ABB A150-M58 User manual

Operation Manual / A150-M58/68
Table of contents
© Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022
Operation Manual / A150-M58/68
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 .................................................................................................... 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
6.3 Expected replacement intervals .............................................................................. 55

Operation Manual / A150-M58/68
Table of contents
© Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022
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
8 Eliminating malfunctions.................................................................................... 77
8.1 Malfunctions when starting....................................................................................... 77
8.2 Malfunctions during operation ................................................................................ 78
8.3 Turbocharger is surging............................................................................................. 81
8.4 Malfunctions when stopping.................................................................................... 82
8.5 Speed measurement system.................................................................................... 83
9 Dismantling and fitting, general........................................................................ 84
9.1 Introduction ................................................................................................................. 84
9.2 Material required......................................................................................................... 85
9.3 Disassembly and assembly concepts ..................................................................... 88
9.4 Weights of individual parts........................................................................................ 91
9.5 Table of tightening torques...................................................................................... 92
10 Dismantling and fitting with removed air inlet and gas outlet ..................... 94
10.1 Removing air inlets..................................................................................................... 94
10.2 Removing the gas outlet casing .............................................................................. 95
10.3 Removing the gas outlet flange............................................................................... 98
10.4 Removing the cartridge group with compressor and turbine casing.............. 99
10.5 Removing the compressor casing.......................................................................... 101
10.6 Removing the cartridge group............................................................................... 102
10.7 Installing the cartridge group on the service support ...................................... 105
10.8 Removing the nozzle ring ........................................................................................ 106
10.9 Measuring clearance A and B.................................................................................. 107
10.10 Nozzle ring compression PD................................................................................... 108
10.11 Installing nozzle ring ................................................................................................ 109
10.12 Installing the cartridge group ................................................................................. 110
10.13 Installing the compressor casing ........................................................................... 113
10.14 Turning the cartridge group with compressor and turbine casing................. 115
10.15 Installing the gas outlet flange ............................................................................... 116
10.16 Radial clearances N and R......................................................................................... 117
10.17 Fitting the insulation................................................................................................. 118
10.18 Installing the cartridge group with compressor and turbine casing .............. 119
10.19 Installing the gas outlet casing.............................................................................. 120
10.20 Installing air inlets ..................................................................................................... 123
11 Dismantling and fitting, cartridge concept ................................................... 124
11.1 Removing air inlets .................................................................................................... 124
11.2 Removing the compressor casing.......................................................................... 125
11.3 Removing the cartridge group................................................................................ 127

Operation Manual / A150-M58/68
Table of contents
© Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022
11.4 Removing the nozzle ring ........................................................................................ 130
11.5 Measuring clearance A and B................................................................................... 131
11.6 Nozzle ring compression PD.................................................................................... 132
11.7 Installing nozzle ring ................................................................................................. 133
11.8 Installing the cartridge group ................................................................................ 134
11.9 Installing the compressor casing ........................................................................... 136
11.10 Radial clearances N and R......................................................................................... 138
11.11 Fitting the insulation................................................................................................. 139
11.12 Installing air inlets .................................................................................................... 140
12 Dismantling and fitting, special tools for fastening strips ......................... 141
12.1 Application, special tools ......................................................................................... 142
13 Removing and installing 6-nozzle turbine cleaning component (optional) ......
145
13.1 Disassembly............................................................................................................... 145
13.2 Assembly .................................................................................................................... 148
14 Fitting the cleaning nozzles with multi-inlet turbine casings...................... 151
15 Taking out of operation at short notice ......................................................... 152
15.1 Possible emergency repairs..................................................................................... 152
15.2 Installing the replacement turbocharger.............................................................. 153
15.3 Installing the replacement cartridge group ......................................................... 153
15.4 Fitting the cover plate.............................................................................................. 154
15.5 Cover plate drawing .................................................................................................. 155
16 Mothballing the turbocharger.......................................................................... 157
16.1 Taking the engine out of operation for up to 12months .................................. 157
16.2 Taking the engine out of operation for more than 12months........................ 158
17 Material and Disposal........................................................................................ 159
17.1 REACH and RoHS Compliance Declaration For Products ................................. 159
17.2 Disposing of turbocharger components ............................................................. 160
18 Spare parts ......................................................................................................... 161
18.1 Ordering spare parts................................................................................................. 161
18.2 Required customer spare part set (97070)........................................................... 161
18.3 Spare part – Illustrations .......................................................................................... 162
19 Tools .................................................................................................................... 176
Figures................................................................................................................. 178
Tables .................................................................................................................. 180

Operation Manual / A150-M58/68
1 Introduction / 1.1 Purpose of the manual
© Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022
1 Introduction
1.1 Purpose of the manual
Fig.1: Serial number(01) on the rating plate
This Operation Manual belongs to the turbocharger with the identical serial number(01), see
the Operation Manual title page and the rating plate on the turbocharger.
Operation Manual
The Operation Manual explains the turbocharger and contains instructions for safe opera-
tion.
The Operation Manual is a complement to and expansion of existing national regulations for
occupational safety, accident prevention and environmental protection.
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
The 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.
Page 4 / 181

Operation Manual / A150-M58/68
1 Introduction / 1.2 Contact information
© Copyright 2022 ABB. All rights reserved. HZTL4041_EN Rev.F February 2022
1.2 Contact information
Contact information for the Turbo Systems service stations is available online.
uScan the QR code to access our website.
Turbo Systems Switzerland Ltd.
Bruggerstrasse 71a
CH-5401 Baden
Switzerland
www.abb.com/turbocharging
1.3 Essential information
Design variants
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 Turbo Systems Service Station if you have any questions regarding a
design variant (see Contact information at www.abb.com/turbocharging).
Accuracy of illustrations
The illustrations in this document are general in nature and intended for ease of understand-
ing. Differences in detail are therefore possible.
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