ABB HT608400 User manual
Turbocharging
Operation Manual / A130-M56
HT608400
Document identification
Document number HZTL4031
Revision N
Language English
Original Operation Manual
Product identification
Serial number HT608400
Customer part number
Delivery date (yyyy-mm-dd) 2021-12-10
Weight 210 kg
Operating limits according to rating plate
Speed limit in test rig operation only nMmax 1012 1/s
Speed limit during operation nBmax 982 1/s
Gas inlet temperature limit in test rig operation only tMmax 630 °C
Gas inlet temperature limit during operation tBmax 600 °C
Operation Manual / A130-M.. - A145-M..
Table of contents
© Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021
Operation Manual / A130-M.. - A145-M..
1 Introduction............................................................................................................ 4
1.1 Purpose of the manual................................................................................................. 4
1.2 Contact information...................................................................................................... 5
1.3 Essential information.................................................................................................... 5
1.4 Layout and function of the turbocharger ................................................................ 6
1.5 Symbols, definitions..................................................................................................... 8
1.6 Storage of new turbochargers and spare parts .................................................... 10
1.7 Registered trademarks............................................................................................... 12
2 Safety .................................................................................................................... 13
2.1 Introduction .................................................................................................................. 13
2.2 CE conformity............................................................................................................... 13
2.3 Definition of mandatory signs .................................................................................. 14
2.4 Definition of safety instructions .............................................................................. 14
2.5 Intended use ................................................................................................................. 15
2.6 Deflagration on gas engines ..................................................................................... 16
2.7 Warning plates on the turbocharger........................................................................ 17
2.8 Turbocharger rating plate.......................................................................................... 18
2.9 Periodic check of the pressure vessels................................................................... 20
2.10 Lifting of loads ............................................................................................................. 21
2.11 Prerequisites for operation and maintenance....................................................... 22
2.12 Hazards during operation and maintenance ......................................................... 23
2.13 Safe operation............................................................................................................. 25
2.14 Safe maintenance ....................................................................................................... 26
3 Removing and Installing...................................................................................... 30
3.1 Turbocharger weight and transportation ............................................................. 30
3.2 Removing the turbocharger....................................................................................... 31
3.3 Installing the turbocharger....................................................................................... 36
4 Commissioning .................................................................................................... 44
4.1 Oil supply ...................................................................................................................... 44
4.2 Inspection procedures............................................................................................... 46
4.3 Commissioning after taking out of operation...................................................... 48
5 Monitoring operation .......................................................................................... 49
5.1 Oil pressure, oil temperature.................................................................................... 49
5.2 Exhaust gas temperature before turbine ............................................................... 51
5.3 Turbocharger speed................................................................................................... 52
6 Operation and service ......................................................................................... 55
6.1 Noise emission ............................................................................................................ 55
Operation Manual / A130-M.. - A145-M..
Table of contents
© Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021
6.2 Service work.................................................................................................................. 57
6.3 Expected replacement intervals ............................................................................... 61
6.4 Stopping the engine................................................................................................... 63
7 Periodic maintenance work ................................................................................ 64
7.1 Foreword to maintenance......................................................................................... 64
7.2 Cleaning the compressor during operation .......................................................... 65
7.3 Cleaning the turbine during operation................................................................... 68
7.4 Cleaning components mechanically ........................................................................ 72
8 Eliminating malfunctions.................................................................................... 82
8.1 Malfunctions when starting...................................................................................... 82
8.2 Malfunctions during operation ................................................................................ 83
8.3 Turbocharger is surging............................................................................................ 86
8.4 Malfunctions when stopping.................................................................................... 87
8.5 Speed measurement system.................................................................................... 88
9 Dismantling and fitting....................................................................................... 89
9.1 Introduction ................................................................................................................. 89
9.2 Material required......................................................................................................... 90
9.3 Weights of individual parts....................................................................................... 92
9.4 Removing the air inlets .............................................................................................. 93
9.5 Removing the gas outlet casing .............................................................................. 94
9.6 Removing the gas outlet flange............................................................................... 95
9.7 Removing the compressor casing........................................................................... 98
9.8 Pressing off the casing ............................................................................................ 100
9.9 Removing the cartridge group................................................................................ 101
9.10 Removing the nozzle ring ........................................................................................ 103
9.11 Installing the cartridge group on the service support ...................................... 104
9.12 Measuring clearance A and B.................................................................................. 105
9.13 Nozzle ring compression PD................................................................................... 106
9.14 Installing the nozzle ring ......................................................................................... 107
9.15 Installing the cartridge group ................................................................................ 108
9.16 Installing the compressor casing ........................................................................... 111
9.17 Measuring radial clearances N and R ..................................................................... 113
9.18 Installing the air inlets .............................................................................................. 114
9.19 Installing the gas outlet flange ............................................................................... 115
9.20 Fitting the insulation of the turbine casing ......................................................... 116
9.21 Installing the gas outlet casing............................................................................... 117
9.22 Table of tightening torques..................................................................................... 119
10 Taking out of operation at short notice .......................................................... 121
10.1 Possible emergency repairs..................................................................................... 121
10.2 Installing the replacement turbocharger.............................................................. 122
10.3 Installing the replacement cartridge group ......................................................... 122
10.4 Fitting the cover plate............................................................................................... 123
Operation Manual / A130-M.. - A145-M..
Table of contents
© Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021
10.5 Cover plate drawing .................................................................................................. 124
11 Mothballing the turbocharger.......................................................................... 125
11.1 Taking the engine out of operation for up to 12months .................................. 125
11.2 Taking the engine out of operation for more than 12months......................... 126
12 Disposing of turbocharger components ........................................................ 127
13 Spare parts ......................................................................................................... 129
13.1 Ordering spare parts................................................................................................. 129
13.2 Required customer spare part set (97070)........................................................... 129
13.3 Spare part – Illustrations ......................................................................................... 130
14 Tools .................................................................................................................... 145
Figures................................................................................................................. 146
Tables .................................................................................................................. 148
Operation Manual / A130-M.. - A145-M..
1 Introduction / 1.1 Purpose of the manual
© Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 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 / 149
Operation Manual / A130-M.. - A145-M..
1 Introduction / 1.2 Contact information
© Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 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.
Page 5 / 149
Operation Manual / A130-M.. - A145-M..
1 Introduction / 1.4 Layout and function of the turbocharger
© Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021
1.4 Layout and function of the turbocharger
Fig.2: Layout and function of the turbocharger
01 Filter silencer / 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 6 / 149
Operation Manual / A130-M.. - A145-M..
1 Introduction / 1.4 Layout and function of the turbocharger
© Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021
Mode of operation
The turbocharger is a turbomachine and consists of the following main components:
¡Turbine
¡Compressor.
These components are installed on a common shaft and form the rotor.
The exhaust gases of the internal combustion engine flow through the turbine casing(10)
and the nozzle ring(09) onto the turbine(07). The turbine(07) uses the energy contained in
the exhaust gas to drive the rotor and, hence, the compressor wheel(13). The exhaust gases
then reach the atmosphere through the exhaust gas pipe connected to the gas outlet
flange(08).
The compressor wheel(13) sucks fresh air through the air suction branch or the filter silen-
cer(01). In the compressor wheel (13), 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).
1.4.1 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 (M6..) on the rating plate.
Page 7 / 149
Operation Manual / A130-M.. - A145-M..
1 Introduction / 1.5 Symbols, definitions
© Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021
1.5 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 / 149
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