ABB HT613213 User manual
Turbo Systems Switzerland Ltd
Operation Manual / A175-M66
HT613213
Document identification
Document number HZTL4033
Revision K
Language English
Original Operation Manual
Product identification
Serial number HT613213
Customer part number
Delivery date (yyyy-mm-dd) 2022-05-23
Weight 4600 kg
Operating limits according to rating plate
Speed limit in test rig operation only nMmax 316 1/s
Speed limit during operation nBmax 302 1/s
Gas inlet temperature limit in test rig operation only tMmax 650 °C
Gas inlet temperature limit during operation tBmax 620 °C
Operation Manual / A170-M.. - A175-M..
Table of contents
© Copyright 2022 ABB. All rights reserved. HZTL4033_EN Rev.K January 2022
Operation Manual / A170-M.. - A175-M..
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 Removal and installation .................................................................................... 28
3.1 Turbocharger weight ................................................................................................. 28
3.2 Removing the turbocharger...................................................................................... 29
3.3 Installing the turbocharger........................................................................................ 32
4 Commissioning .................................................................................................... 38
4.1 Oil supply ...................................................................................................................... 38
4.2 Inspection procedures............................................................................................... 39
4.3 Commissioning after taking out of operation...................................................... 40
5 Monitoring during operation.............................................................................. 41
5.1 Oil pressure, oil temperature..................................................................................... 41
5.2 Turbocharger speed................................................................................................... 43
6 Operation and service ......................................................................................... 46
6.1 Noise emission ............................................................................................................ 46
6.2 Service work................................................................................................................. 48
6.3 Expected replacement intervals ............................................................................... 51
Operation Manual / A170-M.. - A175-M..
Table of contents
© Copyright 2022 ABB. All rights reserved. HZTL4033_EN Rev.K January 2022
6.4 Stopping the engine................................................................................................... 52
7 Periodic maintenance.......................................................................................... 53
7.1 Foreword to maintenance......................................................................................... 53
7.2 Cleaning the filter silencer ........................................................................................ 54
7.3 Cleaning the slotted diffuser..................................................................................... 57
7.4 Cleaning the compressor during operation .......................................................... 58
7.5 Cleaning turbine and nozzle ring ............................................................................. 64
8 Troubleshooting................................................................................................... 70
8.1 Malfunctions when starting...................................................................................... 70
8.2 Malfunctions during operation ................................................................................. 71
8.3 Surging of the turbocharger...................................................................................... 73
8.4 Malfunctions when stopping.................................................................................... 74
8.5 Speed measurement system..................................................................................... 75
9 Disassembly and assembly................................................................................. 76
9.1 Introduction ................................................................................................................. 76
9.2 Weight of assemblies................................................................................................. 78
9.3 Removing the air inlets .............................................................................................. 79
9.4 Axial clearance A prior to disassembly .................................................................... 81
9.5 Removing the compressor casing........................................................................... 82
9.6 Removing the cartridge group................................................................................. 86
9.7 Removing the nozzle ring .......................................................................................... 89
9.8 Installing the nozzle ring ........................................................................................... 94
9.9 Installing the cartridge group .................................................................................. 99
9.10 Fitting the spinner nose cone ................................................................................ 102
9.11 Installing the compressor casing .......................................................................... 104
9.12 Axial clearance A after assembly............................................................................ 108
9.13 Installing the air inlets ............................................................................................. 109
9.14 Removing and installing turbine-end nozzle ring................................................ 112
9.15 Table of tightening torques..................................................................................... 116
10 Taking a turbocharger out of operation......................................................... 119
10.1 Possible emergency repairs..................................................................................... 119
10.2 Locking the rotor ...................................................................................................... 120
10.3 Fitting the cover plate............................................................................................... 123
10.4 Blanking off the inlets and outlets ......................................................................... 125
10.5 Engines with bypass around the turbocharger ................................................... 125
11 Mothballing the turbocharger.......................................................................... 126
11.1 Taking the engine out of operation for up to 12months .................................. 126
11.2 Taking the engine out of operation for more than 12months ......................... 127
12 Material and Disposal........................................................................................ 128
12.1 REACH and RoHS Compliance Declaration For Products .................................. 128
12.2 Disposing of turbocharger components .............................................................. 129
Operation Manual / A170-M.. - A175-M..
Table of contents
© Copyright 2022 ABB. All rights reserved. HZTL4033_EN Rev.K January 2022
13 Spare parts ......................................................................................................... 130
13.1 Ordering spare parts................................................................................................ 130
13.2 Spare part – Illustrations.......................................................................................... 131
14 Tools .................................................................................................................... 141
Figures................................................................................................................. 143
Tables .................................................................................................................. 145
Operation Manual / A170-M.. - A175-M..
1 Introduction / 1.1 Purpose of the manual
© Copyright 2022 ABB. All rights reserved. HZTL4033_EN Rev.K January 2022
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 / 146
Operation Manual / A170-M.. - A175-M..
1 Introduction / 1.2 Contact information
© Copyright 2022 ABB. All rights reserved. HZTL4033_EN Rev.K January 2022
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 / 146
Operation Manual / A170-M.. - A175-M..
1 Introduction / 1.5 Layout and function of the turbocharger
© Copyright 2022 ABB. All rights reserved. HZTL4033_EN Rev.K January 2022
1.5 Layout and function of the turbocharger
Fig.2: Layout and function
01 Filter silencer / air suction branch 06 Gas inlet casing
02 Compressor wheel 07 Nozzle ring
03 Diffuser 08 Turbine
04 Bearing bush 09 Bearing casing
05 Gas outlet casing 10 Compressor casing
Page 6 / 146
Operation Manual / A170-M.. - A175-M..
1 Introduction / 1.5 Layout and function of the turbocharger
© Copyright 2022 ABB. All rights reserved. HZTL4033_EN Rev.K January 2022
Mode of operation
The turbocharger is a turbomachine consisting of two main components, a turbine and a
compressor. These components are mounted on a common shaft and form the rotor.
In the turbocharger shown in the illustration, the exhaust gas flows through the gas inlet
casing(06) and the nozzle ring(07) and arrives at the turbine(08). The turbine utilises the
energy contained in the exhaust gas to drive the rotor. The exhaust gases then escape into
the open air through the gas outlet casing(05) and the exhaust gas pipe connected to it.
The rotor runs in two radial plain bearings, which are located between the compressor and
the turbine in the bearing bush(04). The axial bearing is also a plain bearing. The plain bear-
ings are connected to a central lubricating oil duct which is normally supplied by the lubric-
ating oil circuit of the engine. The oil outlet is situated at the lowest point of the bearing
casing(09).
The compressor wheel(02) connected to the shaft draws in fresh air through the filter silen-
cer(01) or the air suction branch. The air is compressed in the compressor and the down-
stream diffuser(03) and then led to the charge air cooler via the compressor casing(10).
Turbocharger version with compressor wheel cooling
Fig.3: Connection of the compressor wheel cooling
Depending on the application, 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 cool-
ing the compressor wheel.
Cooling of the compressor wheel is compulsory to ensure the reliability and replacement in-
tervals for the relevant operating conditions. In the turbocharger version with compressor
wheel cooling, the cooling air is supplied through the lateral connection (15) in the bearing
casing.
Page 7 / 146
Operation Manual / A170-M.. - A175-M..
1 Introduction / 1.6 Symbols, definitions
© Copyright 2022 ABB. All rights reserved. HZTL4033_EN Rev.K January 2022
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 / 146
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