Operation Manual
A175-M62
HT845667 English
Original Operation Manual
Chapter
Document-ID
HZTL4005_EN_G
HZTL4023_EN_E
HT845667
1
2
3
4
Introduction
Safety
Safety data sheet
Product description
HZTL4033_EN_F
ABB Switzerland Ltd, Turbocharging
Operation Manual / 1 Introduction
Table of contents
Introduction
Storage of new turbochargers and spare parts...................................................... 5
© Copyright 2020 ABB. All rights reserved.
HZTL4005_EN
Rev.G
March 2020
Operation Manual / 1 Introduction
1 Introduction / 1.1 Purpose of the manual
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
chapter 3 (Safety data sheet) 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.
© Copyright 2020 ABB. All rights reserved.
HZTL4005_EN
Rev.G
March 2020
Operation Manual / 1 Introduction
1 Introduction / 1.2 Symbols, definitions
1.2
Symbols, definitions
Symbols
The following symbols are used in this document:
u Indicates 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 or as ABB Turbo Sys-
tems in this document.
Official service stations of ABB Turbocharging
Official service stations are regularly audited and certified by ABB Turbocharging. See also
© Copyright 2020 ABB. All rights reserved.
HZTL4005_EN
Rev.G
March 2020
Operation Manual / 1 Introduction
1 Introduction / 1.2 Symbols, definitions
Definition of pictograms
The following pictograms can occur in this document. These point out actions that must be
taken in accordance with the meaning of the relevant pictogram.
Pictogram Meaning
Tighten with specified torque
Tighten over specified tightening angle
Hand-tight, tighten without tools
Oil
Apply screw locking paste (e.g. Loctite)
Apply high-temperature grease
Apply other paste in accordance with specifications
Oil free, grease free and dry
Affix
Measure
Note
Visually inspect
Please note text for numbered work step.
See document
Dispose of in an environmentally compatible, professional way and in compliance
with locally applicable regulations.
Table 1: Definition of pictograms
© Copyright 2020 ABB. All rights reserved.
HZTL4005_EN
Rev.G
March 2020
Operation Manual / 1 Introduction
1 Introduction / 1.3 Storage of new turbochargers and spare parts
1.3
Storage of new turbochargers and spare parts
Storage of new turbochargers and spare parts up to 6 months
New turbochargers and spare parts can be stored in sealed packaging without additional
mothballing measures for up to 6 months from the date of delivery (marked by the VCI label
on the package).
Fig. 2: Volatile Corrosion Inhibitor (VCI)
Only dry rooms in which the relative humidity is between 40…70 % and no condensation can
form are suitable for storage.
Storage of new turbochargers and spare parts for more than 6 months
WARNING
Protection of health when handling VCIs
VCI products are not hazardous in the sense of the Hazardous Substances
Ordinance. Nevertheless, the following points are to be observed when
handling VCIs:
u Observe specifications in the safety data sheet
u Ensure good room ventilation.
u Do not eat, drink or keep food at the workplace while working with VCIs.
u Clean hands and face after working with VCIs.
Wear safety gloves to protect against mechanical hazards.
The following mothballing measures are required every 6 months:
u Open the package.
u Remove the VCI corrosion protection emitter from the package and replace it with a new,
identical VCI corrosion protection emitter. New VCI corrosion protection emitters can be
u Dispose of the old VCI corrosion protection emitter in an environmentally compatible
manner, professionally and in accordance with local regulations.
u Seal the package. The better the external seal is designed, the more permanent the pro-
tection.
© Copyright 2020 ABB. All rights reserved.
HZTL4005_EN
Rev.G
March 2020
Operation Manual / 1 Introduction
1 Introduction / 1.3 Storage of new turbochargers and spare parts
Long-term storage of turbochargers
The turbochargers will be prepared for prolonged storage by ABB Turbo Systems on re-
quest. The package is equipped with a hygrometer (see illustration).
Fig. 3: Package with hygrometer
The following measures are required every 6 months:
u Check the hygrometer (02) in the sight-glass. There is an opening (01) in the wooden
crate which allows this check to be carried out. When the display field has changed colour
at the 70% level, the maximum permissible humidity has been exceeded. In this case the
turbocharger must be inspected by an ABB Turbocharging Service Station and repacked.
u Inspect the package for damage. If the package is damaged, the turbocharger must be in-
spected by an ABB Turbocharging Service Station and repacked.
After every 3 years the following work steps must be performed by an ABB Turbocharging
Service Station:
¡
¡
¡
Inspect the components
Replace the desiccant agent
Repackage the components.
If the 70% display field of the hygrometer (02) has not changed colour and the package is
undamaged, the turbocharger can be placed into operation without any prior testing by an
ABB Turbocharging Service Station.
Unpacking turbochargers
The corrosion protection effect ends after the material is unpacked from the VCI package.
To avoid the formation of condensation, the surroundings and the content of the package
must have the same temperature during unpacking.
© Copyright 2020 ABB. All rights reserved.
HZTL4005_EN
Rev.G
March 2020
Operation Manual / 1 Introduction
1 Introduction / 1.4 Contact information
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 Switzerland Ltd, Turbocharging
Bruggerstrasse 71a
CH-5401 Baden
Switzerland
© Copyright 2020 ABB. All rights reserved.
HZTL4005_EN
Rev.G
March 2020
Operation Manual / 2 Safety / A100-M axial
Table of contents
Safety
Safety ...................................................................................................................... 2
CE conformity................................................................................................................. 2
Intended use .................................................................................................................. 4
Warning plates on the turbocharger......................................................................... 6
Periodic check of the pressure vessels..................................................................... 8
Lifting of loads .............................................................................................................. 9
Hazards during operation and maintenance ......................................................... 11
Safe operation.............................................................................................................. 13
© Copyright 2020 ABB. All rights reserved.
HZTL4023_EN
Rev.E
October 2020
Operation Manual / 2 Safety / A100-M axial
1 Safety / 1.1 Introduction
1
Safety
1.1
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.
Nevertheless, there may be some residual risks during operation of and work on the tur-
bocharger which:
¡
¡
¡
¡
are caused by the turbocharger itself or its accessories.
are caused by the operating equipment used or supplies and materials.
are a consequence 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 during all work on the turbocharger.
must also be observed.
1.2
CE conformity
Information
ABB turbochargers comply with the Machinery Directive 2006/42/EC and are partly com-
pleted machinery as defined by Article 2 g in this directive.
© Copyright 2020 ABB. All rights reserved.
HZTL4023_EN
Rev.E
October 2020
Operation Manual / 2 Safety / A100-M axial
1 Safety / 1.3 Definition of mandatory signs
1.3
Definition of mandatory signs
To be worn at all times
Protective clothing
Safety footwear to protect
against mechanical hazard and
risk of falling
Table 1: Personal protective equipment to be worn at all times
To be worn specific to the respective task
Safety glasses
Safety goggles
Safety gloves to protect
against
Respiratory mask to protect
against
- Dusts
- Gases
- Mechanical hazard
- Chemical hazard
- Thermal hazard
- Electrical hazard
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 fatal accidents.
u Warning signs must always be observed.
CAUTION
Definition of Caution
Non-compliance or inaccurate compliance with working or operating in-
structions indicated by this symbol and the word CAUTION can lead to seri-
ous damage to engine or property with grave consequences.
u Caution signs must always be observed.
© Copyright 2020 ABB. All rights reserved.
HZTL4023_EN
Rev.E
October 2020
Operation Manual / 2 Safety / A100-M axial
1 Safety / 1.5 Intended use
1.5
Intended use
Use on internal combustion engines in general
ABB turbochargers are intended for charging internal combustion engines.
To ensure compliance with the machinery directive 2006/42/EC when using on gas engines,
the turbocharger must be operated in an engine room classified as "not at risk of explosion".
This is in accordance with the position paper [2] relating to ATEX issued by EUROMOT [1].
The turbocharger supplies the engine with the air volume or air/gas mixture and the associ-
ated charging pressure 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-intended uses.
[1]Euromot = The European Association of Internal Combustion Engine Manufacturers
[2]Directive 94/9/EC concerning equipment and protective systems intended for use in po-
tentially explosive atmospheres (ATEX) The Euromot Position as of November 2003, ATEX
Euromot Position 191103
WARNING
Unapproved operation
Any operation of the turbocharger outside of its operating limits can be haz-
ardous to personnel.
u Only operate the turbocharger within the operating limits.
u Only trained personnel must operate the turbocharger.
The intended use of the turbocharger includes compliance with all regulations and condi-
tions. In particular, the following must be observed:
¡
¡
Operation Manual
Instructions of the enginebuilder
© Copyright 2020 ABB. All rights reserved.
HZTL4023_EN
Rev.E
October 2020
Operation Manual / 2 Safety / A100-M axial
1 Safety / 1.6 Deflagration on gas engines
State of the art
The turbocharger is designed and manufactured according to the state of the art and is safe
to operate.
Perfect condition
The turbocharger must only be used when it is in a technically flawless condition and oper-
ated in compliance with its intended use.
ABB excludes any liability for damage resulting from unauthorized modifications to the tur-
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 recommends verifying the following points on the turbochar-
ger:
¡
¡
¡
Position of the turbine and compressor casings to the bearing casing
Shifting of the bearing casing in relation to the bracket
Cracks in casings
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 inspection.
© Copyright 2020 ABB. All rights reserved.
HZTL4023_EN
Rev.E
October 2020
Operation Manual / 2 Safety / A100-M axial
1 Safety / 1.7 Warning plates on the turbocharger
1.7
Warning plates on the turbocharger
Warning plates are attached to the turbocharger and must be observed. The warning plates
must 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
warning plates on the insulation. This is the responsibility of the enginebuilder.
© Copyright 2020 ABB. All rights reserved.
HZTL4023_EN
Rev.E
October 2020
Operation Manual / 2 Safety / A100-M axial
1 Safety / 1.8 Turbocharger rating plate
1.8
Turbocharger rating plate
Fig. 2: Rating plate
Operating limits
01 Turbocharger operating limits at engine overload (110 %).
In test rig operation only, unless otherwise agreed with the en-
ginebuilder.
02 Turbocharger operating limits during operation
Recommended replacement intervals of turbocharger components
03 Replacement 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 kg
09 Turbocharger type
10 Serial number
11 Year of construction of turbocharger
12 Manufacturing plant
© Copyright 2020 ABB. All rights reserved.
HZTL4023_EN
Rev.E
October 2020
Operation Manual / 2 Safety / A100-M axial
1 Safety / 1.9 Periodic check of the pressure vessels
Explanations regarding the rating plate
The recommended replacement intervals and the corresponding operating limits are jointly
defined with the enginebuilder. This information is specific to the system.
Operation above the indicated values nBmax, tBmax can considerably shorten the recommended
replacement intervals. In such cases ABB recommends contacting the nearest ABB Tur-
bocharging Service Station.
nMmax, tMmax normally apply only when running at overload (110%) during trials on the engine
test bed. These limit values can also be permitted during operation for special applications.
Operation above nMmax and tMmax is not permitted.
Non-observance of the recommended replacement intervals increases the risk of unpredict-
able 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 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.
¡
The operating company is responsible for the safe operation of the pressure vessel.
WARNING
Danger due to pressure vessels
The operating company must make sure the pressure vessels are in proper
working condition and monitor them. Necessary repair or maintenance work
must be performed promptly, and the required safety measures must be
taken.
u Pressure equipment must not be operated if defects are present.
© Copyright 2020 ABB. All rights reserved.
HZTL4023_EN
Rev.E
October 2020
Operation Manual / 2 Safety / A100-M axial
1 Safety / 1.10 Lifting of loads
1.10
Lifting of loads
WARNING
Suspended loads
Loads that are not attached according to regulations can cause injury to
personnel or fatal accidents.
u Loads must always be fastened to properly functional lifting gear with a
sufficient load limit.
u Pay attention to the correct attachment of loads on the crane hook.
u People must not stand beneath suspended loads.
Wear safety gloves to protect against 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 described in the respective action steps.
u Use a suitable edge guard if there are sharp edges.
u The assembly devices must be completely screwed in and must not loosen during use.
u Use assembly devices only for the described applications.
u Put down dismantled components of the turbocharger in such a way that they cannot tip
over.
© Copyright 2020 ABB. All rights reserved.
HZTL4023_EN
Rev.E
October 2020
Operation Manual / 2 Safety / A100-M axial
1 Safety / 1.11 Prerequisites for operation and maintenance
1.11
Prerequisites for operation and maintenance
Responsibility of the operating company
In awareness of its responsibility, the operating company must ensure that only authorised
personnel work on the turbocharger, who:
¡
Are versed in the general and locally applicable regulations for occupational safety and
accident prevention
¡
¡
¡
Are equipped with the prescribed personal protective equipment
Have read and understood the Operation Manual
Have been instructed in the use of the turbocharger.
The safety-conscious work of the personnel and adherence to the Operation Manual must be
checked 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 turbocharger
Modifications to the turbocharger must be approved by ABB.
WARNING
Use original parts
Operation of the turbocharger with non-original parts can impair the safety
of the turbocharger and can cause serious damage to property and injury to
personnel.
u Only use original parts from ABB.
Original parts and accessories are specially designed for ABB turbochargers.
ABB accepts no liability for any damage resulting from the use of non-original parts and cor-
responding accessories.
© Copyright 2020 ABB. All rights reserved.
HZTL4023_EN
Rev.E
October 2020
Operation Manual / 2 Safety / A100-M axial
1 Safety / 1.12 Hazards during operation and maintenance
1.12
Hazards during operation and maintenance
Noise hazards
The turbocharger's noise emission is influenced by its installation and operating conditions.
A noise level exceeding 85 dB(A) is harmful.
WARNING
Noise hazards
Exposure to noise can harm the hearing system, impair health and the psy-
chological state and may lead to lack of attention and irritation.
u When the engine is 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.
WARNING
Danger of burns
Touching hot surfaces or contact with hot operating fluids can cause burns.
u Do not touch hot surfaces. Observe the warning plate on the turbochar-
ger.
u Wear heat-resistant safety gloves and protective clothing.
u Wait for the turbocharger to cool down before carrying out any work.
Wear safety gloves to protect against thermal hazards.
© Copyright 2020 ABB. All rights reserved.
HZTL4023_EN
Rev.E
October 2020
Operation Manual / 2 Safety / A100-M axial
1 Safety / 1.12 Hazards during operation and maintenance
WARNING
Hot surfaces on a non-insulated turbocharger
Non-insulated turbochargers can cause serious injuries to personnel (burns).
The turbocharger is supplied with or without insulation in accordance with
the purchase order received from the enginebuilder. If supply is without in-
sulation, the enginebuilder is responsible for providing the turbocharger
with proper insulation and for providing protection against contact with hot
surfaces.
u Compliance with the instructions and specifications given by the en-
ginebuilder to protect against hot turbocharger surfaces is compulsory.
Wear safety gloves to protect against thermal hazards.
Hazards due to rotating parts
WARNING
Hazards due to rotating parts
Contact with rotating parts can cause severe injury. The turbocharger is
never allowed to be operated without filter silencer or air-inlet casing. 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 against unintentional rotation during maintenance.
Wear safety gloves to protect against mechanical hazards.
© Copyright 2020 ABB. All rights reserved.
HZTL4023_EN
Rev.E
October 2020
Operation Manual / 2 Safety / A100-M axial
1 Safety / 1.13 Safe operation
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 work.
u Remove any obstacles and objects littering the workplace.
u Check all pipes to and from the turbocharger for damage and leaks before commission-
ing.
u Check turbocharger for recognisable damage or defects every 12 hours of operation or at
least once a day.
u Report any damage and any alterations of operational characteristics to the responsible
department immediately.
u In case of damage, take the turbocharger out of operation immediately and safeguard
against accidental/unauthorised use.
u When switching on operating energy supplies (hydraulics, pneumatics, electricity), pay at-
tention to the risks that may occur as a consequence of this energy input.
© Copyright 2020 ABB. All rights reserved.
HZTL4023_EN
Rev.E
October 2020
Operation Manual / 2 Safety / A100-M axial
1 Safety / 1.14 Safe maintenance
1.14
Safe maintenance
Occupational safety
WARNING
Injuries to persons
Severe injuries to personnel or fatal accidents can be caused by mechanical
influences as a consequence of hazardous and inadequate operational pro-
cedures or non-compliance with safety and health standards.
u When working on the turbocharger always wear safety footwear and pro-
tective clothing to protect against mechanical hazards.
u Keep personal protective equipment in perfect condition.
u Obey mandatory signs.
u Observe the general rules for occupational safety and prevention of acci-
dents.
u Only perform operations that are described in this chapter.
u Only perform operations for which you 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
height.
u Only perform work on the turbocharger when you are in a physically and psychologically
stable condition.
u Only work with suitable tools, equipment and appliances that function properly.
u Power tools must be grounded and cables must be undamaged.
u Keep the workplace clean; clear away any loose objects and obstacles on the floor.
u Keep the floor, equipment, and turbocharger clean.
u Have oil binding agents ready and provide or keep oil pans at hand.
u Clean up any spills.
u Have fire protection means and extinguishing agents available.
© Copyright 2020 ABB. All rights reserved.
HZTL4023_EN
Rev.E
October 2020
Operation Manual / 2 Safety / A100-M axial
1 Safety / 1.14 Safe maintenance
Use of assembly devices
Assembly devices are specially constructed and designed for the defined use; they are not
commercially available products.
u Use assembly devices only for the described applications.
Welding work in the vicinity of the turbocharger
u When performing welding work in the vicinity of the turbocharger, always cover the filter
silencer to prevent the filter mat from being damaged.
u Keep flammable objects and substances out of the vicinity of flying sparks.
u Cover all connections on the turbocharger so that no foreign objects can enter the tur-
bocharger.
u Wear personal protective equipment (PPE) for welding operations.
Safety during cleaning
If cleaning agents or solvents are used for cleaning, the corresponding material safety data
sheet and the safety instructions in section Hazards due to operating materials and supplies
must be observed.
u Observe the material safety data sheet for the cleaning agent or solvent.
u Wear personal protective equipment (PPE) according to the material safety data sheet.
u Inspect the electric cables for abrasion and damage before and after your cleaning work.
Safety 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
engine and wait until the turbocharger has come to a standstill.
u Make sure that the oil supply is interrupted, especially with an external oil supply.
u Only restart the engine after all parts have been properly fitted again and oil supply is en-
sured.
CAUTION
Mechanical operations on the turbocharger
Components of the turbocharger can be damaged or destroyed as a result
of improper procedures.
u Only perform operations that are described in this chapter.
u Only perform operations for which you have received instruction or train-
ing.
© Copyright 2020 ABB. All rights reserved.
HZTL4023_EN
Rev.E
October 2020
Operation Manual / 2 Safety / A100-M axial
1 Safety / 1.14 Safe maintenance
Safety when taking out of operation or preparing for mothballing
u Observe the material safety data sheet for the cleaning and mothballing agents.
u Wear personal protective equipment (PPE) according to the material safety data sheet.
Mechanical hazards when working on the turbocharger
WARNING
Mechanical hazard
Severe injuries to personnel or fatal accidents can be caused by mechanical
influences as a consequence of hazardous and inadequate operational pro-
cedures.
u Observe the general rules for occupational safety and prevention of acci-
dents.
u Ensure workplace safety.
u Only perform operations that are described in this chapter.
u Only perform operations for which you have 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 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 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.
© Copyright 2020 ABB. All rights reserved.
HZTL4023_EN
Rev.E
October 2020
Operation Manual / 2 Safety / A100-M axial
1 Safety / 1.14 Safe maintenance
WARNING
Danger of fire or explosion
Flammable and combustible operating materials and supplies can catch fire
or resulting vapours can lead to an explosion.
u Observe the information in the material safety data sheet for the operat-
ing materials and supplies.
u Comply with local legislation.
u Do not allow any exposed flame or ignition source during cleaning work.
u Carry out cleaning in the open or provide sufficient ventilation.
CAUTION
Environmental hazard
Improper handling of operating materials and supplies can lead to environ-
mental damage.
u Observe the information 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-combustible insulation materials.
u Ensure good ventilation at the workplace.
u Avoid whirling up dust.
u Use dust-free tools and working methods.
u Remove package at the workplace only.
u Proceed with particular care when removing old insulation materials.
u Dispose of insulation materials properly and in an environmentally com-
patible manner in compliance with the legal regulations.
Wear safety goggles.
Wear a respiratory mask to protect against dusts.
Wear safety gloves to protect against chemical hazards.
© Copyright 2020 ABB. All rights reserved.
HZTL4023_EN
Rev.E
October 2020
Operation Manual / A175-M62 / Safety data sheet
Page 1 / 1
Safety data sheet
A175-M62
HT845667
A175-M62
320
HT845667
650
305
620
HZTL53350K
4600
36
50
50
2020
© Copyright 2020 ABB. All rights reserved.
HT845667
November 2020
Operation Manual / 4 Product description / A100-M axial
Table of contents
Product description
Registered trademarks................................................................................................. 3
Layout and function of the turbocharger ................................................................ 4
Warning plates on the turbocharger......................................................................... 6
Removal and installation ...................................................................................... 8
Turbocharger weight ................................................................................................... 8
Removing the turbocharger........................................................................................ 9
Installing the turbocharger........................................................................................ 12
Commissioning .................................................................................................... 18
Inspection procedures................................................................................................ 19
Commissioning after taking out of operation...................................................... 20
Monitoring during operation.............................................................................. 21
Turbocharger speed.................................................................................................... 23
Operation and service ......................................................................................... 26
Noise emission ............................................................................................................ 26
Service work................................................................................................................. 28
Periodic maintenance.......................................................................................... 33
Foreword to maintenance......................................................................................... 33
Cleaning the filter silencer ........................................................................................ 34
Cleaning the compressor during operation .......................................................... 38
Cleaning turbine and nozzle ring ............................................................................. 44
Malfunctions when starting...................................................................................... 50
Surging of the turbocharger..................................................................................... 53
Malfunctions when stopping.................................................................................... 54
Speed measurement system.................................................................................... 55
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
Table of contents
Introduction ................................................................................................................. 56
Weight of assemblies................................................................................................. 58
Removing the air inlets .............................................................................................. 59
Removing the compressor casing........................................................................... 62
Removing the cartridge group................................................................................. 66
Removing the nozzle ring .......................................................................................... 69
Installing the cartridge group .................................................................................. 78
Installing the compressor casing ............................................................................ 83
Axial clearance A after assembly.............................................................................. 87
Installing the air inlets ............................................................................................... 88
Table of tightening torques...................................................................................... 94
Taking a turbocharger out of operation........................................................... 97
Possible emergency repairs...................................................................................... 97
Locking the rotor ........................................................................................................ 98
Blanking off the inlets and outlets ........................................................................ 103
Spare parts ......................................................................................................... 107
Ordering spare parts................................................................................................ 107
View of turbocharger with part numbers ............................................................ 108
Tools .................................................................................................................... 110
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
1 Introduction / 1.1 Essential information
1
Introduction
1.1
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
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 documents
Chapter
Document number
Operation Manual / 1 Introduction
Operation Manual / 2 Safety
Operation Manual / 3 Safety data sheet *)
Table 1: Related documents
HZTL4005
HZTL4023 / HZTL4080
Serial number of the turbocharger
*) This chapter is only available in serialised operation manuals.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
1 Introduction / 1.4 Layout and function of the turbocharger
1.4
Layout and function of the turbocharger
Fig. 1: Layout and function
01 Filter silencer / air suction branch
02 Compressor wheel
03 Diffuser
06 Gas inlet casing
07 Nozzle ring
08 Turbine
04 Bearing bush
05 Gas outlet casing
09 Bearing casing
10 Compressor casing
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
1 Introduction / 1.4 Layout and function of the turbocharger
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. 2: 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.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
1 Introduction / 1.5 Warning plates on the turbocharger
1.5
Warning plates on the turbocharger
Warning plates are affixed at the following locations:
Fig. 3: Warning plates on the turbocharger
If warning 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 be equipped later with
warning plates on the insulation. This is the responsibility of the enginebuilder.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
1 Introduction / 1.6 Locations of the rating plates
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 foot of the tur-
bocharger.
On turbochargers with insulation supplied by ABB, at least one additional rating plate is at-
tached to the insulation of the gas outlet casing.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
2 Removal and installation / 2.1 Turbocharger weight
2
Removal and installation
2.1
Turbocharger weight
Lifting gear with a sufficient load limit must be used for removing, installing and transport-
ing the turbocharger. The weight specified below applies to the heaviest variant possible.
Depending on the specification, the weight specified on the rating plate may be lower than
the standard value specified here.
Fig. 5: Turbocharger suspension points
Product
Weight of complete turbocharger unit [kg]
A170-M
A175-M
3100
4600
Table 2: Weight of complete turbocharger unit
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
2 Removal and installation / 2.2 Removing the turbocharger
2.2
Removing the turbocharger
WARNING
Risk of tipping
If the turbocharger is not sufficiently supported or not supported at all dur-
ing removal and installation, it may tip over and cause severe injury to per-
sonnel or accidents resulting in fatalities.
u Support the turbocharger at a suitable location.
u Secure with lifting gear wherever possible.
u If present: Loosen cable to speed sensor.
u Disconnect all gas, air and lubricating oil pipes.
Fig. 6: Turbocharger suspension points
u If present: Remove insulation segments on bearing casing and feet.
u Attach lifting gear to the suspension lug of the bearing casing and through the boles on
the turbine-end foot.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
2 Removal and installation / 2.2 Removing the turbocharger
Turbocharger with clamping nuts
Fig. 7: Removing the foot mounting
1. Treat the threads of the threaded rods with penetrating oil and allow it to work in.
Do not oil the pressure screws of the clamping nut.
3. Fit transport screws (90334 / 90335) to secure the sliding block (68003) on the left and
right on the turbine-end foot.
u Lift the turbocharger from the engine and put it down.
u Cover all oil connections.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
2 Removal and installation / 2.2 Removing the turbocharger
2.2.1
Loosening the clamping nut
CAUTION
Incorrect procedure can make loosening impossible
If individual pressure screws are fully relieved, the pressure screws can be-
come compressed, making it impossible to loosen them.
u Comply with the following steps 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. In case of non-compliance, it cannot be ensured that the
necessary tension force is reached.
u Do not clean pressure screws.
u Do not lubricate pressure screws.
If a screw jams, the previously loosened screw must be tightened again a little.
Fig. 8: Loosening the clamping nut
1. Working in a circle, break loose each pressure screw (≤ 20°).
2. Working in a circle, loosen each pressure screw by 45° in 4 rounds.
3. In 1 to 5 rounds, loosen each pressure screw by 90° in circular order until all pressure
screws have been relieved.
u Unscrew and remove the clamping nut by hand.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
2 Removal and installation / 2.3 Installing the turbocharger
2.3
Installing the turbocharger
WARNING
Risk of tipping
If the turbocharger is not sufficiently supported or not supported at all dur-
ing removal and installation, it may tip over and cause severe injury to per-
sonnel or accidents resulting in fatalities.
u Support the turbocharger at a suitable location.
u Secure with lifting gear wherever possible.
Fig. 9: Turbocharger suspension points
u If present: Remove insulation segment on the bearing casing.
u Attach lifting gear to the suspension lug of the bearing casing and the turbine-end foot.
u Remove the covers from the oil connections.
u Align turbocharger and place on bracket.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
2 Removal and installation / 2.3 Installing the turbocharger
Removing auxiliary screws
Fig. 10: Removing auxiliary screw
u Remove shipping screws (90334 / 90335) on the left and right side of the foot and place
in the toolbox.
The turbocharger is delivered with a pre-installed sliding block (68003). The shipping screws
secure the sliding block in the preset position. In operation, the foot can slip due to thermal
expansion.
u Tighten clamping nuts as described in the following sections.
u Connect all gas, air and oil pipes.
u If present: Re-fit the insulation segments.
u If present: Connect cable to speed sensor.
Compressor-end (CE) foot
Fig. 11: Compressor-end foot
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
2 Removal and installation / 2.3 Installing the turbocharger
Turbine-end (TE) foot
Fig. 12: Turbine-end foot
Product
Foot screw dimension
[mm]
Strength class
A170-M
A175-M
M30
M36
10.9
10.9
Table 3: Foot screws, dimension and strength class
Product
Dimension CE [mm]
a1
82
95
b1
ø32x23
ø38x31
c1
68
85
A170-M
A175-M
Table 4: Foot screws, dimension CE
Product
Dimension TE [mm]
a2 / a3
94 / 124
113 / 148
b2
ø32x11
ø38x12
c2 / c3
56 / 45
66 / 54
A170-M
A175-M
Table 5: Foot screws, dimension TE
Product
A170-M
A175-M
Number of cup springs X
9
11
Table 6: Foot screws, number of cup springs
Holes b1/b2 are needed to achieve the required clamping length. An additional drill hole is
not needed at the higher turbine-end foot side (01).
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
2 Removal and installation / 2.3 Installing the turbocharger
Fixing clamping nuts
Fig. 13: CE foot contact surface
Fig. 14: TE foot: Handling of cup spring contact surface / foot contact surface
grease.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
2 Removal and installation / 2.3 Installing the turbocharger
2.3.1
Tightening the clamping nut
Preparation for tightening
CAUTION
Do not clean pressure screws (d)
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.
NOTICE
Pressure screws (d) must not protrude from the clamping nut (c) in the dir-
ection of the thrust washer (b)
In order to correctly fit the clamping nuts, the pressure screws must not
protrude in the direction of the thrust washer.
Fig. 15: Tightening the foot screws (1)
1. Clean the bolt thread (a) and the contact surface.
Coat the bolt thread with grease.
2. Fit thrust washer (b) (component of clamping nut).
3. Tighten clamping nut (c) by hand.
4. Screw back clamping nut by ¼ of a turn (90°).
The distance between the thrust washer and the clamping nut is now about 1 mm.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
2 Removal and installation / 2.3 Installing the turbocharger
Tightening procedure
Fig. 16: Tightening procedure
Product
A170-M
A175-M
Fixing screw [mm]
Tightening torques [Nm]
M30
M36
45
85
Table 7: Torque-controlled tightening of the pressure screws
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 table.
5. Tighten pressure screws to 100 % in 5 … 7 rounds until the required residual tightening
angle of < 20° is achieved.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
3 Commissioning / 3.1 Oil supply
3
Commissioning
3.1
Oil supply
3.1.1
Introduction
In all operating states, a functioning and carefully executed oil supply is an important pre-
requisite for trouble-free operation of the turbocharger.
The lubrication of the turbocharger is usually carried out with oil from the engine oil circula-
tion.
u Comply with the enginebuilder's specifications regarding the selection of lubricating oil
and the oil change intervals.
3.1.2
Pre-lubrication and post-lubrication
The pre-lubrication time is at least 2 minutes.
The post-lubrication time is 10 minutes.
If the engine is operated in idle mode 10 minutes before stopping, no additional post-lubric-
ation is required.
3.1.3
Oil filtering
Filtering of the lubricating oil with a filter mesh width of ≤ 0.050 mm is sufficient for the tur-
bocharger.
3.1.4
Oil pressure
Comply precisely with the oil pressure before the turbocharger for trouble-free operation.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
3 Commissioning / 3.2 Inspection procedures
3.2
Inspection procedures
3.2.1
Introduction
Inspection procedures include preventative visual controls, monitoring and measuring work
before and during commissioning. Inspection procedures enable changes to the turbochar-
ger to be detected. Machine damage can be prevented.
3.2.2
Checks before commissioning
Filter mat (if available)
u Check for damage and contamination.
Lubricating system
CAUTION
Contaminated oil
Serious damage to engine or property can be caused by dirt and solid ma-
terial 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.
3.2.3
Checks after commissioning (engine in idle mode)
Lubricating system
u Check the oil pressure in the oil supply pipes.
u Check oil inlet temperature.
The admissible values are specified in section Oil supply.
Gas, air and oil pipes
u After starting the engine, check all gas, air and oil pipes for leaks.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
3 Commissioning / 3.3 Commissioning after taking out of operation
3.2.4
Checks when starting up the engine
u Measure speed, oil pressure and charging pressure at various engine performances.
u Measure the exhaust gas temperature before and after the turbine.
u Measure the air temperature before and after the compressor.
u Compare the measured values with the values of the acceptance report. Different operat-
Escape of oily fluids
Lubricants and pastes used during assembly can liquefy or vaporise and escape as oily fluids
during the initial hours of operation. Continual escape of an oily fluid indicates an oil leak.
u If there is a leak, contact an ABB Turbocharging Service Station.
3.3
Commissioning after taking out of operation
If present
u Remove cover plates (blind flanges) from the compressor casing, the gas inlet and the
gas outlet.
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 Put engine-side oil circulation to the turbocharger into operation.
u The turbocharger is now ready for operation.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
4 Monitoring during operation / 4.1 Oil pressure, oil temperature
4
Monitoring during operation
4.1
Oil pressure, oil temperature
Lubricating oil pressure
CAUTION
Assuring lubricating oil pressure
Serious damage to the engine or property can result from a missing or insuf-
ficient lubricating oil supply.
u The lubricating oil pressure must be monitored during operation and the
necessary pressure assured at the oil inlet.
For monitoring the lubricating oil pressure, ABB Turbocharging recommends installing a
manometer "M". If the pressure is controlled electronically, the relevant signals should be
triggered at the warning and alarm values.
Fig. 17: Lubricating oil pressure measuring point
The permitted oil pressure ranges at measuring point M of the turbocharger are listed be-
low.
Status for operation
Pressure at measuring point M
Poil, in [bar]
1.3 ... 2.5
1.3 ... 5.0
1.3 ... 2.5
1.3 ... 2.5
0.2 ... 0.5
1.0 ... 1.3
< 1.0
Normal operation
Engine start: Cold oil, admissible for max. 15 minutes
Pre-lubrication
Post-lubrication
Long-term lubrication
Warning signal: Temporarily admissible (<1 h )
Alarm signal: Not permissible. Stop the engine immediately
Table 8: Oil pressure range
Lubricating oil temperature at the inlet
CAUTION
Machine damage
If the oil temperature at the oil inlet exceeds the admissible range, this may
lead to engine damage.
u Observe oil temperature at the oil inlet according to the following table.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
4 Monitoring during operation / 4.1 Oil pressure, oil temperature
Status for operation
Oil temperature at the inlet
Toil,inlet [°C]
< 90
Admissible
Temporarily admissible (< 1 h) → alarm
Not admissible → stop engine
Table 9: Oil temperature at the inlet
> 90
> 95
Lubricating oil temperature 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 according to the current regulations.
Status for operation
Oil temperature at the outlet
Toil,outlet [°C]
Admissible
≤ 135
Temporarily admissible → alarm
Not admissible → stop engine
Table 10: Oil temperature at the outlet
> 135
> 155
If the turbocharger has been operated for a longer period of time outside the admissible
range, ABB Turbocharging recommends having the turbocharger inspected by an ABB Tur-
bocharging Service Station.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
4 Monitoring during operation / 4.2 Turbocharger speed
4.2
Turbocharger speed
4.2.1
Introduction
Speed measurement systems enable the constant monitoring of the turbocharger speeds.
CAUTION
Do not put the speed measurement cables under strain by pulling them
If you pull the speed measurement cables too hard, contacts can be pulled
out.
u Do not strain the speed measurement cables by pulling.
4.2.2
Layout and overview
Fig. 18: Speed measurement
86505
86506
86515
86526
86528
42047
32118
*)
Speed sensor
O-ring
Cable connector
F/I converter
Tachometer
Screw plug
Auxiliary bearing with cams
Alternative mounting position for speed sensor
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
4 Monitoring during operation / 4.2 Turbocharger speed
4.2.3
Speed differences with several turbochargers per engine
The speeds of all turbochargers on an engine vary only slightly from each other in standard
operation.
The difference between the highest and the lowest turbocharger speed must not be more
than 3 %, relative to the speed limit nBmax
.
If this permissible range of difference is exceeded, the following steps must be carried out:
u Reduce the engine performance immediately to the point at which the maximum tur-
bocharger speed does not exceed 70 % of nBmax
.
u If the engine cannot 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 contacted.
u Check the pressure loss of the alternative air inlet and compare it with normal values.
If the engine can be stopped temporarily:
u Inspect air lines, gas piping and the turbochargers and remedy any malfunctions.
u In any case, contacting the nearest ABB Turbocharging Service Station is recommended.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
4 Monitoring during operation / 4.2 Turbocharger speed
4.2.4
Replacing the speed sensor
WARNING
Hot cable connector and hot speed sensor
Danger of burns. The cable connector and speed sensor can reach temperat-
ures in excess of 100 °C during operation.
u When disassembling the cable connector and speed sensor, wear safety
gloves.
Wear safety gloves to protect against thermal hazards.
u Reduce the engine performance to idling and then stop the engine. Pay attention to post-
u Switch off the lubricating oil supply to the turbocharger.
u Disconnect the cable connector from the speed sensor.
u Screw out defective speed sensor.
u Screw in new speed sensor to the stop.
The speed sensor is designed with a sealing lip and does not require any additional gasket
for assembly.
u Connect cable connector (86515) with the speed sensor (86505)
u Switch on lubricating oil supply to the turbocharger.
4.2.5
Malfunction of the speed measurement system
The possible reasons for malfunction of the speed measurement system are described in
chapter Troubleshooting (Reasons for malfunction of the speed sensor).
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
5 Operation and service / 5.1 Noise emission
5
Operation and service
5.1
Noise emission
WARNING
Noise hazards
Exposure to noise can harm the hearing system, impair health and the psy-
chological state and may lead to lack of attention and irritation.
u When the engine is running, always wear ear protection.
u Always wear ear protection if the sound pressure level exceeds 85 dB(A).
Wear ear protection.
The emission sound pressure level (A-weighted) is measured at 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 air inlet. The following prerequisites must be fulfilled with regard to the turbochar-
ger 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 insulated by the enginebuilder (see Fig. 19:
The enginebuilder is responsible for insulating the charge air/scavenging air line and the
charge air cooler.
1)
2)
Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7 :
A-weighted emission sound pressure level
The enginebuilder must provide acoustically equivalent measures in case of deviating in-
sulation versions
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
5 Operation and service / 5.1 Noise emission
Suggestion for noise insulation, bellows
Fig. 19: Noise insulation, bellows
01
02
03
04
05
06
Compressor casing
Bellows
Charge air duct / scavenging air duct
Insulation cushion
Insulation mat (at least 15 mm)
Sheet metal cover
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
5 Operation and service / 5.2 Service work
5.2
Service work
Service work includes visual controls, monitoring, measuring and inspection as well as func-
tional checks. Service work enables the detection and rectification of changes to the tur-
bocharger and ensures full operability of the turbocharger.
CAUTION
Service intervals
Any service work on the turbocharger that is omitted or performed too late
can cause excessive contamination, wear and operating failures.
u Carry out the service work at the specified time intervals.
CAUTION
Specific service interval
Exceptional stresses such as a high number of starts and stops, harsh envir-
onmental conditions, poor fuel quality or high system vibrations can lead to
untimely machine damage even if the prescribed service intervals are ob-
served.
u Agree on a specific service interval with ABB Turbocharging.
To prevent machine damage caused by ageing and downtime, we recommend having an in-
spection carried out by an ABB Turbocharging Service Station no later than 5 years after the
last service.
5.2.1
Service work every 25 … 50 hours
u Visual check for air, exhaust gas, water and oil leaks.
u Record operating data and enter in the engine logbook.
u In case of deviations, determine the cause.
CAUTION
Unknown operational changes
Unknown operating conditions may result in problems ranging from impair-
ment to possible operating failure.
u Unknown causes must be clarified by an ABB Turbocharging Service Sta-
tion.
5.2.2
Service work at 100 hours after commissioning
u Clean or replace the oil filter located in the supply pipe to the turbocharger while the en-
gine is stopped, in accordance with the instructions of the enginebuilder.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
5 Operation and service / 5.2 Service work
5.2.3
Service work every 8000 ... 16000 hours of operation
Checking and assessment of the rotor and the bearing parts must be carried out by an ABB
Turbocharging Service Station.
u Dismantle the turbocharger.
u Clearance measurement.
u Clean turbine casing and compressor casing and check for cracks and erosion/corrosion.
u Clean bearing casing and blow through oil holes.
u Clean nozzle ring and check for cracks and erosion.
u Check and assess rotor and bearing parts.
u Balancing rotor.
5.2.4
Service work every 24000 ... 36000 hours of operation
Service work on the rotor and bearing parts must be carried out by an ABB Turbocharging
Service Station. Damaged and worn out parts must be replaced with original ABB parts.
u Disassemble the turbocharger.
u Clearance measurement.
u Clean turbine casing and compressor casing and check for cracks and erosion/corrosion.
u Clean bearing casing and blow through oil holes.
u Clean nozzle ring and check for cracks and erosion.
u Dismantle the rotor, inspect and balance it.
u Replace the plain bearings.
5.2.5
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, in accordance with the instructions of the enginebuilder.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
5 Operation and service / 5.2 Service work
5.2.6
Entries in the engine logbook
Monitoring the engine system enables conclusions to be made on the operating behaviour
of the turbocharger.
The following operating data and measured values must be entered regularly into the engine
logbook of the enginebuilder:
¡
¡
¡
¡
¡
¡
¡
Performance and speed of the engine
Speed of the turbocharger
Air intake temperature
Exhaust gas temperature before and after the turbine
Pressure of the charge air
Pressure loss in the charge air cooler
Lubricating oil pressure and lubricating oil temperature
If present:
¡
¡
Air temperature after the compressor and after the charge-air cooler
Pressure loss in the filter silencer
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
5 Operation and service / 5.3 Expected replacement intervals
5.3
Expected replacement intervals
5.3.1
Influencing parameters
Rotating components
The recommended replacement intervals for compressor wheels and turbine wheels are spe-
cified based on the safety concept for rotating parts (SIKO) and dependent on the operating
conditions. These intervals are shown on the rating plate of the turbocharger.
Non-rotating components
Depending on the system-specific operating conditions, a differentiation must be made
between the intervals to be expected for:
¡
¡
replacing the bearing parts and
replacing the non-rotating components exposed to hot gas.
A decisive role is played by various influencing parameters which, in extreme cases, can
drastically reduce the replacement interval of these parts.
During the prescribed periodic service work, the individual parts are examined for wear and
replaced if necessary.
Influencing parameters for bearing parts
¡
¡
¡
Inferior lubricating oil quality (lubricating oil filtering, lubricating oil condition)
Exceptional stresses (vibrations, start/stop frequency)
Inadmissible unbalance of the rotor
Influencing parameters for exhaust gas-charged, non-rotating components
¡
¡
¡
¡
¡
Fuel quality (gas, MDO, HFO)
Load profile (thermal cycling, number of start/stop cycles)
Temperature level of the exhaust gas
Frequency of turbine cleaning
Turbine cleaning process
Influencing parameters for exhaust gas-charged, rotating components
¡
¡
¡
¡
Fuel quality (gas, MDO, HFO)
Frequency of turbine cleaning
Turbine cleaning process
Load profile
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
5 Operation and service / 5.4 Stopping the engine
5.3.2
Replacement intervals
The specified values are only guide values and not guaranteed, see influencing parameters.
Expected replacement intervals [h]
Component
GAS / MDO
HFO
Gas inlet casing
50000 …
25000 … 50000
100000
Gas outlet casing
50000 …
100000
35000 …
100000
Nozzle ring
Turbine diffuser / cover ring
Other casings
Turbine blades (due to wear)
Table 11: Expected replacement intervals
35000 … 50000 25000 … 50000
35000 … 50000 25000 … 50000
100000
- -
100000
≥ 12000
GAS = Gas
MDO = Marine Diesel Oil
HFO = Heavy Fuel Oil
Recommended replacement intervals [h]
Rotor components
Bearings
See information on rating plate
See information on rating plate
Table 12: Recommended replacement intervals
5.4
Stopping the engine
CAUTION
Stopping the engine
In the turbocharger, the heat from the lubricating oil that continues to circu-
late must be dissipated.
u Let the engine continue to run at idling speed for 10 minutes before stop-
ping it.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
6 Periodic maintenance / 6.1 Foreword to maintenance
6
Periodic maintenance
6.1
Foreword to maintenance
Maintenance work includes regular visual controls and cleaning operations which are inten-
ded to ensure the trouble-free functioning of the turbocharger.
Described maintenance points:
¡
¡
¡
¡
Filter silencer
Diffuser
Compressor
Turbine and nozzle ring
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
6 Periodic maintenance / 6.2 Cleaning the filter silencer
6.2
Cleaning the filter silencer
Fig. 20: Cleaning the filter silencer
81135 Filter silencer body
81136 Absorption segment
81266 Cover grid
81269 Connecting rods
81272 Screw
81137
Sheet-metal covering
81265 Filter ring (if present)
81273 Lock nut
E
Insert unit = absorption segment + sheet-metal covering
Cleaning the filter 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 in cold water. Avoid high mechanical
loads (water jet).
u Let the filter ring dry completely before assembling.
u Dirty water and mild detergent must be disposed of in compliance with locally applicable
regulations.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
6 Periodic maintenance / 6.2 Cleaning the filter silencer
Cleaning the absorption segments
u Loosen and remove lock nuts (81273).
u Loosen and remove screws (81272) to the connecting rods (81269).
u Remove connecting rods (81269).
u Remove and clean cover grid (81266).
u Pull out insert units (E), bend up sheet-metal coverings (81137) and take out absorption
segments (81136).
u Clean the absorption segments (81136).
When cleaning, note that the absorption segments (81136) must only be cleaned lightly
with pressurized air, with a soft brush or a moist cleaning cloth.
u Have any heavily contaminated absorption segments and filter rings as well as damaged
connecting rods replaced by an ABB Turbocharging Service Station.
Fitting the cover grids and absorption segments
CAUTION
Penetration of dirt and foreign particles
Any penetration of dirt and foreign particles into the compressor can dam-
age it.
u Fit the connecting rods (81269) correctly in the slots on the filter silencer
body (81135).
u It must not be possible to rotate or move the cover grid (81266) after as-
sembly.
u Check the position and alignment of the connecting rods during and after
assembly.
u Assemble the insert units (E) by inserting the absorption segments (81136) into the
sheet-metal coverings (81137).
u Bend the sheet-metal coverings (81137) back into the original shape.
u Insert the insert units (E) into the slotted guides in the filter silencer body (81135).
If a cleaning container is attached to the filter silencer (option, depending on turbocharger),
the water injection pipe must now be reinstalled.
u Place the cover grids (81266) evenly and in the correct position.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
6 Periodic maintenance / 6.2 Cleaning the filter silencer
Fig. 21: Cleaning the filter silencer (2)
u Push the connecting rods (81269) through the lugs of the cover grids (81266).
u Connect the connecting rods (81269) with the screws (81272). While tightening the screws
(81272), make sure that the connecting rods (81269) lie correctly in the slots on the filter
silencer body (81135). Now alternately tighten the screws (81272) up to the following max-
imum tightening torque:
Screw
Tightening torque [Nm]
81272
20
Table 13: Tightening torque (81272)
u Fit lock nuts (81273) on screws (81272) and tighten with the following tightening torque:
Lock nut
Tightening torque [Nm]
81273
40
Table 14: Tightening torque (81273)
u Fit the filter ring (81265), if present.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
6 Periodic maintenance / 6.3 Cleaning the slotted diffuser
6.3
Cleaning the slotted diffuser
Fig. 22: Cleaning the slotted diffuser
u Clean the diffuser slots (S).
When cleaning, please note that this should only take place using lightly pressurized air, a
brush and a moist cleaning cloth.
u Have any heavily contaminated or damaged diffusers replaced by an ABB Turbocharging
Service Station.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
6 Periodic maintenance / 6.4 Cleaning the compressor during opera-
tion
6.4
Cleaning the compressor during operation
6.4.1
Introduction
Approval by enginebuilder
The following instructions for wet cleaning only apply to cleaning with pure water and under
the precondition that the enginebuilder approves the process.
General
The contamination of the compressor stage (compressor wheel and diffuser) depends on
the degree of purity of the sucked-in air.
Deposits can form in the flow channels if salt, oil mist or dust are sucked in with the air.
Consequences of contamination:
¡
¡
¡
¡
Impaired compressor efficiency
Higher exhaust gas temperatures
Increased fuel consumption
Increased rotor unbalance
Periodic cleaning of the compressor during operation prevents or delays any major increase
in contamination. But it never replaces the regular service work where the turbocharger is
completely dismantled and the compressor is mechanically cleaned.
6.4.2
Cleaning interval
The time period between the periodical cleaning cycles depends greatly on the operating
conditions. Cleaning should normally be done every 25 … 100 hours of operation.
If the specified cleaning intervals are incompatible with operation of the engine, contact
ABB.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
6 Periodic maintenance / 6.4 Cleaning the compressor during opera-
tion
6.4.3
Principle of wet cleaning
Principle of wet cleaning
To clean the compressor stage during operation, water is injected before the compressor
wheel.
The water does not act as a solvent. The coating is removed by the mechanical action of the
impacting droplets. The process is particularly suitable as long as the contamination is not
too advanced.
CAUTION
Corrosion and deposits when cleaning
Salt water and cooling water treatment substances damage and adversely
affect turbocharger parts.
u Never use salt water, but only pure water for cleaning.
CAUTION
Volume of water
Uncontrolled volumes of water can damage the turbocharger and the en-
gine.
u Never connect the water line without the orifice specified for the tur-
bocharger.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
6 Periodic maintenance / 6.4 Cleaning the compressor during opera-
tion
6.4.4
Wet cleaning with direct water supply
Prerequisites
On V-engines with several turbochargers per engine, parallel cleaning of both turbochargers
is recommended. This cleaning process is faster and reduces the risk of surging of the tur-
bocharger.
WARNING
Increased stress on material
During cleaning of the compressor at an engine load of 85 to 100 %, the
stress on the material of the compressor-end turbocharger parts can be in-
creased.
u No personnel is allowed to be present in the vicinity of the turbocharger
during compressor cleaning.
u Compressor cleaning must be activated from the engine control panel.
Wet cleaning operations for compressor with direct water supply
u Trigger water injection according to the specifications of the enginebuilder.
u Observe specified water pressure upstream of the connection to the turbocharger.
u Operate engine for at least five additional minutes after cleaning.
Not more than three cleaning cycles should be conducted consecutively.
Cleaning parameters for each compressor
Product Engine load Water pres-
Water injection
Cleaning interval
[h]
Ø of ori-
fice
[mm]
[%]
sure
period
[s]
[bar]
A170-M
A175-M
50 … 100
2.5 … 4.5
10
25 … 100
2.9
3.4
Table 15: Compressor cleaning parameters
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
6 Periodic maintenance / 6.4 Cleaning the compressor during opera-
tion
Surging of the compressor stage
Should repeated surging of the compressor stage occur during compressor cleaning, first
the cleaning parameters (water flow rate) as well as the engine-side system must be
checked with regard to deviations (e.g. an increased pressure loss in the charge air cooler)
and corrected if necessary.
If surging of the compressor stage continues to occur during compressor cleaning despite
correct settings, this can be remedied by reducing the engine load further during cleaning of
the compressor. The reduction of the engine load can lead to a reduction in the effective-
ness of the compressor cleaning.
u To avoid a reduction in engine availability, the compressor stage can be cleaned at re-
duced engine load during the drying time after wet cleaning of the turbine has been com-
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
6 Periodic maintenance / 6.4 Cleaning the compressor during opera-
tion
6.4.5
Wet cleaning with external water pressure vessel
Operating state prerequisites for cleaning the compressor
On V-engines with several turbochargers per engine, parallel cleaning of both turbochargers
is recommended. This cleaning process is faster and reduces the risk of surging of the tur-
bocharger.
To carry out the cleaning operation checked and recommended by ABB Turbocharging, the
following prerequisites must be fulfilled:
¡
Engine load 50 … 85 %
u Start the cleaning operation according to the following description.
Operation of compressor wet cleaning
Fig. 23: Operation of water pressure vessel
Operation of the water pressure vessel
u The prerequisites for operating state for cleaning the compressor with XC3 must be ful-
filled before the cleaning.
u Screw out sealing plug (X).
u Fill container with pure water.
u Screw in sealing plug (X).
u Push valve activator (Y) against the spring and hold for 10 to 15 seconds until the whole
volume of water is injected.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
6 Periodic maintenance / 6.4 Cleaning the compressor during opera-
tion
u After cleaning operations, a waiting period of at least 5 minutes is required for the tur-
bocharger to dry.
If the cleaning is unsuccessful after three attempts, we recommend having the turbocharger
checked and cleaned by an ABB Turbocharging Service Station in the event of unsatisfactory
engine values.
Cleaning parameters for each turbocharger compressor
Product
Engine load
Water temperature Contents of metering
container
[°C]
[dm3]
A170-M
A175-M
50 … 85%
5 … 50
1
Table 16: Compressor cleaning parameters
Surging of the compressor stage
Should repeated surging of the compressor stage occur during compressor cleaning, first
the cleaning parameters (water flow rate) as well as the engine-side system must be
checked with regard to deviations (e.g. an increased pressure loss in the charge air cooler)
and corrected if necessary.
If surging of the compressor stage continues to occur during compressor cleaning despite
correct settings, this can be remedied by reducing the engine load further during cleaning of
the compressor. The reduction of the engine load can lead to a reduction in the effective-
ness of the compressor cleaning.
u To avoid a reduction in engine availability, the compressor stage can be cleaned at re-
duced engine load during the drying time after wet cleaning of the turbine has been com-
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
6 Periodic maintenance / 6.5 Cleaning turbine and nozzle ring
6.5
Cleaning turbine and nozzle ring
6.5.1
Introduction
Approval by enginebuilder
The following instructions for wet cleaning only apply to cleaning with pure water and under
the precondition that the enginebuilder approves the process.
General
The combustion of heavy fuel oil (HFO) has the effect of contaminating the turbine stage
(turbine wheel and nozzle ring).
The use of fuels with poor quality in conjunction with high exhaust gas temperatures can
lead to extremely hard deposits on turbine components.
ABB Turbocharging recommends the use of fuels with low ash, sulphur, sodium and vana-
dium contents.
Consequences of contamination:
¡
¡
¡
¡
¡
Low turbine efficiency
Elevated exhaust gas temperatures
Increased charging and ignition pressures with increasing turbocharger speed
Lower engine performance
Rotor sticking after stopping the engine
Periodic cleaning of the turbine during operation prevents or delays any major increase in
contamination, but never replaces the regular service work where the turbocharger is com-
pletely dismantled and mechanically cleaned.
6.5.2
Cleaning interval
The time period between the periodical cleaning cycles depends greatly on the operating
conditions. Cleaning should normally be carried out every 50 … 200 hours of operation.
If the specified cleaning intervals are incompatible with operation of the engine, contact
ABB.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
6 Periodic maintenance / 6.5 Cleaning turbine and nozzle ring
6.5.3
Cleaning method
Cleaning of the turbine and the nozzle ring during operation is carried out by the cleaning
method described in the following and is tested and approved by ABB Turbocharging:
¡
Wet cleaning
Wet cleaning makes use of various effects. These effects are used with varying levels of in-
tensity, depending on the type of contamination:
¡
¡
¡
Erosion
The dirt is removed by the mechanical action of the impacting water droplets
Solubility
Water solubility of the dirt deposits in water
Thermal shock
Spalling of contamination due to temperature difference
CAUTION
Corrosion and deposits when cleaning
Salt water and cooling water treatment substances damage and adversely
affect turbocharger parts.
u Never use salt water, but only pure water for cleaning.
The influence of the cleaning water on the peripheral units (such as the boiler) must be clari-
fied by the operator before commencing wet cleaning.
The turbine-end components are cleaned at reduced engine load. The exhaust gas temperat-
ure must not exceed the value specified in the cleaning instructions (see section Prerequis-
ites).
CAUTION
Reduced service life of the components
Failure to comply with the minimum stabilisation time before cleaning, the
prescribed turbine inlet temperatures and the drying time after cleaning sig-
nificantly reduces the expected service life of the components.
V-engines
On V-engines with several turbochargers, we recommend the parallel cleaning of both tur-
bochargers for each engine. This cleaning process is faster and reduces the risk of surging
of the turbochargers.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
6 Periodic maintenance / 6.5 Cleaning turbine and nozzle ring
6.5.4
Wet cleaning of turbine and nozzle ring
Prerequisites:
Procedure without automated cleaning
The following operating state and the following prerequisites have been tested and ap-
proved by ABB Turbocharging for cleaning operations:
u Set the engine load between 20 … 50 % so that the turbine inlet temperature is between
380 … 430 °C.
Fig. 24: Turbine and nozzle ring cleaning cycle
u Once the turbine inlet temperature is stable and has dropped below 430 °C, wait at least
another 10 minutes to allow the turbine-end turbocharger parts to cool down.
u Start the cleaning cycle according to the following description Wet cleaning procedure.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
6 Periodic maintenance / 6.5 Cleaning turbine and nozzle ring
Procedure with automated cleaning
The following operating state and the following prerequisites have been tested and ap-
proved by ABB Turbocharging for cleaning operations:
u Set the engine load as follows:
¡
¡
¡
Turbine mass flow MTurb ≈ 4.1 kg/s
Turbine pressure ratio PIT ≈ 1.1
Turbine inlet temperature between 380 … 430 °C
Fig. 25: Cleaning cycle of turbine and nozzle ring with load ramp
u As soon as the turbine inlet temperature is stable and less than 430 °C, wait for least 10
additional minutes for the turbine-end turbocharger components to cool down.
u Start the cleaning cycle according to the following description Wet cleaning procedure.
u Continuously increase the engine load during washing:
¡
¡
¡
Turbine mass flow MTurb ≈ 6.5 kg/s
Turbine pressure ratio PIT = 1.6 … 2.0
Turbine inlet temperature <430 °C
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
6 Periodic maintenance / 6.5 Cleaning turbine and nozzle ring
Procedure
Fig. 26: Procedure Wet cleaning of turbine and nozzle ring
The prerequisites and the operating state must be fulfilled prior to cleaning.
u Make sure that the water supply (01) is connected, switched on and safeguarded.
u Switch the 3-way valve (04) from scavenging air mode to water supply.
u Set the necessary water quantity on the flowmeter (08) according to the table Cleaning
u Shut off the water supply again by switching the 3-way valve (04) to scavenging air mode
after the prescribed injection time has elapsed.
The injection process is complete.
u After cleaning, continue to operate the engine for at least 10 minutes without any load
change.
It is necessary to have the corresponding water pipe pressure in order to achieve the correct
not be achieved. A reduced cleaning effect can be expected in this case.
Repetition of wet cleaning
The repeating of cleaning cycles one immediately after the other must be avoided as this
can lead to excessive mechanical stress, hence reducing the operating life of the compon-
ents.
If the cleaning process is ineffective, the duration can be extended. If the injection time is ex-
tended, it is important to ensure that no impermissible volume of water collects in the gas
outlet casing. A drainage system should be installed for the gas outlet casing and opened
during cleaning. If there is no drainage system, the amount of water injected can be mon-
itored with a flowmeter in the water supply. The permitted amount of water must be de-
termined with the help of an ABB Turbocharging Service Station.
To be observed during cleaning
¡
The action of the cleaning water on the peripheral units (such as boiler) must be clarified
by the operator.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
6 Periodic maintenance / 6.5 Cleaning turbine and nozzle ring
¡
¡
The exhaust gas temperature downstream of the turbocharger drops drastically during
cleaning (typical turbocharger outlet temperatures during cleaning: 60...180°C).
If there is no drainage of the gas outlet casing, the turbocharger speed and/or the gas
inlet temperature must be monitored during the cleaning process. If the load is too low,
water can collect in the gas outlet casing. Indicators for this are a sudden severe drop in
the turbocharger speed or a very large increase in the gas inlet temperature. In such
cases, the cleaning operations must be stopped and the cleaning cycle restarted with re-
duced water pressure or higher engine load.
Cleaning parameters for wet cleaning of turbine and nozzle ring
Product
Maximum temperature Injection time Water volume flow per turbocharger1)
when starting cleaning
t i [min]
VW [dm³/min]
TTI [°C]
430
430
A170-M
A175-M
10
10
30
41
Table 17: Cleaning parameters Wet cleaning of turbine and nozzle ring
1) Water pressure pwater as guideline value:
¡
¡
2.3 bar when used with an axial gas inlet casing
3 bar when used with a radial gas inlet casing
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
7 Troubleshooting / 7.1 Malfunctions when starting
7
Troubleshooting
7.1
Malfunctions when starting
Delayed start-up
Possible causes
Remedy
Turbochar-
ger
Turbocharger contaminated
Bearing damaged
Rotor rubbing
Contact ABB Turbocharging Service
Station
Foreign object in the turbocharger
Table 18: Malfunctions when starting – Delayed start-up
Vibrations
Possible causes
Remedy
Turbochar-
ger
Rotor unbalance
Turbine or compressor damaged
Bearing damaged
Contact ABB Turbocharging Service
Station
Engine
Vibrations from engine
Contact enginebuilder
Table 19: Malfunctions when starting – Vibrations
Rubbing of rotating parts
Normal behaviour, not a malfunction
Turbochar-
ger
A slight amount of uniform wear at the circumference of the rotor components
caused by slight local rubbing against adjacent components is permitted. This
causes the compressor or turbine blades to be somewhat shortened. 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 Tur-
bocharging Service Station.
¡
Have a dimension check carried out by an ABB Turbocharging Service Sta-
tion.
Table 20: Malfunctions when starting – Rubbing of rotating parts
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
7 Troubleshooting / 7.2 Malfunctions during operation
7.2
Malfunctions during operation
Lubricating oil pressure too low
WARNING
Danger of fire and explosion due to lubricating oil leaks
Leaking oil may ignite on hot surfaces. This can result in serious injuries to
personnel or fatal accidents.
u Cordon off danger area.
u Raise the alarm and, depending on the situation, stop the engine.
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.
Possible causes
Remedy
Turbochar-
Axial clearance of the rotor excessive
Contact an ABB Turbocharging
ger
Service Station
Engine
Oil filter heavily contaminated
Clean
Oil pump in lubricating system defect- Check/replace
ive
Manometer displays incorrectly
Replace manometer
Table 21: Malfunctions during operation – Lubricating oil pressure too low
Drop in speed
Possible causes
Remedy
Turbochar-
ger
Heavy contamination of the turbine
Clean (see chapter Periodic mainten-
and/or nozzle ring
Damaged rotor components or bearing Contact ABB Turbocharging Service
Station
Engine
Pipes
Defect on the connected cylinders in
pulse charging
Contact enginebuilder
Repair
Defects, such as leaks, in the exhaust
gas pipes or charge air ducts
Table 22: Malfunctions during operation – Drop in speed
Increase in speed
Possible causes
Remedy
Turbochar-
ger
turbine and/or nozzle ring (with 4-
stroke application)
bocharging Service Station
Table 23: Malfunctions during operation – Speed increases
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
7 Troubleshooting / 7.2 Malfunctions during operation
Exhaust gas temperature too high
Engine performance and engine speed unchanged
Possible causes
Remedy
Turbocharger
ter silencer is blocked by dirt
Compressor/turbine contaminated
Exhaust gas back pressure too high
Clean or repair boiler or exhaust gas si-
lencer
Turbine damaged or eroded
Contact ABB Turbocharging Service
Station
Engine
Malfunction in the injection system
Cooler contaminated
Cooling water volume too low
Repair or contact manufacturer
Clean
Fill
Charge air
cooler
Inlet temperature of cooling water
Check/clean cooling system
too high
Insufficient ventilation
Improve ventilation
Table 24: 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
Supply pipe to manometer not sealed
Replace manometer
Repair leak
pressure drop too high
Compressor end and/or turbine end
contaminated
Compressor/turbine damaged
Exhaust gas back pressure too high
Air receiver not sealed
Contact ABB Turbocharging Service
Station
Clean or repair boiler or exhaust gas si-
lencer
Repair
Engine
Pipes
Gas pipe between engine and turbine
not sealed
Injection mistimed
Valve control misadjusted
Set correctly
Repair.
Pipes downstream to the compressor
outlet not sealed.
Table 25: Malfunctions during operation – Charge air pressure too low
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
7 Troubleshooting / 7.3 Surging of the turbocharger
Charge air pressure too high
Engine performance and engine speed unchanged, suction condition normal
Possible causes
Remedy
Turbochar-
Manometer display not correct
Replace manometer
ger
Engine
Malfunction in the injection system
Injection mistimed
Repair or contact manufacturer
Set correctly
Engine performance higher than indic- Check engine performance
ated
Table 26: Malfunctions during operation – Charge air pressure too high
7.3
Surging of the turbocharger
CAUTION
Continuous or periodic surging
If the turbocharger surges continuously or periodically, parts of the tur-
bocharger may be damaged.
u Gradually reduce the engine load.
u Have the cause 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.
Surging of the turbocharger
Possible causes
Remedy
Turbocharger
Filter silencer or diffuser contamin-
ated
Heavy dirt deposits in the turbine or
in the nozzle ring
Engine
Protective grating in front of the tur- Clean/replace
bocharger contaminated or damaged
Charge air
cooler
Cooler contaminated
Charge air duct blocked
Clean
Table 27: Surging of the turbocharger
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
7 Troubleshooting / 7.4 Malfunctions when stopping
Sporadic surge blows
Surging of the turbocharger can occur during certain operating states, such as when redu-
cing the engine load quickly when manoeuvring. When this happens, the flow direction in the
compressor is momentarily reversed. Such sporadic surge blows do not impair the safe op-
eration of the turbocharger.
¡
A surge blow is accompanied by a loud bang and escape of hot air from the filter silencer.
7.4
Malfunctions when stopping
Runout noises
Possible causes
Remedy
Turbochar-
ger
Turbocharger contaminated
Bearing damaged
Rotor rubbing
Clean
Contact an ABB Turbocharging
Service Station
Foreign object in the turbocharger
Table 28: Malfunctions when stopping – Runout noises
Shortened runout time
Possible causes
Remedy
Turbochar-
ger
Turbocharger contaminated
Bearing damaged
Rotor rubbing
Clean
Contact an ABB Turbocharging
Service Station
Foreign object in the turbocharger
Table 29: Malfunctions when stopping – Shortened runout time
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
7 Troubleshooting / 7.5 Speed measurement system
7.5
Speed measurement system
No signal or poor signal amplitude of the speed measurement
Possible causes
Remedy
Turbochar-
ger
The speed sensor was acci-
The screw plug for the sensor is fitted with an ad-
dentally fitted with an addi- ditional gasket (copper ring).
tional gasket.
For information regarding the disassembly and as-
sembly of the speed sensor, refer to the chapter
Turbocharger speed.
An enlarged distance
between the sensor tip and
the signal-emitting sealing
disc reduces the voltage
amplitude of the speed sig-
nal.
Install the speed sensor without the additional
gasket (copper ring).
Sensor defective
Contact ABB Turbocharging Service Station.
Table 30: Malfunction, No speed measurement signal or poor signal amplitude
Measured speed too high
Possible causes
Remedy
Turbochar-
ger
Sensor tip contaminated,
For information regarding the disassembly and as-
since it is magnetic and can sembly of the speed sensor, refer to the chapter
attract metallic particles.
Turbocharger speed.
This reduces the distance to Dismantle the sensor, clean the sensor tip, and fit
the signal-emitting sealing
the sensor back on with the specified tightening
disc, which can lead to ampli- torque.
fication of the noise com-
ponent and, hence, to false
triggering.
Table 31: Malfunction, Measured speed too high
Measured speed too low
Possible causes
Remedy
Turbochar-
- -
Contact ABB Turbocharging Service Station
ger
Table 32: Malfunction, Measured speed too low
NOTICE
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 Sta-
tion.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.1 Introduction
8
Disassembly and assembly
8.1
Introduction
CAUTION
Further work
This Operation Manual may be used to carry out only the work described in
it. Further work that is carried out in an incorrect way can lead to serious
damage to the machine.
u ABB Turbocharging recommends having further work carried out only by
trained personnel from an ABB Turbocharging Service Station.
u Mark the casing position for assembly.
Customer tool set
Not all tools are marked with a part number. Identification is guaranteed by the tool list. This
list is enclosed with the tool set.
WARNING
Servicing the tools
The tools must be checked for damage before and after use.
u Visually inspect for corrosion, cracks, deformation and wear.
u Damaged tools must no longer be used and must be replaced.
Customer spare part set
Before starting work, make sure the required customer spare part set is available (see
Tightening torques for components
The specified tightening torques of the bolted connections must be observed.
Tightening torques for assembly devices
Unless otherwise described, the screws and nuts of the assembly devices supplied by ABB
must be tightened in such a way that they are tight-fitting.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.1 Introduction
WARNING
Suspended loads
Loads that are not attached according to regulations can cause injury to
personnel or fatal accidents.
u Only fasten the turbocharger, assemblies or individual parts on properly
functional lifting gear with sufficient load limit.
u Pay attention to the correct attachment of loads on the crane hook.
u People must not stand beneath suspended loads.
Wear safety gloves to protect against mechanical hazards.
Wear safety helmet.
Definition of terms
¡
Suspension point
Defined loading point on a component or an assembly (blind hole thread, eyelet, lug).
¡
Assembly device
Devices that are fitted on the turbocharger in order to obtain a suspension point. As-
sembly devices are specially constructed and designed for the defined use; they are not
commercially available products. Use assembly devices only for the described applica-
tions.
¡
Lifting gear
Equipment for the lifting and transporting of loads (ropes, chain block, crane). Lifting
gear is not supplied by ABB.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.2 Weight of assemblies
8.2
Weight of assemblies
The specified weights of the individual parts or assemblies are rounded-up standard values.
Fig. 27: Weight of assemblies
Position Component
A170-M
[kg]
260
120
210
30
430
750
80
40
17
170
115
A175-M
[kg]
400
170
320
45
620
1100
130
60
01
02
03
04
05
06
07
08
09
10
11
Filter silencer
Radial air suction branch
Wall insert
Diffuser
Compressor casing
Cartridge group
Turbine diffuser
Cover ring
Nozzle ring
Gas inlet casing, radial
Gas inlet casing, axial
25
230
170
Table 33: Assembly weights
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.3 Removing the air inlets
8.3
Removing the air inlets
8.3.1
Removing the filter silencer
u Dismantle insulation as far as necessary.
Fig. 28: Removing the filter silencer
1. Loop lifting gear through the fin on the filter silencer and secure to the eyelets at the rear
with shackles (90195).
2. Loosen nuts (72027) and remove with washers (72028).
u Remove and put down filter silencer.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.3 Removing the air inlets
8.3.2
Removing the air suction branch
u Disconnect all air lines according to the instructions of the enginebuilder.
u Dismantle insulation as far as necessary.
Fig. 29: Removing the air suction branch
1. Loop lifting gear around air suction branch.
2. Loosen and remove the nuts (72027) with washers (72028).
u Remove and put down the air suction branch.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.4 Axial clearance A prior to disas-
sembly
8.4
Axial clearance A prior to disassembly
WARNING
Physical hazards due to sharp edges on compressor wheel
The compressor wheel has sharp edges which can result in injury.
u Wear safety gloves.
Wear safety gloves to protect against mechanical hazards.
The axial clearance (A) must be measured prior to removal and after installation of the cart-
ridge group.
CAUTION
Clearances outside the tolerance
Serious damage to engines or property can be caused by clearances outside
the tolerance and excessively worn parts.
u Have the components assessed and, if necessary, replaced by an ABB Tur-
bocharging Service Station.
Fig. 30: Axial clearance
Product
A170-M
Axial clearance A [mm]
0.30 ... 0.61
A175-M
0.35 ... 0.69
Table 34: Axial clearance A
u Measure and note axial clearance (A).
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.5 Removing the compressor casing
8.5
Removing the compressor casing
Removing wall insert
Fig. 31: Removing wall insert
1. Loosen screws (72011) and remove with washers (72008).
2. To secure the wall insert, screw in one screw (72011) a third of the way.
3. Press off wall insert with three screws (72011) until the lifting device (90190) and the fix-
ing segment (90192) can be fitted.
4. Fit the lifting device (90190) and the fixing segment (90192) to the flange of the wall in-
sert (77000) using the screws (90197) and washers (90198).
Depending on the hole pattern of the wall insert (77000), the screws (90197) cannot be
fitted symmetrically.
5. Put on shackle (90195) and fasten to lifting gear.
6. Remove locking screw (72011).
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.5 Removing the compressor casing
7. Pull out wall insert (77000).
Transporting and turning wall insert
Fig. 32: Transporting and turning wall insert
1. Fit support angle (90025) with bolts and nuts.
2. Carefully turn wall insert over support angle (90025) and place on supports.
u Place wall insert such that lifting device (90190/90195) can be removed.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.5 Removing the compressor casing
Removing the diffuser
Fig. 33: Removing the diffuser
1. Remove and dispose of the O-ring (77040).
2. Loosen and remove screws (77015).
3. Loop lifting gear around diffuser (79000) and remove diffuser.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.5 Removing the compressor casing
Removing the compressor casing
Fig. 34: Removing the compressor casing
1. Using screws (90196) and washers (90198), fasten lifting device (90190 / 90195) to com-
pressor casing (72000) and secure to crane.
2. Loosen and remove nuts (61037).
3. Use press-off nuts (61090) to fully press off and remove compressor casing (72000).
4. Remove and dispose of the O-ring (42012).
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.6 Removing the cartridge group
8.6
Removing the cartridge group
CAUTION
Safety-relevant screws
The six screws (01) are relevant for containment safety and must not be
loosened.
Fig. 35: Safety-relevant screws
CAUTION
Oil orifices
There is an orifice for adjusting the oil pressure in each of the two oil supply
pipes of the bearing casing. When the cartridge group, the bearing casing or
the turbocharger-is being fitted to the engine, it must be ensured that the
orifices specified for the turbocharger are installed in both oil supply pipes.
u Check that the oil orifices have been correctly installed.
Version with compressor wheel cooling
u Separate oil inlet and outlet pipes.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.6 Removing the cartridge group
Fig. 36: Removing cartridge group 1
1. Unplug cable connector (86515) and unscrew speed sensor (86505) with O-ring (86506).
Dispose of the O-Ring (86506).
2. Loosen socket screw (25013) and remove washer (25014).
3. Press off the spinner nose cone (25012) using the press-off screw (90917).
4. Loosen and remove the screw (61059).
5. Loosen and remove nuts (42128).
6. Attach lifting gear to bearing casing.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.6 Removing the cartridge group
CAUTION
Clearance between blade tip and casing
Serious damage to machinery or property can result from the rubbing or
jamming of the blade tips on the casing.
u Check that the blades do not rub on the turbine diffuser during disas-
sembly/assembly by rotating the rotor.
Fig. 37: Removing cartridge group 2
1. Evenly press off cartridge group by screwing three press-off screws (90900) into the
designated holes.
2. Using two guide studs (90490), move out cartridge group.
3. Fit supports (90450) and put down cartridge group.
4. Remove guide studs (90490). Fit and tighten the spinner nose cone (25012) together
with socket screw (25013) and washer (25014) until hand-tight.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.7 Removing the nozzle ring
8.7
Removing the nozzle ring
Removing turbine diffuser
Fig. 38: Removing turbine diffuser 1
1. Remove screws (61069).
2. Using press-off screws (90915), press off turbine diffuser.
3. Fit guide plates (90328) with nuts (61037).
4. Screw in guide stud (90802).
Fig. 39: Removing turbine diffuser 2
5. Pull turbine diffuser (63000) out as far as it will go at guide plates.
6. Loop around turbine diffuser and secure to lifting gear.
7. Remove nuts (61037) and guide plates (90328).
8. Completely pull out and put down turbine diffuser.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.7 Removing the nozzle ring
Removing cover ring
Fig. 40: Removing cover ring 1
1. Refit guide plates (90328) with nuts (61037).
2. Loosen and remove (57005) bolts.
Press off cover ring with the press-off screws (90916 for A170-M or 90901 for A175-M) in
the provided holes.
3. Pull cover ring (57001) out as far as it will go at the guide plates.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.7 Removing the nozzle ring
Fig. 41: Removing cover ring 2
4. Loop around cover ring and secure to lifting gear.
5. Remove guide plates (90328) and nuts (61037).
6. Fully pull out and put down cover ring (57001).
Removing the nozzle ring
Fig. 42: Removing nozzle ring 1
1. Bend open locking washers (56015), loosen and remove screws (56014).
2. Secure retaining plate (90338) with screws (90339) and hook guide rod (90336) into re-
taining plate.
3. Fit guide plate (90328) with nuts (61037).
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.7 Removing the nozzle ring
Fig. 43: Removing nozzle ring 2
4. Pull nozzle ring (56001) out as far as it will go at guide plate.
5. Loop around nozzle ring (56001) and secure to lifting gear.
6. Remove guide plate (90328) and nuts (61037).
7. Fully pull out and put down nozzle ring (56001).
Blocked areas on nozzle ring
If a nozzle ring is blocked in some areas or is covered by loose parts, it is recommended to
appoint an ABB Turbocharging Service Station to inspect the turbine blades and carry out a
crack inspection.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.8 Installing the nozzle ring
8.8
Installing the nozzle ring
Fig. 44: Installing nozzle ring 1
1. Secure retaining plate (90338) with screws (90339) and hook in guide rod (90336).
2. Using lifting gear, position nozzle ring (56001) on guide rod (90336). Do not take strain
off lifting gear yet.
3. Fit guide plate (90328) with nuts (61037).
4. Remove the lifting gear.
5. Position nozzle ring (56001) in gas outlet casing.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.8 Installing the nozzle ring
Fig. 45: Installing nozzle ring 2
Product
A170-M
A175-M
Size
M10
M10
Tightening torque [Nm]
50
50
Table 35: Tightening torque (56014)
6. Loosen nuts (61037) and remove guide plate (90328).
7. Loosen screws (90339) and remove retaining plate (90338) with guide rod (90336).
8. Coat the threads of screws (56014) and the contact surface between screw and locking
washer with high-temperature grease.
9. Fit the nozzle ring (56001) on the gas inlet casing (51001) using the screws (56014) and
locking washers (56015).
10. Bend over locking washers (56015).
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.8 Installing the nozzle ring
Installing cover ring
Fig. 46: Installing cover ring
Product
A170-M
A175-M
Size
M14
M16
Tightening torque [Nm]
130
200
Table 36: Tightening torque (57005)
1. Using lifting gear, move in cover ring (57001) over guide studs (90802) with notch (V) fa-
cing the gas outlet flange until the lifting gear is on the gas outlet casing.
2. Fit guide plates (90328) with nuts (61037).
3. Remove the lifting gear.
4. Slide in cover ring as far as it will go.
5. Remove guide plates (90328) and nuts (61037).
6. Coat threads of screws (57005) with high-temperature grease.
7. Fit and tighten screws (57005).
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.8 Installing the nozzle ring
Installing turbine diffuser
Fig. 47: Installing turbine diffuser 1
1. Using lifting gear, move turbine diffuser (63000) in over guide studs (90802) until the
lifting gear is on the gas outlet casing.
2. Fit guide plates (90328) with nuts (61037).
3. Remove the lifting gear.
4. Slide in turbine diffuser as far as it will go.
5. Remove nuts (61037), guide plates (90328) and guide studs (90802).
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.8 Installing the nozzle ring
Fig. 48: Installing turbine diffuser 2
Product
A170-M
A175-M
Size
M14
M16
Tightening torque [Nm]
130
200
Table 37: Tightening torque (61069)
6. Coat threads of screws (61069) with high-temperature grease.
7. Fit and tighten screws (61069).
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.9 Installing the cartridge group
8.9
Installing the cartridge group
CAUTION
Clearance between blade tip and casing
Serious damage to machinery or property can result from the rubbing or
jamming of the blade tips on the casing.
u Check that the blades do not rub on the turbine diffuser during disas-
sembly/assembly by rotating the rotor.
Fig. 49: Installing the cartridge group 1
1. Fasten lifting gear to bearing casing and lift cartridge group slightly.
2. Remove support (90450).
3. Using two guide rods (90490), carefully move in cartridge group.
4. Remove guide rods (90490).
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.9 Installing the cartridge group
Fig. 50: Installing the cartridge group 2
Product
A170-M
A175-M
Size
M22
M24
Tightening torque [Nm]
400
490
Table 38: Tightening torque (61059 / 42128)
1. Coat thread of screw (61059) and two bolts for the nuts (42128) with high-temperature
grease.
2. Secure cartridge group with screw (61059) and nuts (42128).
3. Remove the lifting gear.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.9 Installing the cartridge group
Fig. 51: Installing the cartridge group 3
Product
Size
Tightening torque [Nm]
A170-M
A175-M
M18x1.5
M18x1.5
150
150
Table 39: Tightening torque (86505)
1. Screw in and tighten speed sensor (86505) with new O-ring (86506).
2. Insert cable connector (86515).
CAUTION
Oil orifices
There is an orifice for adjusting the oil pressure in each of the two oil supply
pipes of the bearing casing. When the cartridge group, the bearing casing or
the turbocharger-is being fitted to the engine, it must be ensured that the
orifices specified for the turbocharger are installed in both oil supply pipes.
u Check that the oil orifices have been correctly installed.
u Remove temporary covers on oil connections.
u Fit all oil pipes according to instructions of enginebuilder.
Version with compressor wheel cooling
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.10 Fitting the spinner nose cone
8.10
Fitting the spinner nose cone
If present:
The spinner nose cone (25012) and Loctite®542 are supplied by the ABB service station to-
gether with the overhauled cartridge group.
CAUTION
Total failure of turbocharger
If the spinner nose cone (25012) is not fitted correctly, or the socket screw
(25013) is not correctly tightened, the spinner nose cone can work loose dur-
ing operation and cause total failure of the turbocharger.
u Follow the assembly instructions.
u Always use a new socket screw (25013) and washer (25014) from the cus-
tomer spare part set (97070).
u Only use new Loctite®542 supplied by the ABB service station.
u Observe and note down control dimension Z.
Fig. 52: Preparing the threaded stud (25008)
Product
A170-M
Size
M8
A175-M
M10
Table 40: Inner thread size (25008)
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.10 Fitting the spinner nose cone
1. Remove residual glue from the inner thread of the threaded stud (25008) by using a
screw tap.
2. Clean and degrease the inner thread of the threaded stud and socket screw (25013).
3. Coat the outer contact surface (A) between the spinner nose cone and the compressor
wheel over its entire circumference with Molykote® TP42.
4. Apply Loctite® 542 to the inner thread of the threaded stud.
Fig. 53: Fitting the spinner nose cone (25012)
Product
A170-M
A175-M
Size
M8
M10
Tightening torque [Nm]
20
40
Table 41: Tightening torque (25013)
Always use a new socket screw (25013) and washer (25014) from the customer spare part set
(97070).
5. Fit the spinner nose cone and secure with washer (25014) and socket screw (25013). Ob-
serve tightening torque. The following must be taken into account:
u The tightening torque must be applied by two people. One person tightens socket
screw (25013), while the second person holds the compressor wheel (25000).
u Apply tightening torque constantly, avoid jerky movements. Observe tightening torque.
u Do not repeat the tightening of socket screw (25013).
6. Measure and note down distance Z between spinner nose cone and compressor wheel at
no less than three points around the circumference.
Permissible distance Z:
Permissible difference of the measurements:
0.1 – 0.7 mm
± 0.1 mm
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.11 Installing the compressor casing
8.11
Installing the compressor casing
Installing the compressor casing
Fig. 54: Installing the compressor casing
Product
A170-M
A175-M
Size
M22
M24
Tightening torque [Nm]
400
490
Table 42: Tightening torque (61037)
Product
A170-M
A175-M
Pre-tightening torque [Nm]
Tightening angle [°]
45° ±5°
30
40
45° ±5°
Table 43: Tightening torque, nuts that are difficult to access (61037)
Product
A170-M
A175-M
Size
M22
M24
Tightening torque [Nm]
50
50
Table 44: Tightening torque (61090)
1. Distributed evenly around the circumference, screw the press-off nuts (61090) onto the
studs of the bearing casing and turn them by hand until they are at the end of the thread.
2. Grease the new O-ring (42012) and fit it.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.11 Installing the compressor casing
3. Using screws (90196) and washers (90198), fasten lifting device (90190 / 90195) to com-
pressor casing (72000) and secure to crane.
4. Position the compressor casing (72000).
Tighten nuts (61037) crosswise.
5. Remove lifting device (90190 / 90195).
6. Tighten the three press-off nuts (61090) against compressor casing (72000) by applying
the corresponding tightening torque.
Installing diffuser
Fig. 55: Installing diffuser
Product
A170-M
Size
M5
Tightening torque [Nm]
6
A175-M
M6
10
Table 45: Tightening torque (77015)
1. Loop around diffuser (79000) with lifting gear and position it on the wall insert (77000).
2. Attach diffuser with screws (77015).
3. Grease the new O-ring (77040) and fit it.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.11 Installing the compressor casing
Turning and moving in wall insert
Fig. 56: Turning and moving in wall insert
1. Secure the lifting device (90190 / 90195) and the fixing segment (90192) to the flange of
the wall insert (77000) using the screws (90197) and washers (90198).
Carefully turn wall insert (77000) with fitted diffuser over the support angle (90025) and
pull up vertically.
2. Remove support angle (90025), screws and nuts.
3. Fit guide studs (90319).
4. Carefully install the wall insert (77000) in the compressor casing. Make sure both mark-
ings are in the correct position.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.11 Installing the compressor casing
Fitting wall insert
Fig. 57: Fitting wall insert
Product
A170-M
A175-M
Size
M20
M24
Tightening torque [Nm]
580
1000
Table 46: Tightening torque (72011)
1. Remove lifting device (90190 / 90195) and fixing segment (90192).
2. Slide wall insert (77000) into compressor casing up to stop and remove guide stud
(90319).
3. Secure wall insert with screws (72011) and washers (72008).
For assembly of the alternative air inlet, see section Installing air inlets.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.12 Axial clearance A after assembly
8.12
Axial clearance A after assembly
WARNING
Physical hazards due to sharp edges on compressor wheel
The compressor wheel has sharp edges which can result in injury.
u Wear safety gloves.
Wear safety gloves to protect against mechanical hazards.
The axial clearance (A) must be measured prior to removal and after installation of the cart-
ridge group.
CAUTION
Clearances outside the tolerance
Serious damage to engines or property can be caused by clearances outside
the tolerance and excessively worn parts.
u Have the components assessed and, if necessary, replaced by an ABB Tur-
bocharging Service Station.
Fig. 58: Axial clearance
Product
A170-M
Axial clearance A [mm]
0.30 ... 0.61
A175-M
0.35 ... 0.69
Table 47: Axial clearance A
u Measure and note axial clearance (A).
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.13 Installing the air inlets
8.13
Installing the air inlets
8.13.1
Installing the air suction branch
Fig. 59: Installing the air suction branch
Product
A175-M
A170-M
Size
M20
M18
Tightening torque [Nm]
220
170
Table 48: Tightening torque (72027)
1. Loop lifting gear around air suction branch.
2. Fit air suction branch together with nuts (72027) and washer (72028). Observe tightening
torque.
u Disconnect all air lines according to the instructions of the enginebuilder.
u Dismantle insulation as far as necessary.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.13 Installing the air inlets
8.13.2
Installing the filter silencer
Fig. 60: Installing the filter silencer
Product
A170-M
A175-M
Size
M18
M20
Tightening torque [Nm]
170
220
Table 49: Tightening torque (72027)
1. Loop lifting gear through the fin on the filter silencer and secure to the eyelets at the rear
with shackles (90195).
2. Fit filter silencer together with nuts (72027) and washers (72028). Observe tightening
torque. Tighten nuts that are difficult to access with a fork/ring spanner.
u Fit insulation.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.14 Removing and installing turbine-
end nozzle ring
8.14
Removing and installing turbine-end nozzle ring
Removing the nozzle ring
If only the nozzle ring has to be removed, this can be done at the turbine end.
CAUTION
Leaking connection
Reusing the removed spiral-wound gasket (61050) will result in leaking con-
nections. Spiral-wound gaskets may only be used once.
u Provide new spiral-wound gasket (61050).
NOTICE
Blocked areas on nozzle ring
If a nozzle ring is blocked in some areas or is covered by loose parts, it is re-
commended to appoint an ABB Turbocharging Service Station to inspect the
turbine blades and carry out a crack inspection.
In order to access the fixing screws, and loop around and transport the gas inlet casing, the
insulation has to be removed as required.
CAUTION
Damaged cleaning pipes
When looping around, ensure that any cleaning pipes present are not
pressed or damaged.
u Never secure the lifting gear to the cleaning pipes.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.14 Removing and installing turbine-
end nozzle ring
Fig. 61: Removing the nozzle ring at the turbine end (radial gas inlet casing)
Fig. 62: Removing the nozzle ring at the turbine end (axial gas inlet casing)
1. If present: Remove connecting pipe for turbine cleaning.
2. Loop around gas inlet casing (51001) and secure with lifting gear.
3. Loosen screws (61009) and move out gas inlet casing with nozzle ring.
4. Bend open locking washers (56015), loosen and remove screws (56014).
5. Pull out nozzle ring (56001).
6. Remove spiral-wound gasket (61050) and provide new one.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.14 Removing and installing turbine-
end nozzle ring
Installing the nozzle ring
Fig. 63: Installing the nozzle ring at the turbine end (radial gas inlet casing)
Fig. 64: Installing the nozzle ring at the turbine end (axial gas inlet casing)
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.14 Removing and installing turbine-
end nozzle ring
Product
A170-M
A175-M
Size
M10
M10
Tightening torque [Nm]
50
50
Table 50: Tightening torque (56014)
Product
Size
Tightening torque [Nm]
Stage 1
80
100
Stage 2
170
240
Stage 3
280
380
A170-M
A175-M
M18
M20
Table 51: Tightening torque (61009)
1. Coat threads of new screws (56014) with high-temperature grease.
Fit the nozzle ring (56001) to the gas inlet casing (51001) using the screws (56014) and
new locking washers (56015).
Bend over locking washers.
2. Fix new spiral-wound gasket (61050) in groove of gas outlet casing (61001) at three
evenly distributed points with a little superglue (such as Loctite® 454).
3. Fit two guide studs (90321) in the upper part of the gas outlet casing (61001).
4. Coat threads of screws (61009) with high-temperature grease.
5. Loop around gas inlet casing (51001) and, using lifting gear, slide over guide studs until
at the gas outlet casing (61001) and secure with screws (61009).
6. Remove the guide studs (90321).
7. Fit remaining screws (61009), then crosswise tighten all screws (61009). Observe tight-
ening torque.
8. If present: Fit connecting pipe for turbine cleaning
u Refit dismantled insulation.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.15 Table of tightening torques
Thread sizes and tightening torques [Nm]
Position
Part number
A170-M
A175-M
01
82005
M22x1.5
M22x1.5
80
80
02
03
04
05
06
07
08
09
10
11
77015
61036
M5
6
M6
10
M22
M24
60
80
61037
M22
400
M24
490
61090
61059 / 42128
61069
M22
M24
50
50
M22
400
M24
490
M14
M16
130
200
63001
M14
170
M18
240
56014
M10
M10
50
50
61009
57005
42059
72011
M18
M20
2801)
3801)
M14
M16
130
200
12
M16
200
M16
200
13
M20
M24
580
1000
14
15
16
17
72027
M18
170
M20
220
72026
M18
M20
50
40
25013
M8
20
M10
40
86505
M18x1.5
M18x1.5
150
150
Table 52: Tightening torques
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
8 Disassembly and assembly / 8.15 Table of tightening torques
Tightening sequence
Fig. 67: Flange tightening sequence
Product
Tightening torque (61009) [Nm]
Step 1
hand-tight
hand-tight
Step 2
80
100
Step 3
170
240
Step 4
280
380
A170-M
A175-M
Table 53: Tightening torques 61009
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
9 Taking a turbocharger out of operation / 9.1 Possible emergency re-
pairs
9
Taking a turbocharger out of operation
9.1
Possible emergency repairs
CAUTION
Machine damage in emergency operation
The assembly of the locking device on the turbocharger is only permissible
in emergencies. It is not permitted to lock the rotor for an engine test. Seri-
ous damage to engine or property can be caused by non-compliance with
the regulations in the event of an emergency.
u The permissible turbocharger speed for the unlocked turbocharger may
not exceed nBmax. Take note of the rating plate.
u After locking the turbocharger, contact an ABB Turbocharging Service
Station and find the nearest port.
u Observe the safety regulations.
u Follow the directives of the enginebuilder.
WARNING
Danger of fire and explosion due to lubricating oil leaks
Leaking oil may ignite on hot surfaces. This can result in serious injuries to
personnel or fatal accidents.
u Cordon off danger area.
u Raise the alarm and, depending on the situation, stop the engine.
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.
If damage has occurred to the turbocharger and the engine has to be brought back into op-
eration again as quickly as possible, the following emergency repair options are available:
¡
¡
¡
¡
Lock the rotor
Attach a cover plate
Blank off the inlet and outlet flanges of casings
Bypass the turbocharger
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
9 Taking a turbocharger out of operation / 9.2 Locking the rotor
9.2
Locking the rotor
9.2.1
Introduction
CAUTION
Cooling of a locked rotor
Serious damage to engine or property can be caused by the overheating of
intact turbocharger components.
If the gas inlet is not blanked off, the lubricating oil supply remains switched
on (see section Further information for operation of 4-stroke engines with
locked rotor).
u If there is a lubricating oil leak on the turbocharger, stop the oil supply.
A locked rotor must be removed after emergency operation and checked for unbalance (see
chapter Removing the cartridge group).
The unbalance check must be carried out by an ABB Turbocharging Service Station.
Exception
The exception concerns customer requirements for test bed runs of new engines at a max-
imum engine load of up to 25 %.
In these cases, subsequent removal of the rotor is not required as the engine is only oper-
ated briefly with a locked rotor.
In these test bed runs, it is not allowed to remove any set screws from the compressor wheel
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
9 Taking a turbocharger out of operation / 9.2 Locking the rotor
9.2.2
Fitting the locking device
CAUTION
Turbocharger damage resulting from rotor unbalance
Removing the balancing screws from the compressor wheel will result in ro-
tor unbalance.
u Only use free threaded holes to fit the lifting spigot (74027).
Fig. 68: Fitting the locking device
Product
A170-M
A175-M
Part number 72011
170 Nm
Part number 94006 / 94007
25 Nm
50 Nm
220 Nm
Table 54: Locking device tightening torque
1. Press off the spinner nose cone (25012) with the press-off screw (90917).
2. Remove two studs (72026) and three screws (72011) in the upper area.
3. Insert the lifting spigot (90441) into the compressor wheel.
Screw screws (94007) into the free threaded holes of the compressor wheel.
4. Position assembly/disassembly device (94003) with screws (72011) and lifting spigot
(90427).
Rotate compressor wheel in such a way that the holes in the lifting spigot (90427) corres-
pond with the holes in the assembly/disassembly device (94003).
5. Secure assembly/disassembly device (94003) to the lifting spigot (90427) with screws
(94006).
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
9 Taking a turbocharger out of operation / 9.2 Locking the rotor
9.2.3
Further information for operation of 4-stroke engines
with locked rotor
4-stroke engine with one turbocharger
No further measures are necessary. The engine can be operated as a suction engine accord-
ing to the instructions of the enginebuilder.
4-stroke engine with several turbochargers
Separate receivers
In engines with separate air and exhaust gas receivers, no further measures are necessary.
The engine can be operated as a suction engine according to the instructions of the en-
ginebuilder.
Common air receiver
CAUTION
Excessive speeds on undamaged turbochargers
The speed limit nBmax specified on the rating plate of the turbocharger must
not be exceeded. Serious damage to engine or property can be caused by
excessive speeds.
u Observe the speeds of the undamaged turbochargers.
u Reduce the engine load if necessary.
If the engine is equipped with a common air receiver and separate exhaust gas receivers, the
bellows on the compressor outlet of the damaged turbocharger must always be removed
and the air line on the engine side must be blanked off. Otherwise the undamaged tur-
bocharger can spin "empty" (without load) and run at overspeed.
Depending on the turbocharging system of the engine, the locked rotor is exposed to more
or less strong pulses from the exhaust gas system. Especially in pulse charging (turbine cas-
ing with more than one gas inlet), the locking device is heavily strained by this process.
Therefore the following operating limits should not be exceeded:
¡
In constant-pressure-similar systems (1 gas inlet), the engine can be operated at a max-
imum engine load of up to 25 %. The pressure in the charge air receiver must not exceed
0.9 bar overpressure.
¡
In pulse charging (2 to 4 gas inlets), the engine can be operated at a maximum engine
load of up to 20 %. The pressure in the charge air receiver must not exceed 0.5 bar over-
pressure.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
9 Taking a turbocharger out of operation / 9.3 Fitting the cover plate
9.3
Fitting the cover plate
The cover plate (01) and spacer sleeves (02) (material: general construction steel, in compli-
ance with DIN EN 10025-2) must be manufactured according to the drawing from the oper-
ator.
Fig. 69: Cover plate (01) / spacer sleeves (02) dimensions
Cover plate (01) / spacer sleeves (02) dimensions [mm]
Product
A170-M
A175-M
B1
13
13
B2
432
500
B3
50
50
B4
50
50
B5
9
9
B6
12
12
B7
8
8
B8
96
112
Table 55: Cover plate dimensions 1
Product
A170-M
A175-M
Ø 1
835
965
Ø 2
915
1050
Ø 3
872.4
1007.5
Ø 4
24
26
Ø 5
34
36
Ø 6
20
20
Table 56: Cover plate dimensions 2
Product
⍺ 1
⍺ 2
⍺ 3
A170-M
A175-M
4 x 90°
4 x 90°
37.5°
37.5°
24 x 15°
24 x 15°
Table 57: Cover plate dimensions 3
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
9 Taking a turbocharger out of operation / 9.3 Fitting the cover plate
Fig. 70: Fitting the cover plate
1. Remove the cartridge group (see chapter Disassembly and assembly / Removing the
cartridge group).
2. Close the opening in the gas outlet casing with the cover plate (01).
3. Attach cover plate with spacer sleeves (02) and nuts (61037).
u Close the lubricating oil supply to the turbocharger.
9.3.1
Further measures and information for the operation of
4-stroke engines with a cover plate of the turbocharger
4-stroke engine with a turbocharger
No further measures are necessary. The engine can be operated as a suction engine accord-
ing to the instructions of the enginebuilder.
4-stroke engine with several turbochargers
Separate receivers
In engines with separate air and exhaust gas receivers, no further measures are necessary.
The engine can be operated as a suction engine according to the instructions of the en-
ginebuilder.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
9 Taking a turbocharger out of operation / 9.4 Blanking off the inlets
and outlets
Common air receiver
CAUTION
Excessive speeds on undamaged turbochargers
The speed limit nBmax specified on the rating plate of the turbocharger must
not be exceeded. Serious damage to engine or property can be caused by
excessive speeds.
u Observe the speeds of the undamaged turbochargers.
u Reduce the engine load if necessary.
The air line must be blanked off on the engine side because the undamaged turbochargers
build up a receiver pressure.
9.4
Blanking off the inlets and outlets
The chapter is only applicable for engines with several turbochargers and joint air and ex-
haust gas receivers.
u Close the lubricating oil supply to the turbocharger.
u Blank off flange from compressor casing outlet, gas inlet and gas outlet by the installa-
tion of cover plates.
u Observe specifications from enginebuilder.
9.5
Engines with bypass around the turbocharger
The chapter only applies for engines with one turbocharger and for systems on which the
connections for a bypass have been prepared and the necessary pipe connections have been
provided.
u Close the lubricating oil supply to the turbocharger.
u Open the bypass around the turbocharger.
u Observe specifications from enginebuilder.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
10 Mothballing the turbocharger / 10.1 Taking the engine out of opera-
tion for up to 12 months
10
Mothballing the turbocharger
10.1
Taking the engine out of operation for up to
12 months
State of the engine lubricating oil
The turbocharger normally remains attached to the engine. The measures to be taken for
mothballing the turbocharger depend on the state of the lubricating oil. No measures are re-
quired under the following conditions:
¡
¡
Acid number (TAN) < 2 mg KOH/g
The engine lubricating oil is replaced by a preservative oil and circulated with the pre-lub-
rication pump before the engine is taken out of operation. Residues of old engine oil are
flushed away in this way and the 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 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.
If the acid number (TAN) is greater than 2 mg KOH/g, the following mothballing measures
are necessary after taking the engine out of operation:
u Dismantle the turbocharger.
u The rotor and bearing parts must be dismantled and subsequently refitted by an ABB Tur-
bocharging Service Station.
u Clean all parts.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
10 Mothballing the turbocharger / 10.2 Taking the engine out of oper-
ation for more than 12 months
u Coat plain surfaces of steel and cast parts with anticorrosive oil.
u Fit turbocharger completely.
Rotation of the rotor in the stack draught
If the rotor turns as a result of the stack draught:
u Install a blind flange between the outlet flange of the compressor casing and the charge
air duct.
10.2
Taking the engine out of operation for more than
12 months
If the engine is taken out of operation, the following variants are possible with regard to the
turbocharger:
¡
¡
Turbocharger remains attached to the engine
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 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 the engine, see section Taking the engine out of op-
eration for up to 12 months, subsection Rotor turning in stack draught.
If the complete turbocharger is removed or the turbocharger is assembled again from the
individual parts:
u Seal all openings of the turbocharger with paraffin paper and wooden lids.
Only dry rooms with 40 ... 70 % atmospheric humidity, in which no water condensation can
form, are suitable as storage locations.
State of the mothballed turbocharger
u Check the turbocharger parts annually for corrosion.
u If there are signs of rust: Thoroughly clean parts and renew corrosion protection.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
11 Disposing of turbocharger components /
11
Disposing of turbocharger components
WARNING
Handling damaged thermal insulation
Damaged thermal insulation can lead to dust exposure. The glass fibres can
cause mechanical irritation of the eyes, skin, and respiratory tracts.
u Avoid the formation of dust.
u Vacuum up dust with a suitable vacuum cleaner.
u Wear a respiratory mask to protect against dusts (P1 or P2 mask).
u Wear safety gloves.
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-metallic materials (filter components of felt and polyethylene),
lubricants (engine oil), electronic parts (speed sensor and associated components), and
thermal insulation.
u Dispose of metals as scrap metal for recycling.
u Dispose of non-metallic materials as waste.
u Dispose of residues of lubricants as waste oil.
u Dispose of electronic components as electronic waste.
u Dispose of thermal insulation as hazardous waste.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
12 Spare parts / 12.1 Ordering spare parts
12
Spare parts
12.1
Ordering spare parts
CAUTION
Spare part storage
All spare parts that were ordered together with the turbocharger must be
kept intact and ready for use.
u Carefully clean any rusted parts and grease them.
Please quote the following data when making queries and ordering spare parts:
¡
¡
¡
Turbocharger type
Serial number (HT……)
Designation and part number.
Spare parts can be ordered from any ABB Turbocharging Service Station.
u If different model variants are not taken 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.
Required customer spare part set (97070)
For the work described in the Operation Manual, the customer spare part set (97070) is re-
quired. These parts are only available in the complete set.
Part number
25013
25014
Designation
Socket screw
Washer
Quantity
1
1
42012
O-ring
1
42041
Gasket
1
42045
42059 / 42064
56014
56015
57005
61037
61069
77015
77040
Gasket
2
2
2
2
5
3
3
3
1
Hexagon-head screw
Hexagon-head screw
Locking washer
Hexagon-head screw
Hexagon nut
Hexagon-head screw
Socket screw
O-ring
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
12 Spare parts / 12.2 View of turbocharger with part numbers
Part number
Designation
Quantity
86506
O-ring (speed sensor)
1
Table 58: Customer spare part set (97070)
12.2
View of turbocharger with part numbers
Fig. 71: Turbocharger with part numbers
( . . . . . ) only available in customer spare part set (97070)
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
12 Spare parts / 12.2 View of turbocharger with part numbers
Turbocharger
Part number
Designation
51001
56001
Gas inlet casing, axial / radial
Nozzle ring
56014 (in customer spare part set)
56015 (in customer spare part set)
57001
Hexagon-head screw
Locking washer
Cover ring
57005 (in customer spare part set)
61001
61037 (in customer spare part set)
Hexagon-head screw
Gas outlet casing
Hexagon nut
61050
Gasket
61069 (in customer spare part set)
63000
68001
68002
Hexagon-head screw
Turbine diffuser
Foot, compressor end
Foot, turbine end
Sliding block
68003
72000
Compressor casing
Socket screw
77015 (in customer spare part set)
77000
Wall insert
77040 (in customer spare part set)
O-ring
79000
Diffuser
81000
Filter silencer
82000
Radial air suction branch
Table 59: Turbocharger with part numbers
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
13 Tools /
13
Tools
For the work described in the Operation Manual, the customer tool set 90009 is required.
90009
90010
90025
90190
90192
90196
90197
90198
Designation
Wooden crate
Support angle complete
Lifting device
Fixing segment
Hexagon-head screw
Hexagon-head screw
Washer
Quantity
1
1
1
1
2
2
2
1
90199
Adapter
90195
90319
90321
90328
Shackle
Guide stud
Guide stud
Guide plate bolt
Guide stud
2
2
2
3
1
90336
90338
90339
90441
90450
90490
90802
90900
90915
90916 / 90901
90917
94003
94006
94007
90321
Mounting plate
Socket screw
Lifting spigot
Support
Guide stud
Guide stud
Press-off screw
Press-off screw
Press-off screw
Press-off screw
Locking device
Hexagon-head screw
Hexagon-head screw
Guide stud
1
2
1
2
2
3
6
3
3
1
1
10
12
2
Table 60: Customer tool set 90009
This tool set can be ordered from any ABB Turbocharging Service Station. The following spe-
cifications must be included in the order:
¡
¡
Turbocharger type
Designation and part number of the tool set.
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Rev.F
August 2020
Operation Manual / 4 Product description / A100-M axial
ꢀFigures
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Revision F
August 2020
Operation Manual / 4 Product description / A100-M axial
ꢀTables
© Copyright 2020 ABB. All rights reserved.
HZTL4033_EN
Revision F
August 2020
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