ABB HT610533 User manual

Turbo Systems Switzerland Ltd
Operation Manual / A130-H66
HT610533
Document identification
Document number HZTL4030
Revision G
Language English
Original Operation Manual
Product identification
Serial number HT610533
Customer part number X00078528
Delivery date (yyyy-mm-dd) 2022-04-19
Weight 190 kg
Operating limits according to rating plate
Speed limit in test rig operation only nMmax 1031 1/s
Speed limit during operation nBmax 1007 1/s
Gas inlet temperature limit in test rig operation only tMmax 680 °C
Gas inlet temperature limit during operation tBmax 650 °C

Operation Manual / A130-H.. - A140-H..
Table of contents
© Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021
Operation Manual / A130-H.. - A140-H..
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 Removing and Installing...................................................................................... 28
3.1 Weight and transportation of the turbocharger.................................................. 28
3.2 Removing the turbocharger...................................................................................... 29
3.3 Installing the turbocharger....................................................................................... 33
4 Commissioning .................................................................................................... 40
4.1 Oil supply ...................................................................................................................... 40
4.2 Inspection procedures............................................................................................... 42
4.3 Commissioning after taking out of operation...................................................... 44
5 Monitoring operation .......................................................................................... 45
5.1 Oil pressure, oil temperature.................................................................................... 45
5.2 Exhaust gas temperature before turbine .............................................................. 47
5.3 Turbocharger speed ................................................................................................... 47
6 Operation and service ......................................................................................... 51
6.1 Noise emission ............................................................................................................. 51

Operation Manual / A130-H.. - A140-H..
Table of contents
© Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021
6.2 Service work................................................................................................................. 53
6.3 Expected replacement intervals ............................................................................... 57
6.4 Stopping the engine................................................................................................... 59
7 Periodic maintenance work ................................................................................ 60
7.1 Foreword to maintenance......................................................................................... 60
7.2 Cleaning components mechanically ........................................................................ 61
8 Eliminating malfunctions.................................................................................... 71
8.1 Malfunctions when starting....................................................................................... 71
8.2 Malfunctions during operation ................................................................................. 72
8.3 Turbocharger is surging............................................................................................. 75
8.4 Malfunctions when stopping.................................................................................... 76
8.5 Speed measurement system..................................................................................... 77
9 Dismantling and fitting....................................................................................... 78
9.1 Introduction ................................................................................................................. 78
9.2 Weights of individual parts....................................................................................... 80
9.3 Removing the air inlets .............................................................................................. 82
9.4 Removing the gas outlet casing .............................................................................. 83
9.5 Removing the gas outlet flange............................................................................... 83
9.6 Removing the compressor casing ........................................................................... 86
9.7 Pressing off the casing .............................................................................................. 88
9.8 Removing the cartridge group................................................................................. 89
9.9 Removing the nozzle ring ........................................................................................... 91
9.10 Installing the cartridge group on the service support ........................................ 92
9.11 Measuring clearance A and B.................................................................................... 93
9.12 Nozzle ring compression PD..................................................................................... 94
9.13 Installing the nozzle ring ........................................................................................... 95
9.14 Installing the cartridge group .................................................................................. 96
9.15 Installing the compressor casing ............................................................................ 98
9.16 Measuring radial clearances N and R .................................................................... 100
9.17 Installing the air inlets .............................................................................................. 101
9.18 Installing the gas outlet flange .............................................................................. 102
9.19 Installing the gas outlet casing.............................................................................. 102
9.20 Table of tightening torques.................................................................................... 103
10 Taking out of operation at short notice ......................................................... 104
10.1 Possible emergency repairs.................................................................................... 104
10.2 Installing the replacement turbocharger............................................................. 105
10.3 Installing the replacement cartridge group ........................................................ 105
11 Mothballing the turbocharger.......................................................................... 106
11.1 Taking the engine out of operation for up to 12months ................................. 106
11.2 Taking the engine out of operation for more than 12months ........................ 107

Operation Manual / A130-H.. - A140-H..
Table of contents
© Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021
12 Material and Disposal........................................................................................ 108
12.1 REACH and RoHS Compliance Declaration For Products ................................. 108
12.2 Disposing of turbocharger components ............................................................. 109
13 Spare parts ......................................................................................................... 110
13.1 Ordering spare parts................................................................................................. 110
13.2 Required customer spare part set (97070)........................................................... 110
13.3 Spare part – Illustrations .......................................................................................... 111
14 Tools .................................................................................................................... 119
Figures................................................................................................................. 120
Tables ................................................................................................................... 121