ABB HT611364 User manual

Turbocharging
Operation Manual / A150-M66
HT611364
Document identification
Document number HZTL4032
Revision S
Language English
Original Operation Manual
Product identification
Serial number HT611364
Customer part number
Delivery date (yyyy-mm-dd) 2022-03-28
Weight 1200 kg
Operating limits according to rating plate
Speed limit in test rig operation only nMmax 555 1/s
Speed limit during operation nBmax 555 1/s
Gas inlet temperature limit in test rig operation only tMmax 630 °C
Gas inlet temperature limit during operation tBmax 600 °C

Operation Manual / A150-M56/66/57/67 - A155-M..
Table of contents
© Copyright 2022 ABB. All rights reserved. HZTL4032_EN Rev.S February 2022
Operation Manual / A150-M.. - A155-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 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 .................................................................................................... 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................................................................................................... 48
6 Operation and service ......................................................................................... 51
6.1 Noise emission ............................................................................................................. 51
6.2 Service work................................................................................................................. 53
6.3 Expected replacement intervals .............................................................................. 56

Operation Manual / A150-M56/66/57/67 - A155-M..
Table of contents
© Copyright 2022 ABB. All rights reserved. HZTL4032_EN Rev.S February 2022
6.4 Stopping the engine................................................................................................... 58
7 Periodic maintenance work ................................................................................ 59
7.1 Foreword to maintenance......................................................................................... 59
7.2 Cleaning the compressor during operation .......................................................... 60
7.3 Cleaning the turbine during operation................................................................... 63
7.4 Cleaning components mechanically ....................................................................... 67
7.5 Changing the absorption element .......................................................................... 80
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, general........................................................................ 89
9.1 Introduction ................................................................................................................. 89
9.2 Material required......................................................................................................... 90
9.3 Disassembly and assembly concepts ..................................................................... 93
9.4 Weights of individual parts....................................................................................... 96
9.5 Table of tightening torques...................................................................................... 97
10 Dismantling and fitting with removed air inlet and gas outlet ..................... 99
10.1 Removing air inlets..................................................................................................... 99
10.2 Removing the gas outlet casing ............................................................................. 101
10.3 Removing the gas outlet flange............................................................................. 104
10.4 Removing the cartridge group with compressor and turbine casing............ 107
10.5 Removing the compressor casing......................................................................... 109
10.6 Removing the cartridge group................................................................................ 111
10.7 Installing the cartridge group on the service support ....................................... 114
10.8 Removing the nozzle ring ......................................................................................... 115
10.9 Measuring clearance A and B................................................................................... 116
10.10 Nozzle ring compression PD.................................................................................... 117
10.11 Installing nozzle ring ................................................................................................. 118
10.12 Installing the cartridge group ................................................................................. 119
10.13 Installing the compressor casing ........................................................................... 122
10.14 Turning the cartridge group with compressor and turbine casing................. 124
10.15 Installing the gas outlet flange ............................................................................... 125
10.16 Radial clearances N and R......................................................................................... 126
10.17 Fitting the insulation................................................................................................. 127
10.18 Installing the cartridge group with compressor and turbine casing .............. 128
10.19 Installing the gas outlet casing............................................................................... 129
10.20 Installing air inlets ..................................................................................................... 132
11 Dismantling and fitting, cartridge concept ................................................... 134
11.1 Removing air inlets ................................................................................................... 134
11.2 Removing the compressor casing.......................................................................... 136

Operation Manual / A150-M56/66/57/67 - A155-M..
Table of contents
© Copyright 2022 ABB. All rights reserved. HZTL4032_EN Rev.S February 2022
11.3 Removing the cartridge group................................................................................ 139
11.4 Removing the nozzle ring ......................................................................................... 142
11.5 Measuring clearance A and B.................................................................................. 143
11.6 Nozzle ring compression PD................................................................................... 144
11.7 Installing nozzle ring ................................................................................................ 145
11.8 Installing the cartridge group ................................................................................ 146
11.9 Installing the compressor casing .......................................................................... 148
11.10 Radial clearances N and R........................................................................................ 150
11.11 Fitting the insulation................................................................................................. 151
11.12 Installing air inlets ..................................................................................................... 152
12 Dismantling and fitting, special tools for fastening strips ......................... 154
12.1 Application, special tools ......................................................................................... 155
13 Removing and installing 6-nozzle turbine cleaning component (optional) ......
162
13.1 Disassembly................................................................................................................ 162
13.2 Assembly .................................................................................................................... 165
14 Fitting the cleaning nozzles with multi-inlet turbine casings...................... 168
15 Taking out of operation at short notice ......................................................... 169
15.1 Possible emergency repairs.................................................................................... 169
15.2 Installing the replacement turbocharger............................................................. 170
15.3 Installing the replacement cartridge group ........................................................ 170
15.4 Fitting the cover plate............................................................................................... 171
15.5 Cover plate drawing .................................................................................................. 172
16 Mothballing the turbocharger.......................................................................... 174
16.1 Taking the engine out of operation for up to 12months .................................. 174
16.2 Taking the engine out of operation for more than 12months ......................... 175
17 Material and Disposal........................................................................................ 176
17.1 REACH and RoHS Compliance Declaration For Products .................................. 176
17.2 Disposing of turbocharger components .............................................................. 177
18 Spare parts ......................................................................................................... 178
18.1 Ordering spare parts................................................................................................. 178
18.2 Required customer spare part set (97070)........................................................... 178
18.3 Spare part – Illustrations.......................................................................................... 179
19 Tools .................................................................................................................... 192
Figures................................................................................................................. 194
Tables .................................................................................................................. 197

Operation Manual / A150-M56/66/57/67 - A155-M..
1 Introduction / 1.1 Purpose of the manual
© Copyright 2022 ABB. All rights reserved. HZTL4032_EN Rev.S 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.
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Operation Manual / A150-M56/66/57/67 - A155-M..
1 Introduction / 1.2 Contact information
© Copyright 2022 ABB. All rights reserved. HZTL4032_EN Rev.S 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.
Page 5 / 198

Operation Manual / A150-M56/66/57/67 - A155-M..
1 Introduction / 1.4 Layout and function of the turbocharger
© Copyright 2022 ABB. All rights reserved. HZTL4032_EN Rev.S February 2022
1.4 Layout and function of the turbocharger
Fig.2: Layout and function of the turbocharger
01 Filter silencer / air suction branch 08 Gas outlet flange
02 Compressor casing 09 Nozzle ring
03 Diffuser 10 Turbine casing
04 Bearing casing 11 Turbine-end bearing flange
05 Axial thrust bearing 12 Compressor-end bearing flange
06 Radial plain bearing 13 Compressor wheel
07 Turbine
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Operation Manual / A150-M56/66/57/67 - A155-M..
1 Introduction / 1.4 Layout and function of the turbocharger
© Copyright 2022 ABB. All rights reserved. HZTL4032_EN Rev.S February 2022
Mode of operation
The turbocharger is a turbomachine and consists of the following main components:
¡Turbine
¡Compressor.
These components are installed on a common shaft and form the rotor.
The exhaust gases of the internal combustion engine flow through the turbine casing(10)
and the nozzle ring(09) onto the turbine(07). The turbine(07) uses the energy contained in
the exhaust gas to drive the rotor and, hence, the compressor wheel(13). The exhaust gases
then reach the atmosphere through the exhaust gas pipe connected to the gas outlet
flange(08).
The compressor wheel(13) sucks fresh air through the air suction branch or the filter silen-
cer(01). In the compressor wheel (13), the energy required for building up the pressure is
transferred to the air. By flowing through the diffuser(03) and the compressor casing(02),
the air is compressed further and is then directed to the engine cylinders.
The rotor runs in two radial plain bearings(06) which are located in the bearing casing(04)
between the compressor and turbine. The axial thrust bearing(05) is located between the
two radial plain bearings.
The plain bearings are connected to a central lubricating oil duct which is normally supplied
by the lubricating oil circuit of the engine. The oil outlet always lies at the deepest point of
the bearing casing(04).
Function of the compressor wheel cooling
Fig.3: Compressor wheel cooling
Depending on the application of an A100 radial turbocharger, the turbocharger is equipped
with compressor wheel cooling. With compressor wheel cooling, after the compressor air
has cooled down by passing through the charge air cooler on the engine side, it is supplied
to the turbocharger for cooling the compressor wheel. Cooling of the compressor wheel is
compulsory to ensure the reliability and replacement intervals for the relevant operating
conditions. In the turbocharger version with compressor wheel cooling, the cooling air is
supplied through a lateral connection in the bearing casing(X).
In addition, the turbocharger version with compressor wheel cooling is indicated by the tur-
bocharger type (M6..) on the rating plate.
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Operation Manual / A150-M56/66/57/67 - A155-M..
1 Introduction / 1.5 Symbols, definitions
© Copyright 2022 ABB. All rights reserved. HZTL4032_EN Rev.S February 2022
1.5 Symbols, definitions
Symbols
The following symbols are used in this document:
uIndicates an action step.
1. Indicates a numbered action step.
→Refers to a page number
Definition of Note
NOTICE
Note
The note provides advice which facilitates the work.
Definition of mandatory signs
Mandatory signs show the protective equipment to be worn for a task. The mandatory signs
are described in chapter Safety and must be complied with.
Definition of Caution / Warning
Caution and warning signs are described in chapter Safety.
Turbo Systems
Turbo Systems Switzerland Ltd is referred to in this document as Turbo Systems.
Official service stations of Turbo Systems
Official service stations are identified in this document as Turbo Systems service stations.
These Turbo Systems service stations are regularly checked and certified by Turbo Systems
Switzerland Ltd. See also chapter Contact information →5.
Page 8 / 198

Operation Manual / A150-M56/66/57/67 - A155-M..
1 Introduction / 1.5 Symbols, definitions
© Copyright 2022 ABB. All rights reserved. HZTL4032_EN Rev.S February 2022
Definition of pictograms
The following pictograms can occur in this document. These point out actions that must be
taken in accordance with the meaning of the relevant pictogram.
Pictogram Meaning
Tighten with specified torque
Tighten over specified tightening angle
Hand-tight, tighten without tools
Oil
Apply screw locking paste (e.g. Loctite)
Apply high-temperature grease
Apply other paste in accordance with specifications
Oil free, grease free and dry
Affix
Measure
Note
Visually inspect
Please note text for numbered work step.
See document
Dispose of in an environmentally compatible, professional way and in compliance
with locally applicable regulations.
Table1: Definition of pictograms
Page 9 / 198

Operation Manual / A150-M56/66/57/67 - A155-M..
1 Introduction / 1.6 Storage of new turbochargers and spare parts
© Copyright 2022 ABB. All rights reserved. HZTL4032_EN Rev.S February 2022
1.6 Storage of new turbochargers and spare parts
Storage of new turbochargers and spare parts up to 6 months
New turbochargers and spare parts can be stored in their closed packages for 6months
from the date of delivery without additional mothballing measures.
Only dry rooms in which the relative humidity is between 40…70% and no condensation can
form are suitable for storage.
Storage of new turbochargers and spare parts for more than 6 months
As the contents of the package are adapted as required, turbochargers may also be de-
livered without a VCI label.
For parts with a VCI label on the package, the following instructions must be observed.
Fig.4: Volatile Corrosion Inhibitor (VCI)
WARNING
Health protection when handling VCI
VCI products are not hazardous in terms of the Ordinance on Hazardous
Substances. Nevertheless, the following points must be observed when
handling VCI:
uObserve information in material safety data sheet
uEnsure proper space ventilation.
uDo not eat, drink or store food at the workplace while working with VCI.
uClean hands and face after working with VCI.
uFor more information, see www.branopac.com.
Wear safety gloves to protect against mechanical hazards.
Every 6months, the following mothballing measures are required:
uOpen package.
uRemove VCI corrosion protection emitter from package and replace with a new VCI corro-
sion protection emitter of the same kind. New VCI corrosion protection emitters can be
obtained from www.branopac.com.
uOld VCI corrosion protection emitters must be disposed of in an environmentally compat-
ible, professional way and in compliance with locally applicable regulations.
uClose package. The more tightly the package is sealed, the longer the protection dura-
tion.
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Operation Manual / A150-M56/66/57/67 - A155-M..
1 Introduction / 1.6 Storage of new turbochargers and spare parts
© Copyright 2022 ABB. All rights reserved. HZTL4032_EN Rev.S February 2022
Long-term storage of turbochargers
The turbochargers will be prepared for long-term storage if requested in the purchase order.
The package is equipped with a hygrometer (see illustration).
Fig.5: Package with hygrometer
Every 6months, the following measures are required:
uCheck the hygrometer(02) in the sight-glass. There is an opening(01) in the wooden
crate which allows this check to be carried out. When the display field has changed colour
at the 70% level, the maximum permissible humidity has been exceeded. In this case, the
turbocharger must be inspected by a Turbo Systems service station and repacked.
uInspect the package for damage. If the package is damaged, the turbocharger must be in-
spected by a Turbo Systems service station and repacked.
After every 3 years the following work steps must be performed by a Turbo Systems service
station:
¡Inspect the component
¡Replace the desiccant agent
¡Repackage the component.
NOTICE
70% field of the hygrometer has not changed colour
If the 70% field of the hygrometer(02) has not changed colour and the pack-
age is undamaged, the turbocharger can be put into operation without any
prior inspection by a Turbo Systems service station.
Unpacking the turbochargers
The corrosion protection effect ends after the material is unpacked from the VCI package.
To avoid the formation of condensation, the surroundings and the content of the package
must have the same temperature during unpacking.
Page 11 / 198

Operation Manual / A150-M56/66/57/67 - A155-M..
1 Introduction / 1.7 Registered trademarks
© Copyright 2022 ABB. All rights reserved. HZTL4032_EN Rev.S February 2022
1.7 Registered trademarks
The trademarks of outside companies are used in this document. These are marked with the
® symbol.
Page 12 / 198

Operation Manual / A150-M56/66/57/67 - A155-M..
2 Safety / 2.1 Introduction
© Copyright 2022 ABB. All rights reserved. HZTL4032_EN Rev.S February 2022
2 Safety
2.1 Introduction
Turbochargers manufactured by ABB reflect the state of the art. The respective safety and
health protection requirements are met. This ensures safe operation of the turbocharger.
Nevertheless, there may be some residual risks during operation of and work on the tur-
bocharger 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 defining measures that regulate safe access to
and safe handling of the turbocharger.
All instructions contained in this chapter must be observed for safe and trouble-free opera-
tion of the turbocharger and during all work on the turbocharger.
All further safety instructions contained and specifically identified in every chapter of this
Operation Manual (Definition of safety instructions →14) must also be observed.
2.2 CE conformity
Information
Turbochargers from Turbo Systems comply with the Machinery Directive 2006/42/EC and
are partly completed machinery as defined by Article2g in this directive.
Page 13 / 198

Operation Manual / A150-M56/66/57/67 - A155-M..
2 Safety / 2.3 Definition of mandatory signs
© Copyright 2022 ABB. All rights reserved. HZTL4032_EN Rev.S February 2022
2.3 Definition of mandatory signs
To be worn at all times
Protective clothing Safety footwear to protect
against mechanical hazard and
risk of falling
Table2: Personal protective equipment to be worn at all times
To be worn specific to the respective task
Safety glasses Safety goggles
Safety gloves to protect
against
- Mechanical hazard
- Chemical hazard
- Thermal hazard
- Electrical hazard
Respiratory mask to protect
against
- Dusts
- Gases
Safety helmet Ear protection
Table3: Personal protective equipment to be worn specific to the respective task
2.4 Definition of safety instructions
WARNING
Definition of Warning
Non-compliance or inaccurate compliance with working or operating in-
structions indicated by this symbol and the word WARNING can lead to seri-
ous injuries to personnel and even to fatal accidents.
uWarning signs must always be observed.
CAUTION
Definition of Caution
Non-compliance or inaccurate compliance with working or operating in-
structions indicated by this symbol and the word CAUTION can lead to seri-
ous damage to engine or property with grave consequences.
uCaution signs must always be observed.
Page 14 / 198

Operation Manual / A150-M56/66/57/67 - A155-M..
2 Safety / 2.5 Intended use
© Copyright 2022 ABB. All rights reserved. HZTL4032_EN Rev.S February 2022
2.5 Intended use
Use on internal combustion engines in general
Turbo Systems turbochargers are intended for charging internal combustion engines.
To ensure compliance with the machinery directive 2006/42/EC when using on gas engines,
the turbocharger must be operated in an engine room classified as "not at risk of explosion".
This is in accordance with the position paper [2] relating to ATEX issued by EUROMOT[1].
For use on pre-mix gas engines with ignitable propellents in the gas control system, the en-
ginebuilder must implement appropriate safety measures for explosion protection [3] (such
as flame barriers in the inlet system, for example) to assure that there is no transient pres-
sure increase exceeding a maximum of 12 bar before the turbocharger in case of a deflagra-
tion.
The turbocharger supplies the engine with the air volume or air/gas mixture and the associ-
ated charging pressure required for operation.
The turbocharger is solely intended to be operated with a clockwise direction of rotation as
viewed from the turbine end.
The specific operating limits of the turbocharger were determined on the basis of informa-
tion from the enginebuilder about the intended use. These data are given on the rating
plate.
The use of the turbocharger is limited to the specific application released at the time of de-
livery.
Turbo Systems accepts no liability and rejects all warranty claims for any non-intended ap-
plications.
[1]Euromot = The European Association of Internal Combustion Engine Manufacturers
[2]Directive 94/9/EC concerning equipment and protective systems intended for use in po-
tentially explosive atmospheres (ATEX) The Euromot Position as of November 2003, ATEX
Euromot Position 191103
[3]Guidelines for proper safety design of inlet systems on gas engines, RWTÜV Essen, 1991
WARNING
Unapproved operation
Any operation of the turbocharger outside of its operating limits can be haz-
ardous to personnel.
uOnly operate the turbocharger within the operating limits.
uOnly trained personnel must operate the turbocharger.
The intended use of the turbocharger includes compliance with all regulations and condi-
tions. In particular, the following must be observed:
¡Operation Manual
¡Instructions of the enginebuilder
Page 15 / 198

Operation Manual / A150-M56/66/57/67 - A155-M..
2 Safety / 2.6 Warning plates on the turbocharger
© Copyright 2022 ABB. All rights reserved. HZTL4032_EN Rev.S February 2022
State of the art
The turbocharger is designed and manufactured according to the state of the art and is safe
to operate.
Perfect condition
The turbocharger must only be used when it is in a technically flawless condition and oper-
ated in compliance with its intended use.
Turbo Systems excludes any liability for damage resulting from unauthorized modifications
to the turbocharger or improper operation.
2.6 Warning plates on the turbocharger
Warning plates are affixed at the following locations:
Fig.6: Warning plate locations
If warning plates are not present in the designated locations or not readable, proceed as fol-
lows:
uOrder new warning plates from Turbo Systems service stations.
uRemove any warning plates that have become unreadable.
uClean and degrease the areas designated for the warning plates.
uFit new warning plates and remove protective sheets.
Turbochargers supplied to the enginebuilder without insulation must be equipped later with
warning plates on the insulation. This is the responsibility of the enginebuilder.
Page 16 / 198

Operation Manual / A150-M56/66/57/67 - A155-M..
2 Safety / 2.7 Turbocharger rating plate
© Copyright 2022 ABB. All rights reserved. HZTL4032_EN Rev.S February 2022
2.7 Turbocharger rating plate
Fig.7: Rating plate
Operating limits
01 Turbocharger operating limits at engine overload (110%).
In test rig operation only, unless otherwise agreed with the en-
ginebuilder.
02 Turbocharger operating limits during operation
Recommended inspection and replacement intervals of turbocharger components
03 Inspection interval of plain bearings in 1000h
04 Replacement interval of compressor in 1000h
05 Replacement interval of turbine in 1000h
Further data
06 Customer part number
07 Designation for special design
08 Weight of turbocharger in kg
09 Turbocharger type
10 Serial number
11 Year of construction of turbocharger
12 Manufacturing plant
Page 17 / 198

Operation Manual / A150-M56/66/57/67 - A155-M..
2 Safety / 2.7 Turbocharger rating plate
© Copyright 2022 ABB. All rights reserved. HZTL4032_EN Rev.S February 2022
Explanations regarding the rating plate
The recommended inspection and replacement intervals and the corresponding operating
limits are jointly defined with the enginebuilder. This information is specific to the system.
Operation above the indicated values nBmax, tBmax can considerably shorten the recommended
replacement intervals. In such cases, we recommend contacting the nearest Turbo Systems
Service Station.
nMmax, tMmax normally apply only when running at overload (110%) during trials on the engine
test bed. These limit values can also be permitted during operation for special applications.
Operation above nMmax and tMmax is not permitted.
Non-observance of the recommended inspection and replacement intervals increases the
risk of unpredictable component failures.
For operating limits, refer to the Operation Manual title page or the rating plate on the tur-
bocharger.
Locations of the rating plates
Fig.8: Locations of the rating plates
One rating plate (01) each is attached on the left and the right side of the turbocharger bear-
ing casing.
Page 18 / 198