ABB A155-M66 User manual

Turbocharging
Operation Manual / A155-M66
HT604673
Document identification
Document number HZTL4032
Revision Q
Language English
Original Operation Manual
Product identification
Serial number HT604673
Customer part number HZTL53377I
Delivery date (yyyy-mm-dd) 2021-07-15
Weight 1800 kg
Operating limits according to rating plate
Speed limit in test rig operation only nMmax 466 1/s
Speed limit during operation nBmax 455 1/s
Gas inlet temperature limit in test rig operation only tMmax 650 °C
Gas inlet temperature limit during operation tBmax 620 °C

Operation Manual / A150-M56/66/57/67 - A155-M..
Table of contents
© Copyright 2021 ABB. All rights reserved. HZTL4032_EN Rev.Q January 2021
Operation Manual / A150-M.. - A155-M..
1 Introduction............................................................................................................ 4
1.1 Purpose of the manual................................................................................................. 4
1.2 Contact information...................................................................................................... 5
1.3 Essential information.................................................................................................... 5
1.4 Layout and function of the turbocharger ................................................................ 6
1.5 Symbols, definitions..................................................................................................... 8
1.6 Storage of new turbochargers and spare parts .................................................... 10
1.7 Registered trademarks............................................................................................... 12
2 Safety .................................................................................................................... 13
2.1 Introduction .................................................................................................................. 13
2.2 CE conformity............................................................................................................... 13
2.3 Definition of mandatory signs .................................................................................. 14
2.4 Definition of safety instructions .............................................................................. 14
2.5 Intended use ................................................................................................................. 15
2.6 Warning plates on the turbocharger........................................................................ 16
2.7 Turbocharger rating plate.......................................................................................... 17
2.8 Periodic check of the pressure vessels.................................................................... 19
2.9 Lifting of loads ............................................................................................................ 20
2.10 Prerequisites for operation and maintenance....................................................... 21
2.11 Hazards during operation and maintenance ......................................................... 22
2.12 Safe operation............................................................................................................. 24
2.13 Safe maintenance ....................................................................................................... 25
3 Removing and Installing...................................................................................... 29
3.1 Turbocharger weight and transportation ............................................................. 29
3.2 Removing the turbocharger...................................................................................... 30
3.3 Installing the turbocharger....................................................................................... 33
4 Commissioning .................................................................................................... 39
4.1 Oil supply ...................................................................................................................... 39
4.2 Inspection procedures................................................................................................ 41
4.3 Commissioning after taking out of operation...................................................... 43
5 Monitoring operation .......................................................................................... 44
5.1 Oil pressure, oil temperature.................................................................................... 44
5.2 Exhaust gas temperature before turbine .............................................................. 46
5.3 Turbocharger speed................................................................................................... 47
6 Operation and service ......................................................................................... 50
6.1 Noise emission ............................................................................................................ 50
6.2 Service work................................................................................................................. 52

Operation Manual / A150-M56/66/57/67 - A155-M..
Table of contents
© Copyright 2021 ABB. All rights reserved. HZTL4032_EN Rev.Q January 2021
6.3 Expected replacement intervals .............................................................................. 55
6.4 Stopping the engine.................................................................................................... 57
7 Periodic maintenance work ................................................................................ 58
7.1 Foreword to maintenance......................................................................................... 58
7.2 Cleaning the compressor during operation .......................................................... 59
7.3 Cleaning the turbine during operation................................................................... 62
7.4 Cleaning components mechanically ....................................................................... 66
7.5 Changing the absorption element .......................................................................... 76
8 Eliminating malfunctions.................................................................................... 78
8.1 Malfunctions when starting...................................................................................... 78
8.2 Malfunctions during operation ................................................................................ 79
8.3 Turbocharger is surging............................................................................................ 82
8.4 Malfunctions when stopping.................................................................................... 83
8.5 Speed measurement system.................................................................................... 84
9 Dismantling and fitting, general........................................................................ 85
9.1 Introduction ................................................................................................................. 85
9.2 Material required......................................................................................................... 86
9.3 Disassembly and assembly concepts ..................................................................... 89
9.4 Weights of individual parts....................................................................................... 92
9.5 Table of tightening torques...................................................................................... 93
10 Dismantling and fitting with removed air inlet and gas outlet ..................... 95
10.1 Removing air inlets..................................................................................................... 95
10.2 Removing the gas outlet casing .............................................................................. 97
10.3 Removing the gas outlet flange............................................................................. 100
10.4 Removing the cartridge group with compressor and turbine casing............ 103
10.5 Removing the compressor casing......................................................................... 105
10.6 Removing the cartridge group............................................................................... 107
10.7 Installing the cartridge group on the service support ....................................... 110
10.8 Removing the nozzle ring ......................................................................................... 111
10.9 Measuring clearance A and B................................................................................... 112
10.10 Nozzle ring compression PD.................................................................................... 113
10.11 Installing nozzle ring ................................................................................................. 114
10.12 Installing the cartridge group ................................................................................. 115
10.13 Installing the compressor casing ........................................................................... 118
10.14 Turning the cartridge group with compressor and turbine casing................ 120
10.15 Installing the gas outlet flange ............................................................................... 121
10.16 Radial clearances N and R......................................................................................... 122
10.17 Fitting the insulation................................................................................................. 123
10.18 Installing the cartridge group with compressor and turbine casing .............. 124
10.19 Installing the gas outlet casing............................................................................... 125
10.20 Installing air inlets ..................................................................................................... 128

Operation Manual / A150-M56/66/57/67 - A155-M..
Table of contents
© Copyright 2021 ABB. All rights reserved. HZTL4032_EN Rev.Q January 2021
11 Dismantling and fitting, cartridge concept ................................................... 130
11.1 Removing air inlets ................................................................................................... 130
11.2 Removing the compressor casing.......................................................................... 132
11.3 Removing the cartridge group................................................................................ 135
11.4 Removing the nozzle ring ......................................................................................... 138
11.5 Measuring clearance A and B................................................................................... 139
11.6 Nozzle ring compression PD................................................................................... 140
11.7 Installing nozzle ring ................................................................................................. 141
11.8 Installing the cartridge group ................................................................................. 142
11.9 Installing the compressor casing .......................................................................... 144
11.10 Radial clearances N and R........................................................................................ 146
11.11 Fitting the insulation................................................................................................. 147
11.12 Installing air inlets .................................................................................................... 148
12 Dismantling and fitting, special tools for fastening strips ......................... 150
12.1 Application, special tools ......................................................................................... 151
13 Removing and installing 6-nozzle turbine cleaning component (optional) ......
158
13.1 Disassembly............................................................................................................... 158
13.2 Assembly ..................................................................................................................... 161
14 Fitting the cleaning nozzles with multi-inlet turbine casings...................... 164
15 Taking out of operation at short notice ......................................................... 165
15.1 Possible emergency repairs.................................................................................... 165
15.2 Installing the replacement turbocharger............................................................. 166
15.3 Installing the replacement cartridge group ........................................................ 166
15.4 Fitting the cover plate............................................................................................... 167
15.5 Cover plate drawing ................................................................................................. 168
16 Mothballing the turbocharger.......................................................................... 170
16.1 Taking the engine out of operation for up to 12months ................................. 170
16.2 Taking the engine out of operation for more than 12months ......................... 171
17 Disposing of turbocharger components ........................................................ 172
18 Spare parts ......................................................................................................... 173
18.1 Ordering spare parts................................................................................................. 173
18.2 Required customer spare part set (97070)........................................................... 173
18.3 Spare part – Illustrations.......................................................................................... 174
19 Tools .................................................................................................................... 188
Figures................................................................................................................. 190
Tables .................................................................................................................. 193