ABB HT842985, Operation Manual

Page 1: ...arging Operation Manual A140 H65 HT842985 English Original Operation Manual Chapter Document ID 1 Introduction HZTL4005_EN_F 2 Safety HZTL4022_EN_E 3 Safety data sheet HT842985 4 Product description HZTL4030_EN_D ...

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

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

Page 4: ...explains the turbocharger and contains instructions for safe opera tion The Operation Manual is a complement to and expansion of existing national regulations for occupational safety accident prevention and environmental protection Target group The Operation Manual is aimed at engineers and trained mechanics responsible for the proper operation of the engine and for the turbocharger connected to i...

Page 5: ...n of mandatory signs Mandatory signs show the protective equipment to be worn for a task The mandatory signs are described in chapter Safety and must be complied with Definition of Caution Warning Caution and warning signs are described in chapter Safety ABB Turbo Systems ABB Turbo Systems Ltd is identified as ABB Turbo Systems in this document Official service stations of ABB Turbo Systems Offici...

Page 6: ...Meaning Pictogram Meaning Tighten with specified torque Affix Tighten over specified tighten ing angle Measure Hand tight tighten without tools Note Oil Visually inspect Apply screw locking paste e g Loctite Please note text for numbered work step Apply high temperature grease See document Apply other paste in accord ance with specifications Dispose of in an environmentally compatible professional...

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

Page 8: ... repackaged by an ABB Turbocharging Service Station u Check the package for damage If the package is damaged the turbocharger or cartridge group must be checked and repackaged by an ABB Turbocharging Service Station After every 3 years the following steps must be carried out by an ABB Turbocharging Service Station Checking the component Replacing the desiccant Repackaging the component NOTICE Repl...

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

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Page 11: ...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: ...ration Manual A140 H65 Safety data sheet Page 1 1 Safety data sheet Copyright 2017 ABB All rights reserved HT842985 August 2017 A140 H65 HT842985 A140 H65 HT842985 742 680 729 650 1200846 460 20 60 60 2017 ...

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Page 31: ...mmissioning 20 3 1 Oil supply 20 3 2 Inspection procedures 22 3 3 Commissioning after taking out of operation 24 4 Monitoring operation 25 4 1 Oil pressure oil temperature 25 4 2 Exhaust gas temperature before turbine 27 4 3 Turbocharger speed 28 5 Operation and service 31 5 1 Noise emission 31 5 2 Service work 33 5 3 Expected replacement intervals 37 5 4 Stopping the engine 38 6 Periodic maintena...

Page 32: ... Installing the cartridge group 74 8 15 Installing the compressor casing 76 8 16 Radial clearances N and R 78 8 17 Installing air inlets 79 8 18 Installing the gas outlet flange 80 8 19 Installing the gas outlet casing 80 8 20 Table of tightening torques 81 9 Taking out of operation at short notice 82 9 1 Possible emergency repairs 82 9 2 Installing a replacement turbocharger 83 9 3 Installing a r...

Page 33: ... 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 34: ...ay 2017 1 4 Layout and function of the turbocharger Fig 1 Layout and function of the turbocharger 01 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 4 91 ...

Page 35: ...dial plain bearings 06 which are located in the bearing casing 04 between 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 deepest point of the bearing casing 04 Turbocharger v...

Page 36: ...g 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 b...

Page 37: ...ns of the rating plates Copyright 2017 ABB All rights reserved HZTL4030_EN Revision D May 2017 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 7 91 ...

Page 38: ...ion Lifting gear with a sufficient load limit must be used for removing and installing the tur bocharger The following weight specification applies to the heaviest variant possible De pending on the specification the weight specified on the rating plate may be lower than the standard value specified here Product Weights kg A130 H 190 A135 H 270 A140 H 460 Table 2 Weights of turbochargers A130 H A1...

Page 39: ...y penetrating oil to thread of stud 02 and nut and let it work in u If present Disconnect the plug to the speed sensor 86505 and secure the rolled up cable on the turbocharger This protects the plug from being crushed u If present Detach the support 61301 from the engine support Depending on the bracket version 04 two positioning pins 05 can be used for positioning and safeguarding against wrong f...

Page 40: ...y damage can result from cooling water freezing in the pipes and the bearing casing u Drain cooling water from bearing casing through two screw plugs before turbocharger transport and storage Manual loosening To remove the turbocharger from the bracket proceed as follows u Loosen and remove water connections Close the openings of the water connections with screw plugs u Attach lifting gear to the ...

Page 41: ...ps for loosening the pressure screws CAUTION Do not clean pressure screws The pressure screws are equipped with a permanent sliding layer that must not be removed Do neither clean nor lubricate the pressure screws In case of non compli ance it cannot be ensured that the necessary tension force is reached u Do not clean pressure screws u Do not lubricate pressure screws Fig 7 Loosening the clamping...

Page 42: ...t positioned 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 8 Putting down the turbocharger u Remove turbocharger from engine support set it down properly in an appropriate place and secu...

Page 43: ...aling is provided by O rings The O rings are not included in the ABB Turbo Systems scope of delivery Fig 9 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 fitte...

Page 44: ...ove nuts 01 again Requirements for the threaded rods Fig 11 Requirements for threaded rods Product Diameter Threaded rod mm Material DIN ISO 898 Part 1 Thread length L1 mm Length of threaded rod L2 mm A130 Ø 16 M16 10 9 12 9 30 250 A135 Ø 20 M20 10 9 12 9 30 325 A140 Ø 24 M24 10 9 12 9 70 410 420 Table 3 Requirements for threaded rods Fastening material scope of delivery The threaded rods and nuts...

Page 45: ...urfaces of the expansion bushes in the bearing casing 3 Attach the lifting gear to the suspension eye of 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 fixing with a standard nut C fit the expansion bushes in the correct position in the slot Safeguard ...

Page 46: ...ening the turbocharger with a standard nut u Fit the nuts and tighten them according to variant 1 or 2 in the table below When the turbocharger is mounted on the engine support the bolt threads and screw heads must be lightly oiled assumed friction coefficient µ 0 12 for tightening torque Product Through hole in bear ing casing mm Fixing screws mm Variant 1 Tightening torques Nm Variant 2 Hydrauli...

Page 47: ...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 13 Preparing the clamping nut for the tightening procedure 1 Check whether the expansion bushes 42190 with reces...

Page 48: ... M24 35 Table 5 Pressure screw tightening torque 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 49: ...ith 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 Fig 15 Connecting the compressor cooling air intake u Remove the screw plug on the connection for the compressor wheel cooling 06 an...

Page 50: ...lection 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 see Table 6 Lubricating oil pressure at oil inlet before turbocharger 25 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 pr...

Page 51: ...ved HZTL4030_EN Revision D May 2017 3 1 5 Oil orifice in the bearing casing Fig 17 Oil orifice 01 Bearing casing 02 Oil orifice 03 Circlip With an oil inlet pressure of more than 3 bar with engine under load before the turbochar ger the bearing casings are equipped as standard with an orifice at the oil inlet Page 21 91 ...

Page 52: ...al particles in the oil u For the initial commissioning phase and after all service work flush the complete lubricating system with warm oil u Use special running in filters when running in the engine and after all ser vice work on the lubricating system u Check that the oil filter is clean before commissioning u Check the oil pressure in the oil supply pipes Warning plates u Check whether warning...

Page 53: ...ssible 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 tempera...

Page 54: ...ipe 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 present u ...

Page 55: ...ur bocharger bar Normal operation 2 0 poil 4 5 Engine start Cold oil admissible for maximal 15 minutes 8 0 Engine idling admissible for maximal 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 5 Table 6 Lubricating oil pressure at oil inlet before turbocharger 01 Turboch...

Page 56: ... 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 outlet temperature is to be considered as alarm value for the turbocharger op eration and must be monitored...

Page 57: ... 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 Operati...

Page 58: ...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 18 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 59: ...t 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 ...

Page 60: ...lip and an O ring No additional gasket is required during assembly Fig 19 Replacing the speed sensor Part number A130 A135 A140 86505 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 38 u Switch off the lubricating oil supply to the turbocharger u ...

Page 61: ... 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 62: ...opyright 2017 ABB All rights reserved HZTL4030_EN Revision D May 2017 Suggestion for noise insulation bellows Fig 20 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 32 91 ...

Page 63: ...rformed 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 Exceptional stresses such as several starts stops per day harsh environ mental conditions poor fuel quality or high system vibrations can lead to untimely machine damage even if the prescribed service intervals are ob served...

Page 64: ...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 12000 operating hours ...

Page 65: ...grid u Remove the protective 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 result in a high thermo mechanical load on the protective grid To ensure proper functionality of the protective grid even under these conditions the protective grid of pre mix gas...

Page 66: ...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 67: ... replacing 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 Pre mix GAS GAS MDO Turbine casing 25000 50000 25...

Page 68: ...y exhaust gas composition For bearing parts Lubricating oil quality oil filtering oil condition oil monitoring Load profile speed pressure conditions temperature Number of starts stops Unbalance of the rotor degree of contamination 5 4 Stopping the engine CAUTION Residual heat in the turbocharger If the residual heat in the turbocharger is not adequately dissipated it may damage the engine u Adequ...

Page 69: ...taining to mechan ical cleaning CAUTION Selection of cleaning tools Turbocharger components are sensitive 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 wir...

Page 70: ...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 71: ...ption 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 22 Cleaning the filter silencer 40 u Insert the absorption segments 81136 into the sheet metal coverings 81137 u Bend the sheet metal coverings 81137 back...

Page 72: ...es 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 The following parts which are relevant in terms of performance can be cleaned in accord ance with the description below Fig 23 Compressor end non rotating p...

Page 73: ...a 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 Baked layers of contamination for example from coked oil occur at the turbine end The fol lowing parts which ...

Page 74: ...ty data sheet 6 2 5 Cartridge group general CAUTION Corrosion If the cartridge 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 heavily contaminated due to poorly filtered suction air turbines can be heavily contaminated due to coked oil Contamination s...

Page 75: ...contamination penetrates the cartridge 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 Clean the compressor wheel with a rag or soft brush which has been soaked in water with a household cleaning agent Do not use wire brushes u Dry the compressor wheel and the gap betw...

Page 76: ... in the following Fig 25 Soaking the turbine end Product A mm B mm C mm A130 108 17 205 A135 128 20 245 A140 157 25 300 Table 11 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 CAUTION Selection o...

Page 77: ...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 78: ...sits 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 wa...

Page 79: ...t ABB Turbocharging Service Station Turbine or compressor damaged Bearing damaged Engine Vibrations from engine Contact enginebuilder Table 13 Malfunctions when starting Vibrations Rubbing of rotating parts Normal behaviour not a malfunction Turbochar ger A minimal and uniform wear at the circumference of the rotor components caused by slight local rubbing against adjacent components is permitted ...

Page 80: ...ion Engine Oil filter heavily contaminated Clean Oil pump in lubricating system defect ive Check replace Manometer displays incorrectly Replace manometer Table 15 Malfunctions during operation Lubricating oil pressure too low Speed reduces Possible causes Remedy Turbochar ger Turbine and or nozzle ring severely contaminated Clean see chapter Periodic mainten ance work 39 Rotor components or bearin...

Page 81: ...ng water too high Check clean cooling system Insufficient ventilation Improve ventilation Table 18 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 82: ...verely 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 39 Optimize ...

Page 83: ...se 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 39 Heavy contamination deposits in the turbine or in the nozzle ring Engine Protective grating in f...

Page 84: ...ble 24 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 ...

Page 85: ...o chapter Ordering spare parts 87 Replacing the speed sensor 30 Table 26 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 amp lification of the noise...

Page 86: ...mal 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 operations This Operation Manual may be used to carry out only those operatio...

Page 87: ...ening torques for components of the turbocharger The specified tightening torques of the screw fittings must be observed Table of tightening torques 81 Tightening torques for assembly devices Unless described otherwise the screws and nuts of the assembly devices supplied by ABB must be tightened so they rest firmly against the surface WARNING Suspended loads Loads that are not attached according t...

Page 88: ... lifting and transporting of loads ropes chain block crane Lifting gear is not supplied by ABB Swivel lifting eyes to be used Two swivel lifting eyes are required for the safe lifting of loads these are not supplied by ABB Turbo Systems Swivel lifting eyes Product Thread M Length L Minimum load limit Quant ity A130 M10 17 mm 100 kg 2 A135 M10 17 mm 150 kg 2 A140 M12 21 mm 250 kg 2 Table 29 Swivel ...

Page 89: ...nded up standard values Fig 26 Weights of assemblies Designation A130 kg A135 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 40 60 110 08 Nozzle ring 2 2 4 09 Burst ring 2 3 5 10 Turbine casing 45 65 120 11 Gas outlet flange 7 13 20 12 Gas outlet ca...

Page 90: ...3 Removing air inlets u Mark the casing position for assembly Fig 27 Removing 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 60 91 ...

Page 91: ...moving the gas outlet casing u Mark the casing position for assembly Fig 28 Removing the gas outlet casing 1 Attach lifting gear to the gas outlet casing 61001 2 Loosen and remove nuts 51009 3 If present Loosen the support 61301 from the 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 Page 61 91 ...

Page 92: ...n observance of the action steps described can lead to inadmissible cracks on the gas outlet flange u Observe the maximum tightening torques when pressing off u Follow the action steps described Only dismantle the gas outlet flange if this is necessary 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 ...

Page 93: ...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 29 Removing the gas outlet flange Product Press off screws to be used strength 8 8 Tightening torque A130 6x M6 10 Nm A135 6x M8 20 Nm A140 6x M10 40 Nm Table 33 6 press off screws gas outlet flange not included in the A...

Page 94: ...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 Loosen screws 79041 and remove from the compressor casing 72000 with fixing discs 79040 and diffuser 79000 If the compressor casing cannot be loosened it ...

Page 95: ...ZTL4030_EN Revision D May 2017 Dismantling the wall insert Fig 31 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 65 91 ...

Page 96: ...2017 8 7 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 32 Press off the casing Page 66 91 ...

Page 97: ... 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 no...

Page 98: ...bus Ripp washers 51003 together with the fasten ing strips 51002 Fig 36 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 axi...

Page 99: ... Revision D May 2017 8 9 Removing the nozzle ring Fig 37 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 69 91 ...

Page 100: ... 2017 ABB All rights reserved HZTL4030_EN Revision D May 2017 8 10 Installing the cartridge group on the service support Fig 38 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 70 91 ...

Page 101: ... 58 1 16 A140 0 12 0 21 0 70 1 37 Table 34 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 5 ...

Page 102: ...ed between the heat shield 42400 and the turbine casing 51000 Fig 40 Nozzle ring compression PD Product Compression PD mm A130 0 15 0 15 A135 0 16 0 16 A140 0 16 0 16 Table 35 Permitted nozzle ring compression PD 42001 Bearing casing 51000 Turbine casing 42400 Heat shield 56001 Nozzle ring 1 Measure dimensions A B and S on cleaned surfaces 2 Calculate compression PD u If the calculated value PD li...

Page 103: ...ng 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 the...

Page 104: ...d position of the 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 8 14 Installing the cartridge group Lifting the cartridge group and rotating it by 90 Fig 43 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 ...

Page 105: ...group Part number A130 A135 A140 51007 M8 25 Nm M10 45 Nm M12 75 Nm Table 37 Tightening torque 51007 1 Coat the threads of the studs 51006 with high temperature grease 2 Align the casing position of the cartridge group with the marking 3 Lower the cartridge group into the turbine casing 4 Remove ring nuts and screws 5 Install the fastening strips 51002 with Verbus Ripp discs 51003 and hexagon nuts...

Page 106: ...ling the compressor casing Fitting the wall insert and the diffuser Fig 45 Fitting the wall insert and the diffuser Part number A130 A135 A140 79041 M6 8 Nm M6 8 Nm M6 8 Nm Table 38 Tightening torque 79041 1 Always replace the O ring 77005 see section Spare parts 2 Install the wall insert 77000 in the compressor casing 3 Secure the diffuser 79000 with fixing discs 79040 and screws 79041 Page 76 91...

Page 107: ... Part number A130 A135 A140 72011 M8 35 Nm M10 70 Nm M12 105 Nm Table 39 Tightening torque 72011 1 Fit a new high temperature resisting O ring 42012 red or green see chapter Required customer spare part set 97070 87 2 Thoroughly clean the fastening strips 72012 before assembly 3 Attach swivel lifting eyes 01 to the compressor casing 72000 and lifting gear 4 Install the compressor casing 72000 5 In...

Page 108: ... The upper direc tion N1 and lower direction N2 must be covered simultaneously 2 Calculate clearance N and compare it with the permissible values in the table 3 Push the feeler gauges 01 into the gap such that there is no clearance The upper direc tion R2 and lower direction R1 must be covered simultaneously 4 Calculate clearance R and compare it with the permissible values in the table CAUTION Cl...

Page 109: ...g 48 Installing the air inlets Part number A130 A135 A140 72020 M12 60 Nm M12 60 Nm M12 60 Nm Table 41 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 tightening torque Pag...

Page 110: ...let flange 57002 in the turbine casing 3 Measure radial clearance R see chapter Radial clearances N and R 8 19 Installing the gas outlet casing Fig 50 Installing the gas outlet casing Part number A130 A135 A140 51009 M8 20 Nm M10 40 Nm M12 65 Nm Table 42 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 ...

Page 111: ...ing torques The following tightening torques must be observed for the designated screw fittings 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 51009 M8 20 Nm M10 40 Nm M12 65 Nm 11 72011 M8 35 Nm M10 70 Nm M12 105 Nm 15 86505 M12 x 1 5 15 Nm M12 x 1 5 15 Nm M12 x 1 5 15 Nm 16 51101 51103 51104 612...

Page 112: ... u Seal the oil 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 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 brough...

Page 113: ...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 Turbo Systems recommends having a replacement cartridge group available in storage see ...

Page 114: ...e 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 ...

Page 115: ...rts 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 ...

Page 116: ...ade of leather Wear safety goggles Wear a respiratory mask to protect against dusts Wear safety gloves to protect against mechanical hazards Disposal must be environmentally compatible professional and in compliance with locally applicable regulations The turbocharger consists largely of metal cast iron materials steel nickel steel alloys alu minium and bearing brass Further components are Non met...

Page 117: ...ken 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 customer spare part set 97070 For th...

Page 118: ...are parts 12 3 View of turbocharger with part numbers Copyright 2017 ABB All rights reserved HZTL4030_EN Revision D May 2017 12 3 View of turbocharger with part numbers Fig 52 Overview of part numbers only available in customer spare part set 97070 Page 88 91 ...

Page 119: ...utlet flange 57003 Metal 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 profile 72000 Compressor casing 72011 Hexagon head screw 72012 Fastening strip 72020 V clamp 77000 Wall insert 77005 in customer spare part set O ring 79000 Diffuser 79041 in the customer spare part set Counter sunk screw 81...

Page 120: ...lter silencer 40 Fig 23 Compressor end non rotating parts 42 Fig 24 Turbine end non rotating parts 43 Fig 25 Soaking the turbine end 46 Fig 26 Weights of assemblies 59 Fig 27 Removing air inlets 60 Fig 28 Removing the gas outlet casing 61 Fig 29 Removing the gas outlet flange 63 Fig 30 Removing the compressor casing 64 Fig 31 Dismantling the wall insert 65 Fig 32 Press off the casing 66 Fig 33 Rem...

Page 121: ... air pressure too low 51 Table 20 Malfunctions during operation Charge air pressure too high 52 Table 21 Malfunctions during operation Engine performance losses 52 Table 22 Malfunction Turbocharger pumping 53 Table 23 Malfunction Sporadic surge blows 53 Table 24 Malfunctions when stopping Runout noises 54 Table 25 Malfunctions when stopping Runout time too short 54 Table 26 Malfunction of the spee...

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