Page 1 ABB Turbocharging Operation Manual A130-M56 HT559842 English Original Operation Manual Chapter Document-ID Introduction HZTL4005_EN_D Safety HZTL4022_EN_B Safety data sheet HT559842 Product description HZTL4031_EN_B ABB Turbo Systems Ltd...
Page 2 We herewith confirm that this Operation Manual has been drawn up in compliance with the "EU Product Liability Directive" 85/374/EEC as well as with the "EU Machinery Directive" 2006/42/EC. © Copyright 2015 ABB. All rights reserved. Design and specifications are subject to change without notice.
Page 3: Table Of Contents
Table of contents Page 1 / 8 Introduction Introduction ....................Purpose of the manual ................Symbols, definitions ..................Storage of new turbochargers and spare parts ........... Contact information ..................HZTL4005_EN Revision D © Copyright 2015 ABB. All rights reserved. September 2015...
Page 5: Introduction
3 (Safety data sheet) and the rating plate on the turbocharger. Operation Manual The Operation Manual explains the turbocharger from ABB Turbo Systems and contains instructions for safe operation. The Operation Manual is a complement to and expansion of existing national regulations for occupational safety, accident prevention and environmental protection.
Page 6: Symbols, Definitions
ABB Turbo Systems Ltd is identified as ABB Turbo Systems in this document. Official service stations of ABB Turbo Systems Official service stations are identified in this document as ABB Turbocharging Service Stations. They are regularly audited and certified by ABB Turbo Systems. Also see chapter Contact information [➙ 8]. HZTL4005_EN Revision D ©...
Page 7 Dispose of in an environmentally with specifications compatible, professional way and in compliance with locally Oil free, grease free and dry applicable regulations. Table 1: Definition of pictograms HZTL4005_EN Revision D © Copyright 2015 ABB. All rights reserved. September 2015...
Page 8: Storage Of New Turbochargers And Spare Parts
Storage of new turbochargers and spare parts Storage of new turbochargers and spare parts up to 6 months New turbochargers and spare parts from ABB Turbo Systems 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).
Page 9 Inspect the package for damage. If the package is damaged, the turbocharger or cartridge  group must be inspected 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 ...
Page 10: Contact Information
Operation Manual / 1 Introduction Introduction Page 8 / 8 Contact information Contact information for the official service stations of ABB Turbo Systems is available online. Scan the QR code to access our website.  ABB Turbo Systems AG Bruggerstrasse 71a...
Page 11 Periodic check of the pressure vessels ............1.10 Lifting of loads .................... 1.11 Prerequisites for operation and maintenance ..........1.12 Hazards during operation and maintenance ..........1.13 Safe operation ................... 1.14 Safe maintenance ..................© Copyright 2015 ABB. All rights reserved. HZTL4022_EN Revision B April 2015...
Page 13: Safety
Safety Introduction Turbochargers manufactured by ABB Turbo Systems are state of the art and comply with the respective health and safety standards in effect at the time the turbocharger was built. This ensures safe operation of the turbocharger. Nevertheless, there may be some residual risks during operation of and work on the turbocharger which: ...
Page 14: Definition Of Mandatory Signs
CAUTION can lead to CAUTION serious damage to engine or property with grave consequences. Caution signs must always be observed.  © Copyright 2015 ABB. All rights reserved. HZTL4022_EN Revision B April 2015...
Page 15: Intended Use
The specific operating limits of the turbocharger were determined on the basis of information from the enginebuilder about the intended use. These data are given on the rating plate. ABB Turbo Systems accepts no liability and rejects all warranty claims for any non-intended uses.
Page 16: Deflagration On Gas Engines
Deflagration on gas engines ABB turbochargers can tolerate a deflagration with a transient pressure increase of 12 bar. ABB Turbo Systems recommends subjecting the turbocharger to a visual inspection after a deflagration event. As part of the inspection, the position of the turbine casing and the position of the compressor casing to the bearing casing must be checked, and the bearing casing must be examined to see if it has shifted in relation to the bracket.
Page 17: Turbocharger Rating Plate
Replacement interval of turbine in 1000 h Further data Customer part number Designation for special design Weight of turbocharger in kg Turbocharger type 10 Serial number 11 Year of construction of turbocharger © Copyright 2015 ABB. All rights reserved. HZTL4022_EN Revision B April 2015...
Page 18: Periodic Check Of The Pressure Vessels
The locations of the rating plates are defined in the Operation Manual / Product description. Periodic check of the pressure vessels The pressure vessels used by ABB Turbo Systems, for example, in the wet or dry cleaning process, are so-called simple pressure vessels.
Page 19: Lifting Of Loads
The assembly devices must be completely screwed in and must not unscrew during use.  Use assembly devices only for the described applications.  Put down dismantled components of the turbocharger in such a way that they cannot tip  over. © Copyright 2015 ABB. All rights reserved. HZTL4022_EN Revision B April 2015...
Page 20: Prerequisites For Operation And Maintenance
WARNING personnel. Only use original parts from ABB Turbo Systems.  ABB Turbo Systems accepts no liability for any damage resulting from the use of non-original parts and associated accessories. © Copyright 2015 ABB. All rights reserved. HZTL4022_EN Revision B...
Page 21: Hazards During Operation And Maintenance
Wear heat-resistant safety gloves and protective clothing.  Wait for the turbocharger to cool down before carrying out any work.  Wear safety gloves against thermal risks. © Copyright 2015 ABB. All rights reserved. HZTL4022_EN Revision B April 2015...
Page 22 Page 12 / 18 Hot surfaces on the non-insulated turbocharger Non-insulated turbochargers can cause serious injuries to personnel (burns). ABB Turbo Systems supplies the turbocharger with or without insulation in WARNING accordance with the purchase order received from the enginebuilder. If...
Page 23: Safe Operation
When switching on operating energy supplies (hydraulics, pneumatics, electricity), pay  attention to the risks that may occur as a consequence of this energy input. © Copyright 2015 ABB. All rights reserved. HZTL4022_EN Revision B April 2015...
Page 24 Insulation (01) with integrated burst protection from ABB Turbo Systems. Variant B Burst protection (03) and insulation (02) from ABB Turbo Systems. Variant C Burst protection (03) from ABB Turbo Systems with appropriate insulation from the enginebuilder. © Copyright 2015 ABB. All rights reserved. HZTL4022_EN...
Page 25: Safe Maintenance
Have oil binding agents ready and provide or keep oil pans at hand.  Clean up any spills.  Have fire protection means and extinguishing agents available.  © Copyright 2015 ABB. All rights reserved. HZTL4022_EN Revision B April 2015...
Page 26 Secure rotor against turning. The rotor can rotate due to the stack draught alone.  Wear appropriate protective clothing.  Observe the material safety data sheet for the cleaning and mothballing agents.  © Copyright 2015 ABB. All rights reserved. HZTL4022_EN Revision B April 2015...
Page 27 Observe the information in the material safety data sheet for the operating  materials and supplies. Comply with local legislation.  Wear safety goggles. Wear safety gloves against mechanical risks. Wear a respiratory mask to protect against gases. © Copyright 2015 ABB. All rights reserved. HZTL4022_EN Revision B April 2015...
Page 28 Dispose of insulation materials properly and in an environmentally  compatible manner in compliance with the legal regulations. Wear safety goggles. Wear a respiratory mask to protect against particles. Wear safety gloves against chemical risks. © Copyright 2015 ABB. All rights reserved. HZTL4022_EN Revision B April 2015...
Page 31 Foreword to maintenance ................Cleaning the compressor during operation ..........Cleaning the turbine during operation ............Cleaning components mechanically ............Troubleshooting ..................Malfunctions when starting ................. Malfunctions during operation ..............© Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 32 Taking the engine out of operation for more than 12 months ...... Disposing of turbocharger components ............ Spare parts ..................... 12.1 Ordering spare parts .................. 101 12.2 View of turbocharger with part numbers ............. 102 © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 33: Introduction
This document is valid for different design variants of turbochargers. There may be sections and descriptions of components that are not relevant for a specific turbocharger variant. ABB Turbocharging Service Stations will be glad to provide information on questions regarding a design variant.
Page 34: Layout And Function Of The Turbocharger
03 Diffuser 10 Turbine casing 04 Bearing casing 11 Turbine-end bearing flange 05 Axial thrust bearing 12 Compressor-end bearing flange 06 Radial plain bearing 13 Compressor wheel 07 Turbine © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 35 (01). In addition, the turbocharger version with compressor wheel cooling is indicated by the turbocharger type (M6..) on the rating plate. © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B...
Page 36: Warning Plates On The Turbocharger
Warning plates are attached at the following locations: Figure 3 If warning plates are not present in the designated locations or not readable, proceed as follows: Order new warning plates from ABB Turbocharging Service Stations.  Remove any warning plates that have become unreadable. ...
Page 37: Locations Of The Rating Plates
Locations of the rating plates Locations of the rating plates Figure 4 One rating plate (01) each is attached on the left and the right side of the turbocharger bearing casing. © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 39: Removal And Installation
Depending on the specification, the weight specified on the rating plate may be lower than the standard value specified here. Product Weights [kg] A130 A135 A140 A145 Table 1 © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 40: Removing The Turbocharger
Depending on the bracket version (04), two positioning pins (05) can be used for positioning and safeguarding against wrong fitting of the NOTICE turbocharger. Therefore the turbocharger must always be removed from and installed on the bracket vertically. © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 41 (see instructions of the enginebuilder). Remove the turbocharger.  Cover the oil connections (03) on the engine side to protect against dirt.  © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 42 Working in a circle, loosen each of the pressure screws by about ¼ of a turn (90°).  Repeat the previous step until all pressure screws are relieved of pressure.  Loosen clamping nut by hand.  © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 43 Secure the turbocharger to prevent it from tipping over by using wooden  beams and wedges and by taking the centre of gravity into account. Figure 8 Centre of gravity Close or cover the openings of the turbocharger.  © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 44: Installing The Turbocharger
The oil is supplied (02) and drained (03) through the bracket (01). The necessary sealing is by means of O-rings which are located in the slots of the bracket. The gaskets are not included in the ABB Turbo Systems scope of delivery and must be provided by the enginebuilder.
Page 45 Fixing material scope of delivery The threaded rods and nuts for fastening the turbocharger on the bracket are not included in the ABB Turbo Systems scope of delivery. These parts depend on the version of the engine- side bracket. The clamping nuts are included in the ABB Turbo Systems scope of delivery.
Page 46 Depending on the bracket version (04), two positioning pins (05) can be used for positioning and safeguarding against wrong fitting of the NOTICE turbocharger. Therefore the turbocharger must always be removed from and installed on the bracket vertically. © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 47 Variant 2: casing Tightening torques Hydraulic pre- [mm] [Nm] **) tensioning forces [kN] A130 Ø 17 A135 Ø 21 A140 Ø 25 Table 3 Remove lifting gear.  © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 48 4. Tighten clamping nut (03) by hand. 5. Unscrew clamping nut (03) by ¼ of a turn (90°). The distance between the thrust washer and the clamping nut is now about 1 mm. © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B...
Page 49 5. Tighten pressure screws to 100 % in 5 … 7 rounds until the required residual tightening angle of < 20° is achieved. Torque-controlled tightening Product Fixing screw [mm] Tightening torques [Nm] A140 A145 Table 4 © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 50 Remove the screw plug on the connection for the compressor wheel cooling (06) and fit  the cooling air line. 2.4.7 Attaching the support Figure 16 If present: Attach support (61301) to the engine support.  © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 51: Commissioning
– 600 °C with non-insulated casing At temperatures below the specified values, post-lubrication must be ensured until the rotors come to a standstill. ABB Turbo Systems recommends post-lubrication for 10 minutes. Observe the oil pressure specified for post-lubrication (see Table 5).
Page 52 With an oil inlet pressure of more than 3 bar (when engine under load) before the turbocharger, the bearing casings are equipped as standard with an orifice at the oil inlet. © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B...
Page 53: Inspection Procedures
CAUTION Make sure there is an uninterrupted supply of cooling air during operation.  Check whether the compressor wheel cooling is fitted on the bearing casing.  © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 55: Commissioning After Taking Out Of Operation
Put engine-side oil circulation to the turbocharger into operation.  Prepare the turbocharger for operation according to section "Checks before  commissioning". The turbocharger is now ready for operation.  © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 57: Monitoring During Operation
Oil pressure measuring point Oil temperature measuring point For monitoring the lubricating oil pressure, ABB Turbo Systems recommends installing an "M" manometer immediately before the turbocharger. If the pressure is controlled electronically, the appropriate signals are to be triggered at the warning and alarm values.
Page 58 Table 7 If the turbocharger was operated for a longer period of time outside of the admissible range, ABB Turbo Systems recommends to have the turbocharger inspected by an ABB Turbocharging Service Station. © Copyright 2014 ABB. All rights reserved.
Page 59: Turbocharger Speed
42188 Screw plug 86515 Cable connector 42189 Gasket 86526 F/I converter Plug with integrated voltage limiter 86528 Tachometer Installation variant for speed sensor 32109 Sealing disc with cams © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 60 If the engine can be stopped temporarily: Inspect air lines, exhaust gas pipes and the turbochargers and remedy any malfunctions.  ABB Turbo Systems recommends contacting the nearest ABB Turbocharging Service  Station. © Copyright 2014 ABB. All rights reserved.
Page 61 4.2.5 Malfunction of the speed measurement system The possible reasons for malfunction of the speed measuring system are described in chapter Troubleshooting / Speed measurement system [➙ 69]. © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 63: Operation And Service
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 insulation versions © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 64 Suggestion for noise insulation, bellows Figure 19 Compressor casing Bellows Charge air duct / scavenging air duct Insulation cushion Insulation mat (at least 15 mm) Sheet metal cover © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 65: Service Work
CAUTION engine damage even if the prescribed service intervals are observed. Agree on a reduced service interval with ABB Turbo Systems.  5-year service inspection To prevent machine damage caused by ageing and downtime, we...
Page 66 Service work according to data on the rating plate (Usually after 8000 … 12000 operating hours) The rotor and bearing parts must be checked and assessed by an ABB Turbocharging Service Station. The following work can be carried out as preparation.
Page 67 Page 37 / 103 5.2.5 Other service work If a protective grid is installed in the radial or axial gas outlet casing (61001) by ABB Turbo Systems: Figure 20 Remove the protective grid (61205) after 50,000 hours and replace it with a new one.
Page 68  Speed of the turbocharger  Air temperature after the compressor and after the charge-air cooler  Exhaust gas temperature before and after the turbine  Pressure loss in the filter silencer. © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 69: Expected Replacement Intervals
50000 50000 Table 8 = Natural Gas = Marine Diesel Oil = Heavy Fuel Oil The specified values are guideline values and not guaranteed values, see Influencing parameters. © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 70  Lubricating oil quality (oil filtering, oil condition, oil monitoring)  Load profile (speed, pressure conditions, temperature)  Number of starts/stops  Imbalance of the rotor (degree of contamination). © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 71: Stopping The Engine
– 600 °C with non-insulated casing At temperatures below the specified values, post-lubrication must be ensured until the rotors come to a standstill. ABB Turbo Systems recommends post-lubrication for 10 minutes. Observe the oil pressure specified for post-lubrication (see Table 5).
Page 73: Periodic Maintenance
Cleaning method To allow you to observe the standard service intervals and to maintain a high turbocharger efficiency, ABB Turbo Systems recommends that the cleaning NOTICE procedure be carried out during operation. This allows the thermal load of the engine to be kept low while ensuring maximum fuel efficiency.
Page 74: Cleaning The Compressor During Operation
The time period between the periodical cleaning cycles depends greatly on the operating conditions. Cleaning should normally be done every 24 ... 72 hours of operation. If the specified cleaning intervals are incompatible with operation of the engine, contact ABB Turbo Systems.
Page 75 CAUTION Never connect injection tubes directly to a water pipe or a larger metering  container other than that specified by ABB Turbo Systems. V-engines 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 turbocharger.
Page 76 (03) is actuated. 6.2.2 Prerequisites To carry out the cleaning operation checked and recommended by ABB Turbo Systems, the engine load must be 50 % to 85 %. 6.2.3 Procedure for wet-cleaning the compressor...
Page 77: Cleaning The Turbine During Operation
Poor quality fuel in conjunction with a high exhaust gas temperature can lead to very hard deposits on the nozzle ring and particularly on the gas outlet flange. ABB Turbo Systems recommends the use of fuels with low ash, sulphur, sodium and vanadium contents. Consequences of contamination: ...
Page 78 The time period between the periodical cleaning cycles depends greatly on the operating conditions. Cleaning should normally be done every 50 to 200 hours of operation. If the specified cleaning intervals are incompatible with operation of the engine, contact ABB Turbo Systems.
Page 79 Water flow meter Even with the water pressure being observed, the volume of water may be too low due to a blockage. ABB Turbo Systems recommends the installation NOTICE of a water flow meter.
Page 80 Corrosion and deposits when cleaning Salt water and cooling water treatment substances damage and adversely affect turbocharger parts. CAUTION Never use salt water, but only pure water for cleaning.  © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 81 The cleaning cycle can be started when the above conditions are fulfilled. 6.3.2 Procedure for wet-cleaning the turbine If the cleaning result is unsatisfactory or there is water leakage, contact an ABB Turbocharging Service Station. Maximum turbine inlet temperature during cleaning During cleaning, the turbine inlet temperature will rise and may strain the material significantly.
Page 82: Cleaning Components Mechanically
Use only soft tools such as rags, brushes or wire brushes.  In case of heavy contamination, the described cleaning methods (such as  soaking, for example) can be applied repeatedly until a satisfactory result is achieved. © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 83 The disassembly and assembly of the components is described in chapter Disassembly and assembly. NOTICE Dirty water and cleaning agents must be disposed of in an environmentally compatible,  professional way and in compliance with locally applicable regulations. © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 84 (water jet). Let the filter ring dry completely before assembling.  Dirty water and mild detergent must be disposed of in compliance with locally applicable  regulations. © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 85  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. Have any heavily contaminated absorption segments replaced by an ABB Turbocharging  Service Station.
Page 86 Spray cleaned surfaces with penetrating oil. Do not spray exterior surfaces of the  turbocharger. Dispose of dirty water and cleaning agents in accordance with the information in the  material safety data sheet. © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 87 Use clean water to completely clean parts of any solvents.  Dry components completely.  Spray cleaned surfaces with penetrating oil. Do not spray exterior surfaces of the  turbocharger. © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 88 Remove turbocharger from engine (see chapter Removal and installation [➙ 9]).  Remove cartridge group (see chapter Disassembly and assembly [➙ 71]).  First clean the compressor end and then the turbine end according to the following description. © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 89 Lightly spray the compressor wheel and the gap between the compressor and the bearing  casing with penetrating oil. Dispose of dirty water and cleaning agents in accordance with the material safety data  sheet. © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 90 Cleaning agents which contain chlorine attack metals. Use only pH-neutral cleaning agents which do not attack metals.  CAUTION Observe safety data sheet.  Fill the container (02) with soaking fluid.  © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 91 Wear safety gloves against mechanical risks. Lift up the cartridge group and align it horizontally.  Remove dirt manually using a soft brush or a wire brush.  © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 92 Lightly spray the turbine and the gap between the turbine and the partition wall with  penetrating oil. Dispose of dirty water and cleaning agents in accordance with the information in the  material safety data sheet. © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 93: Troubleshooting
To prevent significant loss of efficiency, specific tolerances must be fulfilled.  If there is any doubt about the extent of the rubbing, contact an ABB Turbocharging Service Station.  Have a dimension check carried out by an ABB Turbocharging Service Station.
Page 94: Malfunctions During Operation
Possible causes Remedy Turbocharger Light to medium contamination of the Clean (see chapter Periodic maintenance turbine and/or nozzle ring (with 4-stroke [➙ 43]) or contact an ABB Turbocharging application) Service Station Table 18 © Copyright 2014 ABB. All rights reserved.
Page 95 Exhaust gas back pressure too high Clean or repair the boiler or the exhaust gas silencer Pipes Pipes downstream to the compressor Repair. outlet not sealed. Table 20 © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 96 Material of the compressor wheel Prevent exhaust gas leakages in the engine space corroded due to intake air containing exhaust gases or salt Clean (see chapter Periodic maintenance [➙ 43]) Table 23 © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 97: Surging Of The Turbocharger
If the turbocharger surges continuously or periodically, parts of it can be damaged. CAUTION Slowly reduce the engine load.  Have the cause clarified immediately by an ABB Turbocharging service  station and rectified. Have components inspected for damage and, if necessary, replaced by ...
Page 98: Malfunctions When Stopping
Bearing damaged Check clearances (see chapter Axial clearance A and radial clearance B [➙ 83]). If clearances are outside the tolerance or if in doubt, contact an ABB Turbocharging Service Station. Rotor rubbing Check clearances (see chapter Radial clearances N and R [➙...
Page 99: Speed Measurement System
Other causes of If none of the measures described above remedy the malfunction malfunction, it is recommended to have the speed measurement system checked by an ABB Turbocharging Service Station. Table 27 © Copyright 2014 ABB. All rights reserved. HZTL4031_EN...
Page 101: Disassembly And Assembly
ABB Turbo Systems recommends having further operations carried out  only by trained staff or an ABB Turbocharging Service Station. Marking casing position for assembly ABB Turbo Systems recommends marking the casing positions prior to disassembly.
Page 102 [➙ 90]). Tightening torques for assembly devices Unless described otherwise, the screws and nuts of the assembly devices supplied by ABB Turbo Systems must be tightened so they rest firmly against the surface. © Copyright 2014 ABB. All rights reserved.
Page 103  Lifting gear Equipment for the lifting and transporting of loads (ropes, chain block, crane). Lifting gear is not supplied by ABB Turbo Systems. Swivel lifting eyes to be used Two swivel lifting eyes are required for the safe lifting of loads, which are not supplied by ABB Turbo Systems.
Page 104: Weights Of Assemblies
Burst ring Turbine casing * 1 inlet Turbine casing * 2 inlets Turbine casing * 3 inlets Gas outlet flange Gas outlet casing Table 29 * Including burst protection © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 105: Removing / Installing Air-Inlets
(82000) with the O-ring (82010). Installing air inlets Fit the filter silencer (81000) or air suction branch (82000) with the V-clamp (72020).  (Table of tightening torques [➙ 90]) © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 106: Removing / Installing Compressor Casing
3. Remove the compressor casing (72000) and turn it 180°. 4. Remove O-ring (42012). 5. Loosen screws (79041) and remove from the compressor casing (72000) with fixing discs (79040) and diffuser (79000). © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 107 1. Knock the wall insert (77000) out of the compressor casing (72000) with a nylon hammer. 2. Attach swivel lifting eyes (01) to compressor casing (72000) and lifting gear. 3. Lift up the compressor casing (72000). 4. Remove O-ring (77005). © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 108 2. Secure the diffuser (79000) with fixing discs (79040) and screws (79041). A145 1. Attach the lifting beam (90258) to the wall insert (77000). 2. Attach swivel lifting eyes (01) to lifting beam. (Table of tightening torques [➙ 90]) © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 109 2. Attach swivel lifting eyes (01) to the compressor casing (72000) and lifting gear. 3. Install compressor casing (72000). 4. Install the fastening strips (72012) with screws (72011). (Table of tightening torques [➙ 90]) © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 110: Removing The Cartridge Group
WARNING Make sure the surface for the loop on the cartridge group is free from oil.  Wear safety gloves against mechanical risks. Wear safety helmet. © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 111 After the nozzle ring has been removed, the cartridge group can be placed on the service  support (90012). Measure: Axial clearance A and radial clearance B [➙ 83].  © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 112 4. Remove the burst ring (57210). Fixing the cartridge group in place Figure 36 1. Fit service support (90012) according to the illustration. 2. Fasten the cartridge group on the service support (90012). © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 113: Axial Clearance A And Radial Clearance B
Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. CAUTION Have the components assessed and, if necessary, replaced by an ABB  Turbocharging Service Station. Measure and record clearances A and B after the removal and before the installation of the ...
Page 114: Installing The Cartridge Group
-0.16 ... 0.16 A140 -0.16 ... 0.16 A145 -0.16 ... 0.16 Table 31 If the calculated value (PD) lies outside the specified range, contact an ABB Turbocharging  Service Station. © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B...
Page 116 4. Carefully lower the cartridge group into the turbine casing. 5. Secure fastening strips (51002) together with nuts (51007) and Verbus Ripp® washers (51003). (Table of tightening torques [➙ 90]) © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 117 (2), a separate burst protection (3) is fitted. If the insulation from ABB Turbo Systems (1) is not installed, the separate burst protection (3) plus either the insulation (2) or an appropriate insulation supplied by the enginebuilder must be installed for operation.
Page 118: Removing / Installing Gas Outlet Casing
6x M10 A145 6x M12 Table 32 *Not included in the ABB Turbo Systems scope of delivery. Installing the gas outlet casing and gas outlet flange If present: Insert metal C-ring (57003) into the turbine casing and secure with high-vacuum ...
Page 119: Radial Clearances N And R
Clearances outside the tolerance Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. CAUTION Have the components assessed and, if necessary, replaced by an ABB  Turbocharging Service Station. Figure 43 1.
Page 120: Table Of Tightening Torques
A145 72020 79041 51007 51009 72011 86505 M12 x 1.5 M12 x 1.5 M12 x 1.5 M12 x 1.5 51101 / 51103 / 51104 / 61201 Table 34 © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 121 Page 91 / 103 Figure 45 The following tightening torques must be observed for the designated screw fittings: Tightening torques [Nm] Item Part number A130 A135 A140 A145 Table 35 © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 123: Taking Out Of Operation At Short Notice
 If present: Installing a replacement cartridge group [➙ 94].  If a replacement turbocharger or cartridge group is not available: Fitting the cover plate [➙ 95] and contact an ABB Turbocharging Service Station. Observe the following sections in connection with the emergency repairs mentioned.
Page 124: Installing A Replacement Turbocharger
The repair of a cartridge group requires special tools and the expertise of an ABB Turbocharging Service Station. The rotating parts turn very fast and are very sensitive to unbalance.
Page 125: Fitting The Cover Plate
3. Coat the threads of the studs (51006) with high-temperature grease. 4. Fasten cover plate (01) to turbine casing (51000) with fastening strips (51002), Verbus Ripp® washers (51003) and nuts (51007) and screw to bracket. © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B...
Page 126 9.4.1 Cover plate drawing The cover plate is not included in the ABB Turbo Systems scope of delivery and must be manufactured by the operating company according to the following drawing. Material: General structural steel, in compliance with DIN EN 10025-2.
Page 127: Mothballing The Turbocharger
If the total acid number (TAN) is greater than 2 mg KOH/g, the following mothballing measures are necessary after taking an engine out of operation: Dismantle the turbocharger.  The rotor and the bearing parts must be removed by an official ABB Turbocharging service  station and refitted afterwards. Clean all parts.
Page 128: Taking The Engine Out Of Operation For More Than 12 Months
 The casings of the turbocharger remain attached to the engine, the rotor and bearing parts are dismantled by an ABB Turbocharging Service Station and stored separately  The turbocharger has been completely removed, either as a whole unit or in individual...
Page 129: Disposing Of Turbocharger Components
Dispose of non-metallic materials as waste.  Dispose of residues of lubricants as waste oil.  Dispose of electronic components as electronic waste.  Dispose of thermal insulation as hazardous waste.  © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 131: Spare Parts
81010/ 82010 O-ring Table 37 * This gasket can only be installed when a gas outlet casing from ABB Turbo Systems is used. Dispose of replaced parts and parts that are not reusable in a professional and  environmentally compatible manner.
Page 132: View Of Turbocharger With Part Numbers
Operation Manual / 4 Product description / A130-M.. - A145-M.. Spare parts Page 102 / 103 12.2 View of turbocharger with part numbers Figure 48 © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...
Page 133 82010 (in the customer spare part set) O-ring 86505* Speed sensor 86515* Cable connector 86526* F/I converter 86528* Tachometer Table 38 * Depending on the specification of the turbocharger © Copyright 2014 ABB. All rights reserved. HZTL4031_EN Revision B October 2014...

ABB A130-M56 Operation Manual

Introduction

Safety

Table of Contents

1 Introduction

2 Removal and Installation

3 Commissioning

4 Monitoring During Operation

5 Operation and Service

6 Periodic Maintenance

7 Troubleshooting

8 Disassembly and Assembly

9 Taking out of Operation at Short Notice

10 Mothballing the Turbocharger

11 Disposing of Turbocharger Components

12 Spare Parts

Quick Links

Chapters

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Summary of Contents for ABB A130-M56

Table of Contents