ABB HT607788 User manual

Turbocharging
Operation Manual / A145-M66
HT607788
Document identification
Document number HZTL4031
Revision N
Language English
Original Operation Manual
Product identification
Serial number HT607788
Customer part number HZTL53371
Delivery date (yyyy-mm-dd) 2021-11-09
Weight 850 kg
Operating limits according to rating plate
Speed limit in test rig operation only nMmax 593 1/s
Speed limit during operation nBmax 593 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 / A130-M.. - A145-M..
Table of contents
© Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021
Operation Manual / A130-M.. - A145-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 Deflagration on gas engines ..................................................................................... 16
2.7 Warning plates on the turbocharger........................................................................ 17
2.8 Turbocharger rating plate.......................................................................................... 18
2.9 Periodic check of the pressure vessels................................................................... 20
2.10 Lifting of loads ............................................................................................................. 21
2.11 Prerequisites for operation and maintenance....................................................... 22
2.12 Hazards during operation and maintenance ......................................................... 23
2.13 Safe operation............................................................................................................. 25
2.14 Safe maintenance ....................................................................................................... 26
3 Removing and Installing...................................................................................... 30
3.1 Turbocharger weight and transportation ............................................................. 30
3.2 Removing the turbocharger....................................................................................... 31
3.3 Installing the turbocharger....................................................................................... 36
4 Commissioning .................................................................................................... 44
4.1 Oil supply ...................................................................................................................... 44
4.2 Inspection procedures............................................................................................... 46
4.3 Commissioning after taking out of operation...................................................... 48
5 Monitoring operation .......................................................................................... 49
5.1 Oil pressure, oil temperature.................................................................................... 49
5.2 Exhaust gas temperature before turbine ............................................................... 51
5.3 Turbocharger speed................................................................................................... 52
6 Operation and service ......................................................................................... 55
6.1 Noise emission ............................................................................................................ 55

Operation Manual / A130-M.. - A145-M..
Table of contents
© Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021
6.2 Service work.................................................................................................................. 57
6.3 Expected replacement intervals ............................................................................... 61
6.4 Stopping the engine................................................................................................... 63
7 Periodic maintenance work ................................................................................ 64
7.1 Foreword to maintenance......................................................................................... 64
7.2 Cleaning the compressor during operation .......................................................... 65
7.3 Cleaning the turbine during operation................................................................... 68
7.4 Cleaning components mechanically ........................................................................ 72
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....................................................................................... 89
9.1 Introduction ................................................................................................................. 89
9.2 Material required......................................................................................................... 90
9.3 Weights of individual parts....................................................................................... 92
9.4 Removing the air inlets .............................................................................................. 93
9.5 Removing the gas outlet casing .............................................................................. 94
9.6 Removing the gas outlet flange............................................................................... 95
9.7 Removing the compressor casing........................................................................... 98
9.8 Pressing off the casing ............................................................................................ 100
9.9 Removing the cartridge group................................................................................ 101
9.10 Removing the nozzle ring ........................................................................................ 103
9.11 Installing the cartridge group on the service support ...................................... 104
9.12 Measuring clearance A and B.................................................................................. 105
9.13 Nozzle ring compression PD................................................................................... 106
9.14 Installing the nozzle ring ......................................................................................... 107
9.15 Installing the cartridge group ................................................................................ 108
9.16 Installing the compressor casing ........................................................................... 111
9.17 Measuring radial clearances N and R ..................................................................... 113
9.18 Installing the air inlets .............................................................................................. 114
9.19 Installing the gas outlet flange ............................................................................... 115
9.20 Fitting the insulation of the turbine casing ......................................................... 116
9.21 Installing the gas outlet casing............................................................................... 117
9.22 Table of tightening torques..................................................................................... 119
10 Taking out of operation at short notice .......................................................... 121
10.1 Possible emergency repairs..................................................................................... 121
10.2 Installing the replacement turbocharger.............................................................. 122
10.3 Installing the replacement cartridge group ......................................................... 122
10.4 Fitting the cover plate............................................................................................... 123

Operation Manual / A130-M.. - A145-M..
Table of contents
© Copyright 2021 ABB. All rights reserved. HZTL4031_EN Rev.N March 2021
10.5 Cover plate drawing .................................................................................................. 124
11 Mothballing the turbocharger.......................................................................... 125
11.1 Taking the engine out of operation for up to 12months .................................. 125
11.2 Taking the engine out of operation for more than 12months......................... 126
12 Disposing of turbocharger components ........................................................ 127
13 Spare parts ......................................................................................................... 129
13.1 Ordering spare parts................................................................................................. 129
13.2 Required customer spare part set (97070)........................................................... 129
13.3 Spare part – Illustrations ......................................................................................... 130
14 Tools .................................................................................................................... 145
Figures................................................................................................................. 146
Tables .................................................................................................................. 148