ABB HT608505 User manual

Turbocharging
Operation Manual / A175-M66
HT608505
Document identification
Document number HZTL4033
Revision I
Language English
Original Operation Manual
Product identification
Serial number HT608505
Customer part number
Delivery date (yyyy-mm-dd) 2021-12-16
Weight 4600 kg
Operating limits according to rating plate
Speed limit in test rig operation only nMmax 316 1/s
Speed limit during operation nBmax 302 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 / A170-M.. - A175-M..
Table of contents
© Copyright 2021 ABB. All rights reserved. HZTL4033_EN Rev.I November 2021
Operation Manual / A170-M.. - A175-M..
1 Introduction............................................................................................................ 4
1.1 Purpose of the manual................................................................................................. 4
1.2 Contact information...................................................................................................... 5
1.3 Essential information.................................................................................................... 5
1.4 Registered trademarks................................................................................................. 5
1.5 Layout and function of the turbocharger ................................................................ 6
1.6 Symbols, definitions..................................................................................................... 8
1.7 Storage of new turbochargers and spare parts .................................................... 10
2 Safety .................................................................................................................... 12
2.1 Introduction .................................................................................................................. 12
2.2 CE conformity............................................................................................................... 12
2.3 Definition of mandatory signs .................................................................................. 13
2.4 Definition of safety instructions .............................................................................. 13
2.5 Intended use ................................................................................................................. 14
2.6 Deflagration on gas engines ..................................................................................... 15
2.7 Periodic check of the pressure vessels.................................................................... 15
2.8 Warning plates on the turbocharger........................................................................ 16
2.9 Turbocharger rating plate.......................................................................................... 17
2.10 Lifting of loads ............................................................................................................. 19
2.11 Prerequisites for operation and maintenance...................................................... 20
2.12 Hazards during operation and maintenance ......................................................... 21
2.13 Safe operation.............................................................................................................. 23
2.14 Safe maintenance ....................................................................................................... 24
3 Removal and installation .................................................................................... 28
3.1 Turbocharger weight ................................................................................................. 28
3.2 Removing the turbocharger...................................................................................... 29
3.3 Installing the turbocharger........................................................................................ 32
4 Commissioning .................................................................................................... 38
4.1 Oil supply ...................................................................................................................... 38
4.2 Inspection procedures............................................................................................... 39
4.3 Commissioning after taking out of operation...................................................... 40
5 Monitoring during operation.............................................................................. 41
5.1 Oil pressure, oil temperature..................................................................................... 41
5.2 Turbocharger speed................................................................................................... 43
6 Operation and service ......................................................................................... 46
6.1 Noise emission ............................................................................................................ 46
6.2 Service work................................................................................................................. 48
6.3 Expected replacement intervals ............................................................................... 51

Operation Manual / A170-M.. - A175-M..
Table of contents
© Copyright 2021 ABB. All rights reserved. HZTL4033_EN Rev.I November 2021
6.4 Stopping the engine................................................................................................... 52
7 Periodic maintenance.......................................................................................... 53
7.1 Foreword to maintenance......................................................................................... 53
7.2 Cleaning the filter silencer ........................................................................................ 54
7.3 Cleaning the slotted diffuser.................................................................................... 56
7.4 Cleaning the compressor during operation ........................................................... 57
7.5 Cleaning turbine and nozzle ring ............................................................................. 63
8 Troubleshooting................................................................................................... 69
8.1 Malfunctions when starting...................................................................................... 69
8.2 Malfunctions during operation ................................................................................ 70
8.3 Surging of the turbocharger...................................................................................... 72
8.4 Malfunctions when stopping..................................................................................... 73
8.5 Speed measurement system.................................................................................... 74
9 Disassembly and assembly................................................................................. 75
9.1 Introduction .................................................................................................................. 75
9.2 Weight of assemblies.................................................................................................. 77
9.3 Removing the air inlets .............................................................................................. 78
9.4 Axial clearance A prior to disassembly ................................................................... 80
9.5 Removing the compressor casing............................................................................ 81
9.6 Removing the cartridge group................................................................................. 85
9.7 Removing the nozzle ring .......................................................................................... 88
9.8 Installing the nozzle ring ........................................................................................... 93
9.9 Installing the cartridge group .................................................................................. 98
9.10 Fitting the spinner nose cone ................................................................................. 101
9.11 Installing the compressor casing .......................................................................... 103
9.12 Axial clearance A after assembly............................................................................ 107
9.13 Installing the air inlets ............................................................................................. 108
9.14 Removing and installing turbine-end nozzle ring................................................ 111
9.15 Table of tightening torques..................................................................................... 115
10 Taking a turbocharger out of operation......................................................... 118
10.1 Possible emergency repairs..................................................................................... 118
10.2 Locking the rotor ....................................................................................................... 119
10.3 Fitting the cover plate............................................................................................... 122
10.4 Blanking off the inlets and outlets ......................................................................... 124
10.5 Engines with bypass around the turbocharger ................................................... 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 Material and Disposal........................................................................................ 127
12.1 REACH and RoHS Compliance Declaration For Products .................................. 127
12.2 Disposing of turbocharger components .............................................................. 128

Operation Manual / A170-M.. - A175-M..
Table of contents
© Copyright 2021 ABB. All rights reserved. HZTL4033_EN Rev.I November 2021
13 Spare parts ......................................................................................................... 129
13.1 Ordering spare parts................................................................................................. 129
13.2 Spare part – Illustrations.......................................................................................... 131
14 Tools .................................................................................................................... 141
Figures................................................................................................................. 143
Tables .................................................................................................................. 145