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.

Operation Manual / A130-M.. - A145-M..
Contents
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© Copyright 2013 ABB. All rights reserved.
HZTL2413_EN
Revision B
March 2013
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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© Copyright 2013 ABB. All rights reserved.
HZTL2413_EN
Revision
B
March 2013
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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© Copyright 2013 ABB. All rights reserved.
HZTL2413_EN
Revision B
March 2013
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

Operation Manual / A130-M.. - A145-M..
1
Preliminary remarks
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113
© Copyright 2013 ABB. All rights reserved.
HZTL2413_EN
Revision B
March 2013
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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© Copyright 2013 ABB. All rights reserved.
HZTL2413_EN
Revi
sion B
March 2013
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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2
Safety
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© Copyright 2013 ABB. All rights reserved.
HZTL2413_EN
Revision B
March 2013
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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Safety
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© Copyright 2013 ABB. All rights reserved.
HZTL2413_EN
Revision B
March 2013
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.