Operation Manual A175-M62 HT575729 English Original Operation Manual Chapter Document-ID Introduction HZTL4005_EN_F Safety HZTL4023_EN_D Safety data sheet HT575729 Product description HZTL4033_EN_B ABB Turbocharging...
Operating limits and replacement intervals The recommended replacement intervals and the corresponding operating limits in chapter 3 are jointly defined with the enginebuilder. This information is specific to the product. Non-observance of the recommended replacement intervals and the operating limits increases the risk of unpre- dictable component failures.
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 Sta- tions. They are regularly audited and certified by ABB Turbo Systems. Also see chapter Con- tact information →7.
Check the package for damage. If the package is damaged, the turbocharger or cartridge group must be checked and repackaged by an ABB Turbocharging Service Station. After every 3 years, the following steps must be carried out by an ABB Turbocharging Service Station: ¡...
Operation Manual / 1 Introduction 1 Introduction / 1.4 Contact information Contact information Contact information for the ABB Turbocharging Service Stations is available online. Scan the QR code to access our website. ABB Turbo Systems Ltd Bruggerstrasse 71a CH-5401 Baden Switzerland www.abb.com/turbocharging...
Safety Introduction Turbochargers manufactured by ABB reflect the state of the art. The respective safety and health protection requirements are met. This ensures safe operation of the turbocharger. Nevertheless, there may be some residual risks during operation of and work on the tur- bocharger which: ¡...
These data are given on the rating plate. ABB accepts no liability and rejects all warranty claims for any non-intended uses. Euromot = The European Association of Internal Combustion Engine Manufacturers Directive 94/9/EC concerning equipment and protective systems intended for use in po-...
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.
The locations of the rating plates are defined in the Operation Manual, Chapter 4 Product description. 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". ¡...
This document is valid for different design variants of turbochargers. There may be sections and descriptions of components that are not relevant for a specific turbocharger variant. Please contact an ABB Turbocharging Service Station if you have any questions regarding a design variant (see Contact information at www.abb.com/turbocharging).
If warning plates are not present in the designated locations or not readable, proceed as fol- lows: Order new warning plates from ABB Turbocharging Service Stations. Remove any warning plates that have become unreadable. Clean and degrease the areas designated for the warning plates.
One rating plate each is attached on the left and the right side of the foot of the turbochar- ger. On turbochargers with insulation from ABB Turbo Systems, at least one additional rating plate is attached to the insulation of the gas outlet casing.
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. If there is a leak, contact an ABB Turbocharging Service Station. Commissioning after taking out of operation...
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 Turbo Systems recommends installing a manometer "M". If the pressure is controlled electronically, the appropriate signals are to be triggered at the warning and alarm values.
NOTICE 5-year service inspection To prevent machine damage caused by ageing and downtime, we recom- mend having an inspection carried out by an ABB Turbocharging Service Sta- tion no later than 5 years after the last service. 5.2.1 Service work every 25 … 50 hours Visual check for air, exhaust gas, water and oil leaks.
5 Operation and service / 5.2 Service work 5.2.3 Service work every 8000 ... 12000 hours of operation Checking and assessment of the rotor and the bearing parts must be carried out by an ABB Turbocharging Service Station. Dismantle the turbocharger.
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 (see Fig. 20: Cleaning the filter silencer (1) →33)
The use of fuels with poor quality in conjunction with high exhaust gas temperatures can lead to extremely hard deposits on turbine components. ABB Turbo Systems recommends the use of fuels with low ash, sulphur, sodium and vana- dium contents.
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 Turbo Systems: ¡ 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: ¡...
Wet cleaning of turbine and nozzle ring Prerequisites The following operating state and the following prerequisites have been tested and ap- proved by ABB Turbo Systems for cleaning operations: Set the engine load between 20 … 50 % so that the turbine inlet temperature is between 380 … 430 °C.
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 ¡...
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.
Remedy Turbocharger Heavy contamination of the turbine and/ Clean (see chapter Periodic maintenance →33) or nozzle ring Damaged rotor components or bearing Contact ABB Turbocharging Service Sta- tion Engine Defect on the connected cylinders in Contact enginebuilder pulse charging Pipes...
Gradually reduce the engine load. Have the cause clarified and remedied immediately by an ABB Turbochar- ging Service Station. Have parts assessed for damage and, if necessary, replaced by an ABB Turbocharging Service Station. Sporadic surge blows Surging of the turbocharger can occur during certain operating states, such as when redu- cing the engine load quickly when manoeuvring.
Clearances outside the tolerance Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Tur- bocharging Service Station. Fig. 28: Axial clearance...
Blocked areas on nozzle ring If a nozzle ring is blocked in some areas or is covered by loose parts, we would recommend appointing an ABB Turbocharging Service Station to inspect the turbine blades and carry out a crack inspection.
Clearances outside the tolerance Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Tur- bocharging Service Station. Fig. 56: Axial clearance...
Blocked areas on nozzle ring If a nozzle ring is blocked in some areas or is covered by loose parts, we would recommend appointing an ABB Turbocharging Service Station to in- spect the turbine blades and carry out a crack inspection.
Removing the cartridge group →59). 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 %.
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: Dismantle the turbocharger. The rotor and bearing parts must be dismantled and subsequently refitted by an ABB Tur- bocharging Service Station. Clean all parts.
¡ The casings of the turbocharger remain attached to the engine, the rotor and bearing parts are dismantled by an ABB Turbocharging Service Station and stored separately ¡ The turbocharger 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...
Designation and part number. Spare parts can be ordered from any ABB Turbocharging Service Station. If different model variants are not taken into account in this document, contact an ABB Turbocharging Service Station. Dispose of placed and unusable parts in an environmentally-friendly and professional manner in accordance with the local regulations.