ABB HT607515 User manual

Turbocharging
Operation Manual / A150-M67
HT607515
Document identification
Document number HZTL4032
Revision R
Language English
Original Operation Manual
Product identification
Serial number HT607515
Customer part number
Delivery date (yyyy-mm-dd) 2021-10-29
Weight 1200 kg
Operating limits according to rating plate
Speed limit in test rig operation only nMmax 547 1/s
Speed limit during operation nBmax 544 1/s
Gas inlet temperature limit in test rig operation only tMmax 630 °C
Gas inlet temperature limit during operation tBmax 600 °C

Operation Manual / A150-M56/66/57/67 - A155-M..
Table of contents
© Copyright 2021 ABB. All rights reserved. HZTL4032_EN Rev.R August 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....................................................................................... 34
4 Commissioning .................................................................................................... 40
4.1 Oil supply ...................................................................................................................... 40
4.2 Inspection procedures............................................................................................... 42
4.3 Commissioning after taking out of operation...................................................... 44
5 Monitoring operation .......................................................................................... 45
5.1 Oil pressure, oil temperature.................................................................................... 45
5.2 Exhaust gas temperature before turbine .............................................................. 47
5.3 Turbocharger speed................................................................................................... 48
6 Operation and service ......................................................................................... 51
6.1 Noise emission ............................................................................................................. 51
6.2 Service work................................................................................................................. 53
6.3 Expected replacement intervals .............................................................................. 56

Operation Manual / A150-M56/66/57/67 - A155-M..
Table of contents
© Copyright 2021 ABB. All rights reserved. HZTL4032_EN Rev.R August 2021
6.4 Stopping the engine................................................................................................... 58
7 Periodic maintenance work ................................................................................ 59
7.1 Foreword to maintenance......................................................................................... 59
7.2 Cleaning the compressor during operation .......................................................... 60
7.3 Cleaning the turbine during operation................................................................... 63
7.4 Cleaning components mechanically ....................................................................... 67
7.5 Changing the absorption element .......................................................................... 80
8 Eliminating malfunctions.................................................................................... 82
8.1 Malfunctions when starting...................................................................................... 82
8.2 Malfunctions during operation ................................................................................ 83
8.3 Turbocharger is surging............................................................................................ 86
8.4 Malfunctions when stopping.................................................................................... 87
8.5 Speed measurement system.................................................................................... 88
9 Dismantling and fitting, general........................................................................ 89
9.1 Introduction ................................................................................................................. 89
9.2 Material required......................................................................................................... 90
9.3 Disassembly and assembly concepts ..................................................................... 93
9.4 Weights of individual parts....................................................................................... 96
9.5 Table of tightening torques...................................................................................... 97
10 Dismantling and fitting with removed air inlet and gas outlet ..................... 99
10.1 Removing air inlets..................................................................................................... 99
10.2 Removing the gas outlet casing ............................................................................. 101
10.3 Removing the gas outlet flange............................................................................. 104
10.4 Removing the cartridge group with compressor and turbine casing............ 107
10.5 Removing the compressor casing......................................................................... 109
10.6 Removing the cartridge group................................................................................ 111
10.7 Installing the cartridge group on the service support ....................................... 114
10.8 Removing the nozzle ring ......................................................................................... 115
10.9 Measuring clearance A and B................................................................................... 116
10.10 Nozzle ring compression PD.................................................................................... 117
10.11 Installing nozzle ring ................................................................................................. 118
10.12 Installing the cartridge group ................................................................................. 119
10.13 Installing the compressor casing ........................................................................... 122
10.14 Turning the cartridge group with compressor and turbine casing................. 124
10.15 Installing the gas outlet flange ............................................................................... 125
10.16 Radial clearances N and R......................................................................................... 126
10.17 Fitting the insulation................................................................................................. 127
10.18 Installing the cartridge group with compressor and turbine casing .............. 128
10.19 Installing the gas outlet casing............................................................................... 129
10.20 Installing air inlets ..................................................................................................... 132
11 Dismantling and fitting, cartridge concept ................................................... 134
11.1 Removing air inlets ................................................................................................... 134
11.2 Removing the compressor casing.......................................................................... 136

Operation Manual / A150-M56/66/57/67 - A155-M..
Table of contents
© Copyright 2021 ABB. All rights reserved. HZTL4032_EN Rev.R August 2021
11.3 Removing the cartridge group................................................................................ 139
11.4 Removing the nozzle ring ......................................................................................... 142
11.5 Measuring clearance A and B.................................................................................. 143
11.6 Nozzle ring compression PD................................................................................... 144
11.7 Installing nozzle ring ................................................................................................ 145
11.8 Installing the cartridge group ................................................................................ 146
11.9 Installing the compressor casing .......................................................................... 148
11.10 Radial clearances N and R........................................................................................ 150
11.11 Fitting the insulation................................................................................................. 151
11.12 Installing air inlets ..................................................................................................... 152
12 Dismantling and fitting, special tools for fastening strips ......................... 154
12.1 Application, special tools ......................................................................................... 155
13 Removing and installing 6-nozzle turbine cleaning component (optional) ......
162
13.1 Disassembly................................................................................................................ 162
13.2 Assembly .................................................................................................................... 165
14 Fitting the cleaning nozzles with multi-inlet turbine casings...................... 168
15 Taking out of operation at short notice ......................................................... 169
15.1 Possible emergency repairs.................................................................................... 169
15.2 Installing the replacement turbocharger............................................................. 170
15.3 Installing the replacement cartridge group ........................................................ 170
15.4 Fitting the cover plate............................................................................................... 171
15.5 Cover plate drawing .................................................................................................. 172
16 Mothballing the turbocharger.......................................................................... 174
16.1 Taking the engine out of operation for up to 12months .................................. 174
16.2 Taking the engine out of operation for more than 12months ......................... 175
17 Material and Disposal........................................................................................ 176
17.1 REACH and RoHS Compliance Declaration For Products .................................. 176
17.2 Disposing of turbocharger components .............................................................. 177
18 Spare parts ......................................................................................................... 178
18.1 Ordering spare parts................................................................................................. 178
18.2 Required customer spare part set (97070)........................................................... 178
18.3 Spare part – Illustrations.......................................................................................... 179
19 Tools .................................................................................................................... 192
Figures................................................................................................................. 194
Tables .................................................................................................................. 197