ABB HT847358 Manuale utente
Turbo Systems Switzerland Ltd
Operation Manual / A140-H56
HT847358
Document identification
Document number HZTL4030
Revision G
Language English
Original Operation Manual
Product identification
Serial number HT847358
Customer part number 653476
Delivery date (yyyy-mm-dd) 2022-08-12
Weight 460 kg
Operating limits according to rating plate
Speed limit in test rig operation only nMmax 690 1/s
Speed limit during operation nBmax 655 1/s
Gas inlet temperature limit in test rig operation only tMmax 680 °C
Gas inlet temperature limit during operation tBmax 650 °C
Operation Manual / A130-H.. - A140-H..
Table of contents
© Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021
Operation Manual / A130-H.. - A140-H..
1 Introduction............................................................................................................ 4
1.1 Purpose of the manual................................................................................................. 4
1.2 Contact information...................................................................................................... 5
1.3 Essential information.................................................................................................... 5
1.4 Registered trademarks................................................................................................. 5
1.5 Layout and function of the turbocharger ................................................................ 6
1.6 Symbols, definitions..................................................................................................... 8
1.7 Storage of new turbochargers and spare parts .................................................... 10
2 Safety .................................................................................................................... 12
2.1 Introduction .................................................................................................................. 12
2.2 CE conformity............................................................................................................... 12
2.3 Definition of mandatory signs .................................................................................. 13
2.4 Definition of safety instructions .............................................................................. 13
2.5 Intended use ................................................................................................................. 14
2.6 Deflagration 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 and maintenance...................................................... 20
2.12 Hazards during operation and maintenance ......................................................... 21
2.13 Safe operation.............................................................................................................. 23
2.14 Safe maintenance ....................................................................................................... 24
3 Removing and Installing...................................................................................... 28
3.1 Weight and transportation of the turbocharger.................................................. 28
3.2 Removing the turbocharger...................................................................................... 29
3.3 Installing the turbocharger....................................................................................... 33
4 Commissioning .................................................................................................... 40
4.1 Oil supply ...................................................................................................................... 40
4.2 Inspection procedures............................................................................................... 42
4.3 Commissioning after taking out of operation...................................................... 44
5 Monitoring operation .......................................................................................... 45
5.1 Oil pressure, oil temperature.................................................................................... 45
5.2 Exhaust gas temperature before turbine .............................................................. 47
5.3 Turbocharger speed ................................................................................................... 47
6 Operation and service ......................................................................................... 51
6.1 Noise emission ............................................................................................................. 51
Operation Manual / A130-H.. - A140-H..
Table of contents
© Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021
6.2 Service work................................................................................................................. 53
6.3 Expected replacement intervals ............................................................................... 57
6.4 Stopping the engine................................................................................................... 59
7 Periodic maintenance work ................................................................................ 60
7.1 Foreword to maintenance......................................................................................... 60
7.2 Cleaning components mechanically ........................................................................ 61
8 Eliminating malfunctions.................................................................................... 71
8.1 Malfunctions when starting....................................................................................... 71
8.2 Malfunctions during operation ................................................................................. 72
8.3 Turbocharger is surging............................................................................................. 75
8.4 Malfunctions when stopping.................................................................................... 76
8.5 Speed measurement system..................................................................................... 77
9 Dismantling and fitting....................................................................................... 78
9.1 Introduction ................................................................................................................. 78
9.2 Weights of individual parts....................................................................................... 80
9.3 Removing the air inlets .............................................................................................. 82
9.4 Removing the gas outlet casing .............................................................................. 83
9.5 Removing the gas outlet flange............................................................................... 83
9.6 Removing the compressor 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 A and B.................................................................................... 93
9.12 Nozzle ring compression PD..................................................................................... 94
9.13 Installing the nozzle ring ........................................................................................... 95
9.14 Installing the cartridge group .................................................................................. 96
9.15 Installing the compressor casing ............................................................................ 98
9.16 Measuring radial clearances N and R .................................................................... 100
9.17 Installing the air inlets .............................................................................................. 101
9.18 Installing the gas outlet flange .............................................................................. 102
9.19 Installing the gas outlet casing.............................................................................. 102
9.20 Table of tightening torques.................................................................................... 103
10 Taking out of operation at short notice ......................................................... 104
10.1 Possible emergency repairs.................................................................................... 104
10.2 Installing the replacement turbocharger............................................................. 105
10.3 Installing the replacement cartridge group ........................................................ 105
11 Mothballing the turbocharger.......................................................................... 106
11.1 Taking the engine out of operation for up to 12months ................................. 106
11.2 Taking the engine out of operation for more than 12months ........................ 107
Operation Manual / A130-H.. - A140-H..
Table of contents
© Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 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 Required customer spare part set (97070)........................................................... 110
13.3 Spare part – Illustrations .......................................................................................... 111
14 Tools .................................................................................................................... 119
Figures................................................................................................................. 120
Tables ................................................................................................................... 121
Operation Manual / A130-H.. - A140-H..
1 Introduction / 1.1 Purpose of the manual
© Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021
1 Introduction
1.1 Purpose of the manual
Fig.1: Serial number(01) on the rating plate
This Operation Manual belongs to the turbocharger with the identical serial number(01), see
the Operation Manual title page and the rating plate on the turbocharger.
Operation Manual
The Operation Manual 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 it.
Availability of the Operation Manual
The Operation Manual must be available where the turbocharger is used.
All persons operating or working on the turbocharger must have read and fully understood
the Operation Manual.
Page 4 / 122
Operation Manual / A130-H.. - A140-H..
1 Introduction / 1.2 Contact information
© Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021
1.2 Contact information
Contact information for the ABB Turbocharging Service Stations is available online.
uScan the QR code to access our website.
ABB Switzerland Ltd, Turbocharging
Bruggerstrasse 71a
CH-5401 Baden
Switzerland
www.abb.com/turbocharging
1.3 Essential information
Design variants
This 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 Turbocharging Service Station if you have any 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.
1.4 Registered trademarks
The trademarks of outside companies are used in this document. These are marked with the
® symbol.
Page 5 / 122
Operation Manual / A130-H.. - A140-H..
1 Introduction / 1.5 Layout and function of the turbocharger
© Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021
1.5 Layout and function 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 Turbine casing
05 Axial thrust bearing 12 Turbine-end bearing flange
06 Radial plain bearing 13 Compressor-end bearing flange
07 Gas outlet casing 14 Compressor wheel
Page 6 / 122
Operation Manual / A130-H.. - A140-H..
1 Introduction / 1.5 Layout and function of the turbocharger
© Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021
Mode of operation
The turbocharger is a turbomachine and consists of the following main components:
¡Turbine
¡Compressor.
The exhaust gases of the internal combustion engine flow through the turbine casing(11)
and the nozzle ring(10) onto the turbine(08). The turbine(08) uses the energy contained in
the exhaust gas to drive the rotor and thus the compressor wheel(14). The exhaust gases
then reach the atmosphere through the exhaust gas pipe connected to the gas outlet cas-
ing(07).
The compressor wheel(14) sucks in fresh air through the air suction branch (01). In the com-
pressor wheel(14), the energy required for building up the pressure is transferred to the air.
By flowing through the diffuser(03) and the compressor casing(02), the air is compressed
further and is then directed to the engine cylinders.
The rotor runs in two radial plain bearings(06), which are located in the bearing casing(04)
between the compressor and turbine. The axial thrust bearing(05) is located between the
two radial plain bearings.
The plain bearings are connected to a central lubricating oil duct which is normally supplied
by the lubricating oil circuit of the engine. The oil outlet always lies at the deepest point of
the bearing casing(04).
Function of the compressor wheel cooling
Fig.3: Compressor wheel cooling
Depending on the application of an A100 radial turbocharger, the turbocharger is equipped
with compressor wheel cooling. With compressor wheel cooling, after the compressor air
has cooled down by passing through the charge air cooler on the engine side, it is supplied
to the turbocharger for cooling the compressor wheel. Cooling of the compressor wheel is
compulsory to ensure the reliability and replacement intervals for the relevant operating
conditions. In the turbocharger version with compressor wheel cooling, the cooling air is
supplied through a lateral connection in the bearing casing(X).
In addition, the turbocharger version with compressor wheel cooling is indicated by the tur-
bocharger type (H6..) on the rating plate.
Page 7 / 122
Operation Manual / A130-H.. - A140-H..
1 Introduction / 1.6 Symbols, definitions
© Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021
1.6 Symbols, definitions
Symbols
The following symbols are used in this document:
uIndicates an action step.
1. Indicates a numbered action step.
→Refers to a page number
Definition of Note
NOTICE
Note
The note provides advice which facilitates the work.
Definition of mandatory signs
Mandatory signs show the protective equipment to be worn for a task. The mandatory signs
are described in chapter Safety and must be complied with.
Definition of Caution / Warning
Caution and warning signs are described in chapter Safety.
ABB Turbocharging
ABB Switzerland Ltd, Turbocharging is identified as ABB Turbocharging in this document.
Official service stations of ABB Turbocharging
Official service stations are regularly audited and certified by ABB Turbocharging. See also
chapter Contact information →5.
Page 8 / 122
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