Page 1
Operation Manual A140-H55 HT568602 English Original Operation Manual Chapter Document-ID Introduction HZTL4005_EN_E Safety HZTL4022_EN_D Safety data sheet HT568602 Product description HZTL4030_EN_C ABB Turbocharging...
Page 2
Operating limits and replacement intervals The recommended replacement intervals 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 9
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 ...
Operation Manual / 1 Introduction Introduction Page 8 / 8 Contact information Contact information of the ABB Turbocharging Service Stations is available online. Scan the QR code to access our website. ABB Turbo Systems Ltd Bruggerstrasse 71a CH-5401 Baden Switzerland www.abb.com/turbocharging...
Safety Introduction Turbochargers manufactured by ABB reflect the state of the art. The respective safety and health protection requirements are met. This ensures safe operation of the turbocharger. Nev- ertheless, there may be some residual risks during operation of and work on the turbocharger which: ...
The specific operating limits of the turbocharger were determined on the basis of information 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-intended uses. [1] Euromot = The European Association of Internal Combustion Engine Manufacturers...
If 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. An ABB Turbocharging Service Station should be instructed to carry out this inspec- tion.
Periodic check of the pressure vessels The pressure vessels used by ABB Turbocharging, such as those for wet or dry cleaning, are so-called "simple pressure vessels". The locally applicable legal regulations regarding periodic checks of the pressure vessels must be observed.
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. ABB Turbocharging Service Stations will be happy to provide information on questions regarding a design variant (see Operation Manual / 1 Introduction / Customer Service).
Figure 3: Warning plate locations If warning plates are not present in the designated locations or not readable, proceed as follows: Order new warning plates from ABB Turbocharging Service Stations. Remove any warning plates that have become unreadable. ...
The oil is supplied (02) and drained (03) through the bracket (01). The necessary sealing is by means of O-rings which are located in the slots of the bracket. The gaskets are not included in the ABB Turbo Systems scope of delivery and must be provided by the enginebuilder.
Fixing material scope of delivery The threaded rods and nuts for fastening the turbocharger on the bracket are not included in the ABB Turbo Systems scope of delivery. These parts depend on the version of the engine- side bracket. The clamping nuts are included in the ABB Turbo Systems scope of delivery.
Oil pressure measuring point Oil temperature measuring point For monitoring the lubricating oil pressure, ABB Turbo Systems recommends installing an "M" manometer immediately before the turbocharger. If the pressure is controlled electronically, the appropriate signals are to be triggered at the warning and alarm values.
Page 65
If the engine can be stopped temporarily: Inspect air lines, exhaust gas pipes and the turbochargers and remedy any malfunctions. ABB Turbo Systems recommends contacting the nearest ABB Turbocharging Service Station. 4.3.4 Malfunctions on the speed measurement system In the case of malfunctions of the speed measurement system, refer to the chapter entitled Troubleshooting/Speed measurement system [➙...
CAUTION lead to untimely machine damage even if the prescribed service intervals are observed. Agree on a shortened service interval with ABB Turbo Systems. 5-year service inspection To prevent machine damage caused by ageing and downtime, we...
Page 70
Service work according to data on the rating plate (Usually after 8000 … 12000 operating hours) The rotor and bearing parts must be checked and assessed by an ABB Turbocharging Service Station. The following work can be carried out as preparation.
Page 71
Page 39 / 115 5.2.5 Other service work If a protective grid is installed in the radial or axial gas outlet casing (61001) by ABB Turbo Systems: Figure 21: Replacing the protective grid Remove the protective grid (61205) after 50000 hours and replace it with a new one.
– 600 °C with non-insulated casing At temperatures below the specified values, post-lubrication must be ensured until the rotors come to a standstill. ABB Turbo Systems recommends post-lubrication for 10 minutes. Observe the oil pressure specified for post-lubrication (see Table 6).
8000 … 12000 h) Table 11: Maintenance table [h] = Hours of operation If the maintenance intervals are incompatible with operation of the engine, contact ABB Turbo Systems. ABB Turbo Systems recommends having mechanical cleaning carried out by an ABB Turbocharging Service Station during the service work.
In this case, ABB Turbo Systems recommends having the contaminated components cleaned mechanically by an ABB Turbocharging Service Station. Periodic cleaning in operation is no replacement for service work in which an ABB Turbocharging Service Station completely dismantles and maintains the turbocharger.
Page 79
The compressor is cleaned during operation using the wet cleaning method. It is carried out at an engine load of 50 ... 85 %. This cleaning method has been tested and approved by ABB Turbo Systems. V-engines On V-engines with several turbochargers per engine, parallel cleaning of both turbochargers is recommended.
The success of the cleaning can be recognised based on the charging pressure or the exhaust gas temperature. If the engine values are still unsatisfactory after carrying out the process three times, ABB Turbo Systems recommends having the turbocharger checked and cleaned by an ABB Turbocharging Service Station.
In this case, ABB Turbo Systems recommends having the contaminated components cleaned mechanically by an ABB Turbocharging Service Station. Periodic cleaning in operation is no replacement for service work in which an ABB Turbocharging Service Station completely dismantles and maintains the turbocharger.
Page 83
Cleaning method The turbine components are cleaned during operation using the wet cleaning method. This cleaning method is tested and approved by ABB Turbo Systems. The precondition for wet cleaning is that the enginebuilder approves the process and these regulations are observed.
Close the stop valve (02) after 10 minutes. Wait for 10 minutes; do not change the load during this stabilisation phase. If the cleaning result is unsatisfactory or there is water leakage, contact an ABB Turbocharging Service Station. Product Temperature before...
Page 88
When cleaning, note that the absorption segments (81136) must only be cleaned lightly with compressed air, a soft brush or a moist cleaning cloth. Have any heavily contaminated absorption segments replaced by an ABB Turbocharging Service Station. Fitting the filter silencer (see Figure 24) Insert the absorption segments (81136) into the sheet-metal coverings (81137).
To prevent significant loss of efficiency, specific tolerances must be fulfilled. If there is any doubt about the extent of the rubbing, contact an ABB Turbocharging Service Station. Have a dimension check carried out by an ABB Turbocharging Service Station.
Increased speed due to contamination of Clean (see chapter Periodic maintenance nozzle ring work [➙ 45]) or contact an ABB Turbocharging Service Station Table 24: Malfunctions during operation – Charge air pressure too high Reduced compressor performance/efficiency, hence engine performance losses...
Gradually reduce the engine load. Have the cause clarified and remedied immediately by an ABB Turbocharging Service Station. Have parts assessed for damage and, if necessary, replaced by an ABB Turbocharging Service Station. Possible causes Remedy Engine...
Bearing damaged Check clearances (see chapter Axial clearance A and radial clearance B [➙ 87]). If clearances are outside the tolerance or if in doubt, contact an ABB Turbocharging Service Station. Rotor rubbing Check clearances (see chapter Radial clearances N and R [➙...
Table 32: Malfunction of the speed measurement system – Measured speed too low Other causes of malfunction If none of the measures described above remedy the malfunction, have the speed measurement system checked by an ABB Turbocharging Service NOTICE Station.
ABB Turbo Systems recommends having further operations carried out only by trained staff or an ABB Turbocharging Service Station. Marking casing position for assembly ABB Turbo Systems recommends marking the casing positions prior to disassembly.
Lifting gear Equipment for the lifting and transporting of loads (ropes, chain block, crane). Lifting gear is not supplied by ABB Turbo Systems. Swivel lifting eyes to be used Two swivel lifting eyes are required for the safe lifting of loads, which are not supplied by ABB Turbo Systems.
Dismantling and fitting Page 78 / 115 Removing air inlets Marking casing position for assembly ABB Turbo Systems recommends marking the casing positions prior to disassembly. NOTICE Figure 29: Removing the air inlets 1. Loop around the filter silencer (81000) with lifting gear.
Dismantling and fitting Page 79 / 115 Removing the gas outlet casing Marking casing position for assembly ABB Turbo Systems recommends marking the casing positions prior to disassembly. NOTICE Figure 30: Removing the gas outlet casing 1. Loosen and remove nuts (51009).
Operation Manual / 4 Product description / A130-H.. - A140-H.. Dismantling and fitting Page 80 / 115 Removing the gas outlet flange Marking casing position for assembly ABB Turbo Systems recommends marking the casing positions prior to disassembly. NOTICE Figure 31: Removing the gas outlet flange Product Press-off screws to be used (strength 8.8)*...
Page 81 / 115 Removing the compressor casing Removing the compressor casing Marking casing position for assembly ABB Turbo Systems recommends marking the casing positions prior to disassembly. NOTICE Loosening the compressor casing with press-off tool If the compressor casing cannot be loosened, it can be pressed off against...
Figure 34: Removing insulation sheets If present: Remove the insulation sheets (01, 02, 03). Marking casing position for assembly ABB Turbo Systems recommends marking the casing positions prior to disassembly. NOTICE 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 >...
Page 124
(02), a separate burst protection (03) is fitted. If the insulation from ABB Turbo Systems (01) is not installed, the separate burst protection (03) plus either the insulation (02) or an appropriate insulation supplied by the enginebuilder must be installed for operation.
Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. CAUTION Have the components assessed and, if necessary, replaced by an ABB Turbocharging Service Station. Figure 49: Measuring clearances N and R...
If present: Installing a replacement cartridge group [➙ 102]. If a replacement turbocharger or cartridge group is not available: Fit cover plate [➙ 103] and contact an ABB Turbocharging Service Station. Observe the following sections in connection with the emergency repairs mentioned.
The repair of a cartridge group requires special tools and the expertise of an ABB Turbocharging Service Station. The rotating parts turn very fast and are very sensitive to unbalance.
Page 104 / 115 Cover plate drawing The cover plate is not included in the ABB Turbo Systems scope of delivery and must be manufactured by the operating company according to the following drawing. Material: General structural steel, in compliance with DIN EN 10025-2.
If the total acid number (TAN) is greater than 2 mg KOH/g, the following mothballing measures are necessary after taking an engine out of operation: Dismantle the turbocharger. The rotor and the bearing parts must be removed by an official ABB Turbocharging service station and refitted afterwards. Clean all parts.
The casings of the turbocharger remain attached to the engine, the rotor and bearing parts are dismantled by an ABB Turbocharging Service Station and stored separately The turbocharger has been completely removed, either as a whole unit or in individual...