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...

Page 94: ...ll rights reserved HZTL4030_EN Rev G July 2021 9 10 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 s...

Page 95: ...0 70 1 37 Table 36 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...

Page 96: ...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 A1...

Page 97: ...n 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 th...

Page 98: ...nozzle ring control dimension H 1 Measure dimension H as shown in the illustration and compare it with the minimum di mension H in the table 9 14 Installing the cartridge group Lifting the cartridge g...

Page 99: ...duct Size Tightening torque Nm A130 M8 25 A135 M10 45 A140 M12 75 Table 39 Tightening torque 51007 1 Coat thread of studs 51006 with high temperature grease 2 Align the casing position of the cartridg...

Page 100: ...diffuser Fig 53 Fitting the wall insert and the diffuser Product Size Tightening torque Nm A130 M6 8 A135 M6 8 A140 M6 8 Table 40 Tightening torque 79041 1 Fit new O ring 77005 see chapter Required c...

Page 101: ...e O ring 42012 see also chapter Spare parts 110 Product Size Tightening torque Nm A130 M8 35 A135 M10 70 A140 M12 105 Table 41 Tightening torque 72011 1 Fit a new high temperature resisting O ring 420...

Page 102: ...without clearance and measure 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 wi...

Page 103: ...ing the air inlets Product Size Tightening torque Nm A130 M12 60 A135 M12 60 A140 M12 60 Table 43 Tightening torque 72020 1 Secure lifting gear to filter silencer 81000 2 Fit a new O ring 81010 to the...

Page 104: ...et flange 57002 in the turbine casing 3 Measure radial clearance R see chapter Radial clearances N and R 9 19 Installing the gas outlet casing Fig 58 Installing the gas outlet casing Product Size Tigh...

Page 105: ...ble of tightening torques Fig 59 Tightening torques Position Part number A130 A135 A140 02 72020 M12 60 Nm M12 60 Nm M12 60 Nm 04 79041 M6 8 Nm M6 8 Nm M6 8 Nm 08 51007 M8 25 Nm M10 45 Nm M12 75 Nm 09...

Page 106: ...leak u Soak up oil and dispose of in an environmentally compatible manner Wear safety gloves to protect against thermal hazards CAUTION Directives for taking out of operation Serious damage to engine...

Page 107: ...oup 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...

Page 108: ...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 w...

Page 109: ...mantled 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 prepari...

Page 110: ...the presence of such substance s with sufficient information available to the supplier RoHS2 Directive 2011 65 EC in English only The EU Directive 2011 65 EC recast restricts the use of certain hazard...

Page 111: ...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...

Page 112: ...t 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...

Page 113: ...sh Cartridge water cooled 42197 42196 10900 42012 42126 42194 42047 42189 42190 42188 42201 Available within the spare part set if provided HZTL443555 Mod A Part no Designation 10900 Cartridge_water c...

Page 114: ...51105 51006 51002 51003 51007 p pre assembled if provided HZTL443558 Mod A Part no Designation 51000 Turbine casing 51002 Fastening strip 51003 Verbusripp washer 51006 Stud 51007 Hexagon nut 51008 St...

Page 115: ...30_EN Rev G July 2021 Part no Designation 57003 Metal ring 57210 Burst ring Table 48 Gas outlet casing axial 61002 GH02 61001 61001 GH02 GHV03 Available within the spare part set only if provided HZTL...

Page 116: ...1 Gas outlet casing radial 61002 61200 61202 61201 61005 p 61001 61205 p pre assembled Available within the spare part set if provided HZTL443302 Mod C Part no Designation 61001 Gas outlet casing 6100...

Page 117: ...041 79040 77005 72000 77000 72080 72005 p 72020 Available within the spare part set p pre assembled HZTL443559 Mod A Part no Designation 72000 Compressor casing 72005 p Screw plug 72006 p Gasket 72011...

Page 118: ...y 2021 Air suction branch radial 82010 82005 82006 82000 82008 82007 Available within the spare part set HZTL443012 Mod D Fig 60 SPI Air suction branch radial Part no Designation 82000 Air suction bra...

Page 119: ...HZTL4030_EN Rev G July 2021 Air suction branch axial 82008 p 82007 p 82010 82000 82006 p 82005 p Available within the spare part set p pre assembled HZTL443560 Mod A Part no Designation 82000 Air suc...

Page 120: ...tions Copyright 2021 ABB All rights reserved HZTL4030_EN Rev G July 2021 Speed measurement system 86505 86515 86528 86526 if provided HZTL443468 Mod A Part no Designation 86505 Speed sensor 86515 Cabl...

Page 121: ...stomer tool set 90000 is required 90000 Designation Quantity 90012 Service support 1 90042 Press off tool 1 90070 Extraction device 1 Table 55 Customer tool set 90000 Tool sets can be ordered from any...

Page 122: ...27 Replacing the protective grid 55 Fig 28 Cleaning the filter silencer 62 Fig 29 Compressor end non rotating parts 64 Fig 30 Turbine end non rotating parts 65 Fig 31 Soaking the turbine end 68 Fig 3...

Page 123: ...ure too high 73 Table 22 Malfunctions during operation Charge air pressure too low 73 Table 23 Malfunctions during operation Charge air pressure too high 74 Table 24 Malfunctions during operation Engi...

Page 124: ...Operation Manual A130 H A140 H Tables Copyright 2021 ABB All rights reserved HZTL4030_EN Revision G July 2021 Table 55 Customer tool set 90000 119 Page 122 122 Page 122 122...