ABB A135-M65 User manual

Operation Manual
ABB Turbocharging 
Type A135-M65 HT611391
nMmax 893 t Mmax 630
nBmax 873 t Bmax 600
1/s °C
00300 8 50 50
Year 2022 Application according to the Operation Manual
kg
HZTL2413 English
A135-M65
Original Operation Manual

Operating condition and replacement intervals
The operational limits for the turbocharger nBmax, tBmax, nMmax, tMmax, inspection- and replacement intervals for the compon-
ents concerned on the rating plate are valid for the operational mode and compressor inlet condition, which has been agreed upon
between the engine builder and ABB.
Note: Replacement intervals of components depends on the load profile, turbine inlet temperature, suction air temperature and
turbocharger speed. In case the operation conditions differs significantly from what is considered to be normal for the cur-
rent application, it is recommended to contact ABB for a re-calculation of replacement intervals. Frequent load alterations,
high temperatures and high speed lower the life of components.
Unless otherwise agreed, the application limits nMmax, tMmax are valid for the test operation for a limited time.

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Contents
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Table of contents
1
Preliminary remarks................................................................................
5
1.1
Purpose of the manual...............................................................................
5
1.2
Symbols, definitions, contact address ........................................................
6
2
Safety.....................................................................................................
7
2.1
Introduction................................................................................................
7
2.2
Definition of safety instructions...................................................................
7
2.3
Warning plates on the turbocharger ...........................................................
8
2.4
Safe operation and maintenance ...............................................................
8
2.5
Hazards during operation and maintenance...............................................
12
2.6
Periodic check of the pressure vessels ......................................................
16
2.7
Use of ABB turbochargers on gas engines.................................................
17
2.8
Lifting of loads............................................................................................
18
3
Introduction ............................................................................................
19
3.1
Essential information..................................................................................
19
3.2
Layout and function of the turbocharger.....................................................
20
3.3
Storage of new turbochargers and cartridge groups...................................
22
3.4
Intended use..............................................................................................
23
3.5
Prerequisites for operation .........................................................................
25
3.6
Turbocharger rating plate...........................................................................
26
3.7
CE conformity ............................................................................................
27
4
Removal and installation .........................................................................
29
4.1
Transport ...................................................................................................
29
4.2
Turbocharger weight ..................................................................................
29
4.3
Removing the turbocharger........................................................................
30
4.4
Installing the turbocharger..........................................................................
33
5
Commissioning.......................................................................................
41
5.1
Oil supply...................................................................................................
41
5.2
Inspection procedures................................................................................
42
5.3
Commissioning after taking out of operation ..............................................
45
6
Monitoring during operation.....................................................................
47
6.1
Oil pressure, oil temperature......................................................................
47
6.2
Turbocharger speed...................................................................................
49

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B
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7
Operation and service.............................................................................
53
7.1
Noise emission...........................................................................................
53
7.2
Service work ..............................................................................................
54
7.3
Expected replacement intervals .................................................................
57
7.4
Stopping the engine ...................................................................................
58
8
Periodic maintenance .............................................................................
59
8.1
Foreword to maintenance...........................................................................
59
8.2
Cleaning the compressor during operation.................................................
60
8.3
Cleaning the turbine during operation.........................................................
63
8.4
Cleaning components mechanically ...........................................................
66
9
Troubleshooting......................................................................................
73
9.1
Malfunctions when starting.........................................................................
73
9.2
Malfunctions during operation ....................................................................
74
9.3
Surging of the turbocharger........................................................................
77
9.4
Malfunctions when stopping .......................................................................
78
9.5
Speed measurement system......................................................................
79
10
Disassembly and assembly .....................................................................
81
10.1
Introduction ................................................................................................
81
10.2
Weights of assemblies ...............................................................................
83
10.3
Removing / Installing air-inlets....................................................................
84
10.4
Removing / Installing compressor casing ...................................................
85
10.5
Removing the cartridge group ....................................................................
89
10.6
Installing the cartridge group ......................................................................
94
10.7
Removing / Installing gas outlet casing ......................................................
97
10.8
Radial clearances N and R.........................................................................
98
10.9
Axial clearance A and radial clearance B ...................................................
100
10.10
Table of tightening torques.........................................................................
101
11
Taking out of operation at short notice .....................................................
103
11.1
Possible emergency repairs .......................................................................
103
11.2
Installing a replacement turbocharger ........................................................
104
11.3
Installing a replacement cartridge group.....................................................
104
11.4
Fitting the cover plate.................................................................................
105
12
Mothballing the turbocharger...................................................................
107
12.1
Taking the engine out of operation for up to 12 months..............................
107
12.2
Taking the engine out of operation for more than 12 months......................
108

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13
Disposing of turbocharger components....................................................
109
14
Spare parts.............................................................................................
111
14.1
Ordering spare parts ..................................................................................
111
14.2
View of turbocharger with part numbers.....................................................
112

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Preliminary remarks
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1 Preliminary remarks
1.1 Purpose of the manual
Figure 1
This Operation Manual belongs to the turbocharger with the identical HT number (1), see the
Operation Manual cover sheet and the turbocharger rating plate.
Operation Manual
This Operation Manual will familiarise you with the turbocharger of ABB Turbo Systems and
provides information on how to use it in compliance with its intended purpose.
The Operation Manual explains what is important to know in order to operate the turbocharger
safely, appropriately and profitably.
The Operation Manual is a complement to and expansion of existing national regulations for
occupational safety and accident prevention.
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
An 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.

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Preliminary remarks
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sion B
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1.2 Symbols, definitions, contact address
Symbols
The following symbols are used in the documents:
Step of a procedure
List, first level
– List, second level
[➙ ] see page
Definition of Note
Note
The note provides advice to facilitate working with the product.
Definition of Caution / Warning
Caution and warning signs are described in chapter Safety.
ABB Turbo Systems
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.
Contact address
ABB Turbo Systems AG
Bruggerstrasse 71a
CH-5401 Baden
Switzerland
www.abb.com/turbocharging
Customer service
The Contact Information brochure includes a global overview of the official ABB Tur-
bocharging Service Stations.
NOTICE

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Safety
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2 Safety
2.1 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:
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 the organisational measures that regulate the safe
handling of the turbocharger by its personnel.
All instructions contained in this chapter must be observed for safe and trouble-free operation
of the turbocharger and during all work on the turbocharger.
All further safety instructions contained and specifically identified in every chapter of this ma-
nual (Definition of safety instructions [➙ 7]) must also be observed.
2.2 Definition of safety instructions
The following symbols and nomenclature are used in this manual, referring to safety or indi-
cating potential hazards:
Definition of Warning
Non-compliance or inaccurate compliance with working or operating instruc-
tions indicated by this symbol and the word
WARNING
can lead to serious
injuries to personnel and even to fatal accidents.

Warning signs must always be observed.
Definition of Caution
Non-compliance or inaccurate compliance with working or operating instruc-
tions indicated by this symbol and the word
CAUTION
can lead to serious
damage to engine or property with grave consequences.

Caution signs must always be observed
.
WARNING
CAUTION

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2.3 Warning plates on the turbocharger
Warning plates are affixed at the following locations on the turbocharger:
Figure 2: ≤ A145
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.
Clean and degrease the areas designated for the warning plates.
Attach the new warning plates.
Non-insulated turbochargers
Turbochargers supplied to the enginebuilder without insulation must be equipped later with
warning plates to be attached to the insulation. This is the responsibility of the enginebuilder.
2.4 Safe operation and maintenance
The instructions specified in this section are for the safety of personnel. Together with the in-
structions in section "Hazards during operation and maintenance" of this chapter, they allow
the user to safely use the turbocharger.

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Occupational safety and safety at the workplace
Risk of falling
When working on the turbocharger, there is a risk of falling.
Do not climb onto the turbocharger or onto attached parts and do not use
them as climbing aids.
Use suitable climbing aids and working platforms for work above body
height.
Comply with the general accident prevention regulations.
Only perform work on the turbocharger when you are in a physically and psychologically
stable condition.
Wear appropriate protective equipment, such as:
Helmet
Hearing protection
Safety goggles
Safety gloves
Safety boots
Protective clothing
Hair net (for long hair)
Respirator mask
Only work with suitable tools and with equipment and appliances that function properly.
Power tools must be properly earthed and cables must be undamaged.
Keep the workplace clean; clear away any loose objects and obstacles on the floor.
Keep the floor, equipment, and turbocharger clean.
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.
Welding work
When performing welding work above the turbocharger, always cover the filter silencer to
prevent the filter mat from being damaged.
Keep flammable objects and substances out of the vicinity of flying sparks.
Cover all connections on the turbocharger so that no foreign objects can enter the tur-
bocharger.
WARNING

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Safety during commissioning and operation
The turbine casing insulation supplied by ABB Turbo Systems also serves
as a burst protection
Serious injuries or accidents resulting in fatalities can occur if the turbine
casing insulation (1) supplied by ABB Turbo Systems is removed. A burst
protection is integrated into this turbine casing insulation supplied by ABB
Turbo Systems.
For turbochargers which were ordered from ABB Turbo Systems without in-
sulation or which are equipped with the insulation (2), a separate burst pro-
tection (3) is fitted.
Never operate a turbocharger without burst protection and insulation.
If the insulation from ABB Turbo Systems (1) is not installed, the separate
burst protection (3) plus either the insulation (2) or an appropriate insulati-
on supplied by the enginebuilder must be installed for operation.
Figure 3
Visually inspect your working environment before starting work.
Remove any obstacles and objects littering the workplace.
Check all pipes to and from the turbocharger for damage and leaks before commissioning.
Avoid all operational practice which could negatively affect safety at the turbocharger.
Check turbocharger for recognisable damage or defects approximately every 12 hours of
operation, or at least once a day.
Report any damage and any alterations of operational characteristics to the responsible
department immediately.
In case of damage, take the turbocharger out of operation immediately and safeguard
against accidental/unauthorized use.
When switching on operating energy supplies (hydraulics, pneumatics, electricity, water),
pay attention to the risks that may occur as a consequence of this energy input.
WARNING

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Safety during cleaning
It is possible that detergents or solvents are used for cleaning. In this case, the safety instruc-
tions in section "Hazards due to operating materials and supplies" must always be observed.
Protect the floor against unintentional penetration of detergents or solvents before starting
cleaning operations.
Wear appropriate protective clothing.
Inspect the electric cables for abrasion and damage before and after your cleaning work.
Safety during disassembly, assembly, maintenance and repair
Observe the procedures for set-up, maintenance and inspection work and the inspection
intervals.
Inform the operating staff before starting any maintenance or repair work.
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.
Make sure that the oil supply is interrupted, especially with an external oil supply.
Only restart the engine after all parts have been properly fitted again and oil supply is en-
sured.
Mechanical operations on the turbocharger
Components of the turbocharger can be damaged or destroyed.
Only perform operations that are described in this manual.
Only perform operations for which you have previously received instruc-
tion or training.
Safety when taking out of operation at short notice or preparing for mothballing
Secure rotor against turning. The rotor can rotate due to the stack draught alone.
Clean the turbocharger prior to mothballing.
Wear appropriate protective clothing.
CAUTION

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2.5 Hazards during operation and maintenance
Mechanical hazards during operation
During standard operation, no mechanical hazards are caused by the turbocharger itself if it
has been properly installed.
Physical hazards due to rotating parts
Contact with rotating parts can cause severe injury. The turbocharger must
never be used without the air-inlet casing or filter silencer, respectively. With
the engine stopped, the rotor can rotate due to the stack draught alone.
Operate the turbocharger in compliance with the specifications.
Mechanical hazards when working on the turbocharger
During maintenance, various risks may arise due to improper handling of components, non-
compliance with safety and health standards, carelessness, or as a consequence of inadequa-
te qualification.
Mechanical hazards
Severe injuries to personnel or fatal accidents can be caused by mechanical
influences as a consequence of hazardous and inadequate operational pro-
cedures.
Secure rotor against turning.
Observe the general rules for occupational safety and prevention of ac-
cidents.
Ensure workplace safety.
Only perform operations that are described in this manual.
Only perform operations for which you have previously received instruc-
tion or training.
WARNING
WARNING

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Noise hazards
The noise emission during operation is influenced by its installation and operating conditions.
A noise level exceeding 85 dB(A) is harmful.
Danger due to noise
Exposure to noise can harm the hearing system. It can impair health and the
psychological state and may lead to irritation and lack of attention.
When the engine is running, always wear hearing protection.
Always wear hearing protection if the noise level exceeds 85 dB(A).
Standard values for the maximum duration of exposure to areas of noise emission (source:
Unfallverhütungsvorschriften für Unternehmen der Seefahrt (UVV See) [Accident Prevention
Regulations for Enterprises engaged in Seafaring]):
Figure 4
x
Noise level [dB(A)]
y
Maximum duration of exposure [min] per working day
WARNING

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Hazards due to hot surfaces and substances
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 insulation. The
temperature may rise to a level that can cause burns.
Danger of burns
Touching hot surfaces or contact with hot operating fluids can cause severe
burns.
Do not touch hot surfaces. Observe the warning plate on the turbochar-
ger.
Wear heat-resistant safety gloves and protective clothing.
Wait for the turbocharger to cool down before carrying out any work.
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
accordance with the purchase order received from the enginebuilder. If
supply is without insulation, the enginebuilder is responsible for providing the
turbocharger with proper insulation and for providing protection against
contact with hot surfaces.
Compliance with the instructions and specifications given by the engine-
builder to protect against hot surfaces is compulsory.
Hazards due to operating materials and supplies
Operating materials and supplies are substances required for the operation or for the perfor-
mance of maintenance work. Oils, greases, coolants, detergents and solvents, acids and simi-
lar substances can be classified as hazardous substances. Operating materials and supplies
can be flammable and combustible.
Danger of poisoning or acid burns
Swallowing of or skin contact with toxic or caustic operating materials and
supplies or breathing of any such vapours can be harmful to health.
Do not breathe in these substances and avoid contact with the skin.
Wear protective clothing and a breathing mask.
WARNING
WARNING
WARNING

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Danger of fire or explosion
Flammable and combustible operating materials and supplies can catch fire
or resulting vapours can lead to an explosion.
Open flames are forbidden when carrying out cleaning work.
Carry out cleaning in the open or provide sufficient ventilation.
Danger of environmental damage
The emission of operating materials and supplies into the atmosphere or the
contamination of ground or water systems as a result of improper disposal
can cause damage to the environment.
Handle operating materials and supplies with care.
Observe all instructions for use, material safety data sheets and the hazard information
provided on the containers of the operating materials and supplies.
Wear appropriate protective clothing.
Do not breathe in these substances and avoid contact with the skin.
Ensure sufficient ventilation of the workspace.
After use, close containers hermetically and put them away.
Collect used operating materials and supplies safely, store them separately in suitable con-
tainers and dispose of them properly and in an environmentally compatible manner in com-
pliance with the legal regulations.
In the event of leaks or spillage, spread binding agents immediately and dispose of them
properly and in an environmentally compatible manner in compliance with the legal regula-
tions.
Hazards due to the handling of insulation materials
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.
Handle insulation materials with care.
Only use suitable and non-combustible insulation materials.
Ensure good ventilation at the workplace.
Wear suitable work clothing (safety goggles, dust mask).
Avoid whirling up dust.
Use dust-free tools and working methods.
Remove package at the workplace only.
WARNING
CAUTION
WARNING

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Proceed with particular care when removing old insulation materials.
Dispose of insulation materials properly and in an environmentally compatible manner in
compliance with the legal regulations.
Hazards due to electrical components
Danger due to electrical components
Electrical components work with electrical voltages that can be a danger to
humans.
Any work on or with electrical components must only be performed by
specifically qualified electricians.
National regulations must be observed.
2.6 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.
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.
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 ta-
ken.
Pressure equipment must not be operated if defects are present.
WARNING
WARNING

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2.7 Use of ABB turbochargers on gas engines
ABB turbochargers can tolerate a deflagration with a transient pressure increase of 12 bar. In
deflagration tests on engines with flame barriers, a maximum of 11 bar was measured. This
value is supported by the practical experience in operation gained by renowned gas engine
manufacturers. ABB turbochargers have never been damaged in the past when deflagration
events occurred.
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. A crack inspection of the casings
and the bellows is also recommended. The nearest ABB Turbocharging Service Station
should be instructed to carry out this inspection and assessment.

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2.8 Lifting of loads
Figure 5
Suspended loads
Loads that are not attached according to regulations can cause physical inju-
ries with grave consequences or fatal accidents.
Fasten assemblies or individual parts above 25 kg carefully on properly
functional lifting gear with a sufficient load limit.
Pay attention to the correct attachment of loads on the crane hook.
No persons must remain under suspended loads.
Figure 6
If there are two or more suspension points, the attachment angle of 45° must not be excee-
ded. This prevents excessive loading due to diagonal pull.
Attach components of the turbocharger as described in the respective action steps.
Before looping around the components of the turbocharger, let them cool down (maximum
80 °C).
Use a suitable edge guard if there are sharp edges.
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.
WARNING