FREE ENGLISH ABB A130-H57 (01) PDF USER GUIDE
FREE ENGLISH ABB A130-H57 (01) PDF USER MANUAL
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FREE ENGLISH ABB A130-H57 (01) PDF REFERENCE MANUAL
FREE ENGLISH ABB A130-H57 (01) PDF INSTRUCTION MANUAL
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ABB A130-H57 (01) PDF SUMMARY:
What does the Operation Manual explain?
The Operation Manual explains the turbocharger and contains instructions for safe operation. The Operation Manual is a complement to and expansion of existing national regulations for occupational safety, accident prevention, and environmental protection.
What do mandatory signs indicate?
Mandatory signs show the protective equipment to be worn for a task.
What do the pictograms mean?
- Tighten with specified torque
- Affix
- Tighten over specified tightening angle
- Measure
- Hand-tight, tighten without tools
- Note
- Oil
- Visually inspect
- Apply screw locking paste (e.g. Loctite)
- Please note text for numbered work step
- Apply high-temperature grease
- See document
- Apply other paste in accordance with specifications
- Dispose of in an environmentally compatible, professional way and in compliance with locally applicable regulations
- Oil free, grease free and dry
What measures are required every 6 months for storing new turbochargers and spare parts for more than 6 months?
- Open package.
- Remove VCI corrosion protection emitter from package and replace with a new VCI corrosion protection emitter of the same kind. New VCI corrosion protection emitters can be obtained from http://www.branopac.com.
- Old VCI corrosion protection emitters must be disposed of in an environmentally compatible, professional way and in compliance with locally applicable regulations.
- Close package. The more tightly the package is sealed, the longer the protection duration.
What measures are required every 6 months for long-term storage of replacement turbochargers or spare parts?
- Check the hygrometer in the sight-glass. There is an opening in the wooden crate to enable this check. If the 70% indicator field has changed color, the maximum admissible atmospheric humidity has been exceeded. In this case, the turbocharger or cartridge group must be checked and repackaged by an ABB Turbocharging Service Station.
- Check the package for damage. If the package is damaged, the turbocharger or cartridge group must be checked and repackaged by an ABB Turbocharging Service Station.
What steps must be carried out by an ABB Turbocharging Service Station after every 3 years?
- Checking the component
- Replacing the desiccant
- Repackaging the component
What should be done to a replacement turbocharger or replacement cartridge group if the 70% field of the hygrometer has not changed color and the package is not damaged?
The replacement turbocharger or replacement cartridge group can be put into operation without previously having been checked by an ABB Turbocharging Service Station.
What should be observed when handling VCI?
- Observe information in material safety data sheet
- Ensure proper space ventilation.
- Do not eat, drink or store food at the workplace while working with VCI.
- Clean hands and face after working with VCI.
- For more information, see http://www.branopac.com.
- Wear safety gloves to protect against mechanical hazards.
What must be observed for safe and trouble-free operation of the turbocharger and during all work on the turbocharger?
All instructions contained in the safety chapter. All further safety instructions contained and specifically identified in every chapter of this manual must also be observed.
What can non-compliance or inaccurate compliance with working or operating instructions indicated by the word WARNING lead to?
Non-compliance or inaccurate compliance with working or operating instructions indicated by this symbol and the word WARNING can lead to serious injuries to personnel and even to fatal accidents. Warning signs must always be observed.
What can non-compliance or inaccurate compliance with working or operating instructions indicated by the word CAUTION lead to?
Non-compliance or inaccurate compliance with working or operating instructions indicated by this symbol and the word CAUTION can lead to serious damage to engine or property with grave consequences. Caution signs must always be observed.
What does ABB Turbo Systems recommend verifying on the turbocharger after a deflagration event?
- Position of the turbine and compressor casings to the bearing casing
- Shifting of the bearing casing in relation to the bracket
- Cracks in casings
What does ABB Turbo Systems recommend checking before the next start if anomalies are found during external inspection or if a particularly strong deflagration event has taken place?
It is recommended to check the bearings of the turbochargers before the next start. An ABB Turbocharging Service Station should be instructed to carry out this inspection.
What must be done if warning plates are not present in the intended locations or are not legible?
They must be replaced with new warning plates. The necessary information can be found in the Operation Manual, Chapter 4 Product description.
What must the operating company make sure of regarding pressure vessels?
The operating company must make sure the pressure vessels are in proper working condition and monitor them. Necessary repair or maintenance work must be performed promptly, and the required safety measures must be taken. Pressure equipment must not be operated if defects are present.
What should be done with loads that are not attached according to regulations?
Loads must always be fastened to properly functional lifting gear with a sufficient load limit. Pay attention to the correct attachment of loads on the crane hook. People must not stand beneath suspended loads.
What should be done before looping around the components of the turbocharger?
Before looping around the components of the turbocharger, let them cool down (maximum 80 °C). Attach components of the turbocharger as described in the respective action steps. Use a suitable edge guard if there are sharp edges. The assembly devices must be completely screwed in and must not unscrew during use. Use assembly devices only for the described applications. Put down dismantled components of the turbocharger in such a way that they cannot tip over.
What must the operating company ensure in awareness of its responsibility?
In awareness of its responsibility, the operating company must ensure that only authorized personnel work on the turbocharger, who:
- Are versed in the general and locally applicable regulations for occupational safety and accident prevention
- Are equipped with the prescribed personal protective equipment
- Have read and understood the Operation Manual
- Have been instructed in the use of the turbocharger.
What should be checked periodically?
The safety-conscious work of the personnel and adherence to the Operation Manual must be checked periodically.
What should be kept in perfect condition?
Suitable working materials and personal protective equipment must be kept in a perfect condition.
Who may remain in the vicinity of the turbocharger when the engine is running?
Only authorized personnel may remain in the vicinity of the turbocharger when the engine is running.
What must modifications to the turbocharger be approved by?
Modifications to the turbocharger must be approved by ABB Turbo Systems.
What should be done regarding original parts?
Only use original parts from ABB Turbo Systems. Original parts and accessories are specially designed by ABB Turbo Systems for the ABB turbochargers.
What should you do when the engine is running and regarding sound pressure levels?
When the engine is running, always wear ear protection. Always wear ear protection if the sound pressure level exceeds 85 dB(A).
What should you do regarding hot surfaces or contact with hot operating fluids?
Do not touch hot surfaces. Observe the warning plate on the turbocharger. Wear heat-resistant safety gloves and protective clothing. Wait for the turbocharger to cool down before carrying out any work.
What is the enginebuilder responsible for if supply is without insulation?
If supply is without insulation, the enginebuilder is responsible for providing the turbocharger with proper insulation and for providing protection against contact with hot surfaces. Compliance with the instructions and specifications given by the enginebuilder to protect against hot turbocharger surfaces is compulsory.
What should you do if there are rotating parts?
Operate the turbocharger in compliance with the specifications. Secure the rotor against unintentional rotation during maintenance. The turbocharger must never be used without the filter silencer or the air suction branch. With the engine stopped, the rotor can rotate due to the stack draught alone.
What should you do if there are electrical installations?
- Only specially trained personnel should perform work on, or with, electrical components.
- Observe national regulations.
- Ground electrical installations properly with grounding conductors.
- Check the grounding connections on a regular basis and make sure they are properly connected.
- Switch off the power supply before working on any electrical installations.
- After switching off the power supply, wait for 5 minutes to allow capacitors to discharge and hot components to cool down.
- Ensure the power supply is switched off when working on electrical installations.
- Do not carry out any tests with regard to insulation resistance or voltage on the electrical components.
What should you do during commissioning and operation?
- Visually inspect your working environment before starting work.
- Remove any obstacles and objects littering the workplace.
- Check all pipes to and from the turbocharger for damage and leaks before commissioning.
- Check turbocharger for recognizable damage or defects every 12 hours of operation or at least once a day.
- Report any damage and any alterations of operational characteristics to the responsible department immediately.
- In case of damage, take the turbocharger out of operation immediately and safeguard against accidental/unauthorised use.
- When switching on operating energy supplies (hydraulics, pneumatics, electricity), pay attention to the risks that may occur as a consequence of this energy input.
- Only operate the turbocharger with burst protection fitted and insulation fitted in one of the permitted variants.
What should you do when working on the turbocharger?
- When working on the turbocharger always wear safety footwear and protective clothing to protect against mechanical hazards.
- Keep personal protective equipment in perfect condition.
- Obey mandatory signs.
- Observe the general rules for occupational safety and prevention of accidents.
- Only perform operations that are described in this manual.
- Only perform operations for which you have received instruction or training.
- Do not climb onto the turbocharger or onto attached parts and do not use them as climbing aids.
- Use suitable climbing aids and working platforms for work above body height.
- Comply with the general accident prevention regulations.
- Only perform work on the turbocharger when you are in a physically and psychologically stable condition.
- Only work with suitable tools, equipment and appliances that function properly.
- Power tools must be grounded and cables must be undamaged.
- Keep the workplace clean; clear away any loose objects and obstacles on the floor.
- Keep the floor, equipment, and turbocharger clean.
- Have oil binding agents ready and provide or keep oil pans at hand.
- Clean up any spills.
- Have fire protection means and extinguishing agents available.
What should you do when performing welding work in the vicinity of the turbocharger?
- When performing welding work in the vicinity of the turbocharger, always cover the filter silencer to prevent the filter mat from being damaged.
- Keep flammable objects and substances out of the vicinity of flying sparks.
- Cover all connections on the turbocharger so that no foreign objects can enter the turbocharger.
- Wear personal protective equipment (PPE) for welding operations.
What should you do during cleaning?
- Observe the material safety data sheet for the cleaning agent or solvent.
- Wear personal protective equipment (PPE) according to the material safety data sheet.
- Inspect the electric cables for abrasion and damage before and after your cleaning work.
What should you do during disassembly, assembly, maintenance, and repair?
- Observe the procedures for set-up, service and inspection work and the inspection intervals.
- Inform the operating staff before starting any service or repair work. Make sure the engine is not started while work is being conducted on the turbocharger.
- Before taking off any cover or removing any guard from the turbocharger, switch off the engine and wait until the turbocharger has come to a standstill.
- Make sure that the oil supply is interrupted, especially with an external oil supply.
- Only restart the engine after all parts have been properly fitted again and oil supply is ensured.
- Only perform operations that are described in this manual.
- Only perform operations for which you have received instruction or training.
What should you do when taking out of operation or preparing for mothballing?
- Secure rotor against turning. The rotor can rotate due to the stack draught alone.
- Observe the material safety data sheet for the cleaning and mothballing agents.
- Wear personal protective equipment (PPE) according to the material safety data sheet.
What should you do regarding mechanical hazards when working on the turbocharger?
- Observe the general rules for occupational safety and prevention of accidents.
- Ensure workplace safety.
- Only perform operations that are described in this chapter.
- Only perform operations for which you have previously received instruction or training.
What should you do regarding handling operating materials and supplies?
- Do not breathe in these substances and avoid contact with the skin.
- Ensure proper ventilation.
- Observe the information in the material safety data sheet for the operating materials and supplies.
- Wear personal protective equipment (PPE) according to the material safety data sheet.
- Comply with local legislation.
What should you do regarding fire or explosion?
- Observe the information in the material safety data sheet for the operating materials and supplies.
- Comply with local legislation.
- Do not allow any exposed flame or ignition source during cleaning work.
- Carry out cleaning in the open or provide sufficient ventilation.
What should you do regarding environmental hazards?
- Observe the information in the material safety data sheet for the operating materials and supplies.
- Comply with local legislation.
What should you do regarding handling insulation materials?
- Only use suitable and non-combustible insulation materials.
- Ensure good ventilation at the workplace.
- Avoid whirling up dust.
- Use dust-free tools and working methods.
- Remove package at the workplace only.
- Proceed with particular care when removing old insulation materials.
- Dispose of insulation materials properly and in an environmentally compatible manner in compliance with the legal regulations.
What should you do if warning plates are not present in the designated locations or not readable?
- Order new warning plates from ABB Turbocharging Service Stations.
- Remove any warning plates that have become unreadable.
- Clean and degrease the areas designated for the warning plates.
- Fit new warning plates and remove protective sheets.
How to remove the turbocharger?
- Disconnect all pipes according to the instructions of the enginebuilder.
- If present: Loosen and remove the compressor wheel cooling connection. Close the compressor wheel cooling opening with a screw plug.
- Apply penetrating oil to thread of stud and nut and let it work in.
- If present: Disconnect the plug to the speed sensor and secure the rolled-up cable on the turbocharger. This protects the plug from being crushed.
- If present: Detach the support from the engine support.
- Depending on the bracket version, two positioning pins can be used for positioning and safeguarding against wrong fitting of the turbocharger. Therefore, the turbocharger must always be removed from and installed on the bracket vertically.
- The gas outlet casing can remain fitted in the exhaust gas pipe if the locking nuts are accessible. Otherwise, the complete turbocharger unit including gas outlet casing must be removed.
- Loosen and remove water connections. Close the openings of the water connections with screw plugs.
- Attach lifting gear to the suspension eye.
- Loosen and remove nuts.
- Remove the turbocharger.
- Cover the oil connections at the engine side to protect against contamination.
- Remove turbocharger from engine support, set it down properly in an appropriate place and secure it.
- Close or cover the openings of the turbocharger and support.
How to manually loosen the turbocharger to remove it from the bracket?
- Loosen and remove water connections. Close the openings of the water connections with screw plugs.
- Attach lifting gear to the suspension eye.
- Loosen and remove nuts.
How to remove the turbocharger from the bracket if it was fitted by the enginebuilder using a hydraulic tool?
- Attach lifting gear to the suspension eye.
- Remove the turbocharger.
- Cover the oil connections at the engine side to protect against contamination.
What should you never do when loosening the clamping nut?
Never relieve individual pressure screws completely. If this procedure is not complied with, the pressure screws can get compressed, thus making it impossible to loosen them.
What should you not do to pressure screws?
Do not clean pressure screws. Do not lubricate pressure screws. The pressure screws are equipped with a permanent sliding layer that must not be removed.
How to loosen the clamping nuts?
- Break loose each of the pressure screws and rotate them back immediately.
- Working in a circle, repeat the previous step until all of the screws have been relieved.
- Loosen clamping nut by hand.
How to position the turbocharger for storage?
- Place the turbocharger on a clean, level support.
- Secure the turbocharger to prevent it from tipping over by using wooden beams and wedges and by taking the center of gravity into account.
How to install the turbocharger?
- Always use new gaskets and insert them carefully into the slot.
- Lightly oil the surfaces of the threaded rods to be screwed in.
- Screw the threaded rods into the bracket with the aid of locknuts.
- Remove nuts again.
- Make sure that covers of the oil and water connections are removed.
- Make sure that the O-rings are undamaged and positioned correctly in the slots.
- Clean the expansion bushes and the contact surfaces of the expansion bushes in the bearing casing.
- Attach the lifting gear to the suspension eye of the bearing casing and loop around the gas outlet casing.
- Position the turbocharger on the bracket and align it. If present, pay attention to the positioning pin in the bracket.
- When fixing with a standard nut, fit the expansion bushes in the correct position in the slot.
- Fit the nuts and tighten them according to variant 1 or 2 in the table.
- Remove the lifting gear.
- Connect the cable to the speed sensor.
- Connect all exhaust gas, water and air lines according to the instructions of the enginebuilder.
- Remove the screw plug on the connection for the compressor wheel cooling and fit the cooling air line.
- If present: Attach support to engine support or to a connecting piece.
How to insert gaskets?
Always use new gaskets and insert them carefully into the slot.
How to fit threaded rods?
- Lightly oil the surfaces of the threaded rods to be screwed in.
- Screw the threaded rods into the bracket with the aid of locknuts.
- Remove nuts again.
How to place the turbocharger on the bracket?
- Make sure that covers of the oil and water connections are removed.
- Make sure that the O-rings are undamaged and positioned correctly in the slots.
- Clean the expansion bushes and the contact surfaces of the expansion bushes in the bearing casing.
- Attach the lifting gear to the suspension eye of the bearing casing and loop around the gas outlet casing.
- Position the turbocharger on the bracket and align it. If present, pay attention to the positioning pin in the bracket.
- When fixing with a standard nut, fit the expansion bushes in the correct position in the slot.
How to fasten the turbocharger with a standard nut?
Fit the nuts and tighten them according to variant 1 or 2 in the table. Remove the lifting gear.
What should you not do to pressure screws when fastening the turbocharger with a clamping nut?
Do not clean pressure screws. Do not lubricate pressure screws. The pressure screws are equipped with a permanent sliding layer that must not be removed.
How to prepare the clamping nut for the tightening procedure?
- Check whether the expansion bushes with recess are correctly positioned and do not touch the flange of the core hole cover.
- Clean the thread of the bolt and the contact surface.
- Lightly oil the bolt thread.
- Position the thrust washer in place.
- Tighten clamping nut by hand.
- Unscrew clamping nut by ¼ of a turn (90°). The distance between the thrust washer and the clamping nut is now about 1 mm.
How to tighten pressure screws?
- Screw in pressure screws crosswise by hand until reaching the stop.
- Tighten pressure screws crosswise to 50 % of the tightening torque specified in the table.
- Tighten pressure screws crosswise to 100 % of the tightening torque specified in the table.
- Work in a circle to tighten all pressure screws to 100 % of the tightening torque specified in the table.
- Tighten pressure screws to 100 % in 5 … 7 rounds until the required residual tightening angle of < 20° is achieved.
How to connect the turbocharger?
- Connect the cable to the speed sensor.
- Connect all exhaust gas, water and air lines according to the instructions of the enginebuilder.
- Remove the screw plug on the connection for the compressor wheel cooling and fit the cooling air line.
- If present: Attach support to engine support or to a connecting piece.
How to commission the turbocharger?
- Switch on the oil pump.
- Build up oil pressure.
- Do not exceed a pre-lubrication time of 2 minutes.
- Start the engine.
- Let the oil pump run until the pump driven by the engine generates sufficient pressure.
What do inspection procedures include?
Inspection procedures include preventative visual controls, monitoring and measuring work before and during commissioning. Inspection procedures enable changes to the turbocharger to be detected. Machine damage can be prevented.
What checks should be done before commissioning regarding the filter mat (if available)?
Check for damage and contamination.
What should be done to the lubricating system for the initial commissioning phase and after all service work?
Flush the complete lubricating system with warm oil.
What type of filters should be used when running in the engine and after all service work on the lubricating system?
Use special running-in filters.
What checks should be done to the oil filter before commissioning?
Check that the oil filter is clean.
What should be checked in the oil supply pipes?
Check the oil pressure.
What checks should be done to warning plates?
- Check whether warning plates are present and legible.
- Check whether the protective sheets have been removed from new warning plates.
What should be done to ensure uninterrupted cooling air supply during operation for the version with compressor wheel cooling?
Make sure there is an uninterrupted supply of cooling air during operation.
What should be checked on the bearing casing regarding compressor wheel cooling?
Check whether the compressor wheel cooling is fitted on the bearing casing.
What should be done to ensure an uninterrupted supply of cooling water during operation for the version with water-cooled bearing casing?
Make sure that an uninterrupted supply of cooling water is provided during operation.
What should be checked on the bearing casing regarding water cooling?
Check whether the water pipes are fitted on the bearing casing.
What checks should be done to the lubricating system after commissioning (engine in idle mode)?
- Keep to the lubricating oil pressure at the inlet.
- Keep to the lubricating oil temperature at the inlet.
- Refer to chapter Monitoring operation →25 for admissible values.
What should be checked for leaktightness of pipes?
Check all pipes for leaks in accordance with the enginebuilder’s instructions.
What measurements should be taken when starting up the engine, if present?
- Measure speed, oil pressure and charging pressure at various engine performances.
- Measure the exhaust gas temperature before and after the turbine.
- Measure the air temperature before and after the compressor.
- Compare the measured values with the values of the acceptance report. Different operating conditions indicate a malfunction (see chapter Eliminating malfunctions →51).
What should be done with cover plates (blind flanges) from the compressor casing, the gas inlet and the gas outlet, if present?
Remove them.
What should be done with screw plugs on the water connections and fit the water pipe?
Remove the screw plugs and fit the water pipe.
What should be done with the screw plug on the cooling air connection and fit the cooling air line, for the version with compressor wheel cooling?
Remove the screw plug and fit the cooling air line.
What should be checked in the exhaust gas pipe before and after the turbine?
Check the exhaust gas pipe before and after the turbine for combustion residues or water residues and clean it. Remove any foreign objects that may be present.
What should be checked and cleaned?
Check and clean filter silencer or air supply line, and remove any foreign objects that may be present.
What should be put into operation engine-side?
Put engine-side oil circulation to the turbocharger into operation.
What should be prepared?
Prepare the turbocharger for operation (see Checks before commissioning →22).
What is mandatory to limit the oil flow rate through the turbocharger to the admissible values with the engine at full load?
To limit the oil flow rate through the turbocharger to the admissible values with the engine at full load, an oil orifice is mandatory or already fitted at the turbocharger oil inlet if the oil inlet pressure is > 3 bar.
What does ABB Turbo Systems recommends for monitoring the lubricating oil pressure?
For monitoring the lubricating oil pressure, ABB Turbo Systems recommends installing a “P” manometer immediately upstream of the turbocharger oil inlet before the orifice. If the pressure is controlled electronically, the relevant signals should be triggered at the warning and alarm values.
What should be complied with exhaust gas temperature upstream of turbine?
- Measure exhaust gas temperature upstream of turbine.
- Comply with operating limits on rating plate.
- Definition and explanations concerning rating plate: refer to chapter 2 of Operation Manual / Safety.
- Operating limits: refer to chapter 3 of Operation Manual / Safety data sheet or examine rating plate.
What should be done with the speed measurement cables?
Do not strain the speed measurement cables by pulling.
What steps must be carried out if the difference between the highest and the lowest turbocharger speed is more than 3 %, relative to the speed limit nBmax?
- Reduce the engine performance immediately to the point at which the maximum turbocharger speed does not exceed 70 % of nBmax.
- If the engine cannot be stopped, it can continue to be driven at this reduced engine load or turbocharger speed.
- If a turbocharger surges continuously, the engine performance must be reduced further.
- Measure the temperatures in the air lines and gas piping from and to the turbochargers and compare with normal values. If clear deviations of temperature are found, the nearest ABB Turbocharging Service Station has to be contacted.
- Check the pressure loss of the alternative air inlet and compare it with normal values.
If the engine can be stopped temporarily:
- Inspect air lines, gas piping and the turbochargers and remedy any malfunctions.
- In any case, contacting the nearest ABB Turbocharging Service Station is recommended.
What should be done when replacing the speed sensor?
- Reduce the engine performance to idling and then stop the engine. Pay attention to post-lubrication (Stopping the engine →39).
- Switch off the lubricating oil supply to the turbocharger.
- Disconnect cable connector (86515) from speed sensor (86505).
- Unscrew and remove defective speed sensor (86505).
- Screw in new speed sensor (86505) as far as it will go and tighten.
- Connect cable connector (86515) to speed sensor (86505).
- Switch on lubricating oil supply to the turbocharger.
What should always be worn when the engine is running?
Always wear ear protection.
When should ear protection always be worn?
Always wear ear protection if the sound pressure level exceeds 85 dB(A).
What measures must be fulfilled with regard to the turbocharger to observe the limit value of the emission sound pressure level?
- Air-inlet system has been fitted
- All standard, noise-reducing measures have been fitted
- Bellows at the air outlet has been acoustically insulated by the enginebuilder (see Fig. 20: Noise insulation, bellows →32).
What does service work include?
Service work includes visual controls, monitoring, measuring and inspection as well as functional checks. Service work enables the detection and rectification of changes to the turbocharger and ensures full operability of the turbocharger.
What should be done at the specified time intervals?
Carry out the service work.
What should be agreed upon with ABB Turbo Systems for shortened service intervals?
Agree on a shortened service interval with ABB Turbo Systems.
What should be clarified by an ABB Turbocharging Service Station?
Have any unknown causes clarified by an ABB Turbocharging Service Station.
What should be done for service work every 25 … 50 hours?
- Visual check for air, exhaust gas, water and oil leaks.
- Record operating data and enter in the engine logbook.
- In case of deviations, determine the cause.
What should be done for service work at 100 hours after commissioning?
Clean or replace the oil filter located in the supply pipe to the turbocharger while the engine is stopped.
What should be done for service work according to instructions of enginebuilder?
Clean or replace the oil filter located in the supply pipe to the turbocharger while the engine is stopped.
What work can be carried out as preparation for service work according to data on the rating plate?
- Remove turbocharger from engine, dismantle and measure clearance (see Dismantling and fitting, general).
- Clean nozzle ring, turbine casing, compressor casing and diffuser, and check for cracks and erosion/corrosion.
What does ABB Turbo Systems recommends having checked and maintained by an ABB Turbocharging Service Station after 5000 successful engine start cycles for application with frequent engine start/stop cycles (Peak shaving)?
ABB Turbo Systems recommends having the rotor and bearing parts, as well as the casing parts on the turbine end, including the nozzle ring, checked and maintained by an ABB Turbocharging Service Station after 5000 successful engine start cycles.
What should be done if a protective grid is installed in the radial or axial gas outlet casing by ABB Turbo Systems?
Remove the protective grid after 50000 hours and replace it with a new one.
When should the protective grid of pre-mix gas engines be replaced?
Replace the protective grid of pre-mix gas engines after 20000 hours.
What operating data and measured values must be entered regularly into the engine logbook of the enginebuilder?
- Number of times the engine is started successfully (possible aborted start cycles do not need to be recorded)
- Performance and speed of the engine
- Air intake temperature
- Pressure of the charge air
- Pressure loss in the charge air cooler
- Lubricating oil pressure and lubricating oil temperature.
If present:
- Speed of the turbocharger
- Air temperature after the compressor and after the charge air cooler
- Exhaust gas temperature before and after the turbine
- Pressure loss in the filter silencer.
When employing the ‘Peak shaving’ mode, when does ABB Turbo Systems generally recommends replacing the compressor and turbine wheel?
When employing the ‘Peak shaving’ mode, ABB Turbo Systems generally recommends replacing the compressor and turbine wheel after 20000 successful engine start/stop cycles or after reaching the number of operating hours specified on the rating plate.
What does ABB Turbo Systems recommends having the components periodically inspected and replaced, if necessary, by an ABB Turbocharging Service Station based on the number of successful engine start cycles?
ABB Turbo Systems therefore recommends having the components periodically inspected and replaced, if necessary, by an ABB Turbocharging Service Station based on the number of successful engine start cycles specified in the following table.
What should be ensured after stopping the engine?
Adequate cooling of the turbocharger must be ensured after stopping the engine.
What should be done for water-cooled turbocharger variant?
- Post-lubricate as long as the rotor is turning.
- Observe the oil pressure while performing post-lubrication: 0.5 < poil ≤1.0.
- Switch off post-lubrication as soon as the rotor is stationary or after no more than two minutes.
- Deviating procedures must be coordinated with ABB Turbo Systems.
What does maintenance work include?
Maintenance work includes regular visual controls and cleaning operations which are intended to ensure the trouble-free functioning of the turbocharger.
What should be paid attention to pertaining to mechanical cleaning?
Pay attention to the specifications in this chapter pertaining to mechanical cleaning.
What type of tools should be used?
Use only soft tools such as rags, brushes or wire brushes.
What can be repeated until a satisfactory result is achieved in case of heavy contamination?
In case of heavy contamination, the cleaning methods described in this chapter (such as soaking, for example) can be repeated until a satisfactory result is achieved.
What must be disposed of in an environmentally compatible, professional way and in compliance with locally applicable regulations?
Contaminated water and cleaning agents.
What should be done to clean the filter ring (if present)?
- Remove filter ring.
- Clean filter ring as required or every 500 hours of operation and replace after the fifth cleaning process at the latest. Contamination of the filter ring depends on the degree of purity of the sucked-in air.
- Rinse the filter ring with water and mild detergent or, in the case of heavy contamination, soak and carefully push through. Rinse in cold water. Avoid high mechanical loads (water jet).
- Let the filter ring dry completely before assembling.
- Dirty water and mild detergent must be disposed of in compliance with locally applicable regulations.
What should be done to clean the absorption segments?
- Loosen the tension bands.
- Remove the cover grid.
- Pull out and bend up the sheet-metal coverings, and remove the absorption segments.
- Clean the absorption segments. When cleaning, note that the absorption segments must only be cleaned lightly with compressed air, a soft brush or a moist cleaning cloth.
- Have any heavily contaminated absorption segments replaced by an ABB Turbocharging Service Station.
What should be done to fit the filter silencer?
- Insert the absorption segments into the sheet-metal coverings.
- Bend the sheet-metal coverings back to their original shape and insert into the slotted guides in the filter silencer body.
- Fit the cover grid.
- Fit the tension bands and tighten them at the locks.
- Any tension bands that have become damaged must be replaced.
- Fit the filter ring, if present.
What should not be done when handling operating materials and supplies?
- Do not breathe in these substances and avoid contact with the skin.
- Ensure proper ventilation.
- Observe the information in the material safety data sheet for the operating materials and supplies.
- Wear personal protective equipment (PPE) according to the material safety data sheet.
- Comply with local legislation.
What should be done to clean the compressor-end, non-rotating parts?
- Clean the above-mentioned components with steam or ultrasound. Alternatively, soak in diesel oil or water containing household cleaning agent. After soaking, remove contamination with a brush.
- Dry components completely.
- Spray cleaned surfaces with penetrating oil. Do not spray the outer surfaces of the turbocharger.
- Dispose of contaminated water and cleaning agents in accordance with the information in the material safety data sheet.
What should be done to clean the turbine-end, non-rotating parts?
- Dismantle the lamellar sealing ring in the nozzle ring.
- Place contaminated parts in hot water or in a liquid such as brake cleaner to soften the contamination.
- Brush away the contamination or remove with a steam cleaner.
- Repeat the soaking and brushing if necessary.
- Use clean water to remove all traces of solvent from parts.
- Dry components completely.
- Spray cleaned surfaces with penetrating oil. Do not spray the outer surfaces of the turbocharger.
- Dispose of contaminated water and cleaning agents in accordance with the information in the material safety data sheet.
What should be done immediately after cleaning the cartridge group?
Immediately after cleaning, install the cartridge group and put it back into operation.
What should be done to clean the cartridge group?
- Remove turbocharger from engine (see chapter Removing and Installing →8).
- Remove cartridge group (see chapter Dismantling and fitting →58).
First clean the compressor end and then the turbine end according to the following description.
What type of cleaning agents should be used to clean the cartridge group on compressor end?
Use only pH-neutral cleaning agents which do not attack metals.
What should be ensured when cleaning the cartridge group on compressor end?
Make sure that no water or contamination can enter into the cartridge group.
How should the compressor wheel be cleaned?
Clean the compressor wheel with a rag or soft brush which has been soaked in water with a household cleaning agent. Do not use a wire brush!
What should be done after cleaning the compressor wheel?
- Dry the compressor wheel and the gap between the compressor and the bearing casing with low-pressure pressurized air.
- Lightly spray the compressor wheel and the gap between the compressor and the bearing casing with penetrating oil.
- Dispose of dirty water and cleaning agents in accordance with the material safety data sheet.
What should be done to soak the layers of contamination on the turbine?
- Place the container inside a larger container so that the overflowing fluid can be collected.
- Fill the container with soaking fluid. To shorten the soaking time, the fluid can be heated up to a maximum of 60 ºC.
- Place the cartridge group on suitable supports made of wood or metal.
- Observe dimension (B) for the supports so that the cartridge group is not immersed too deeply.
- Let the layers of contamination on the turbine soak for four hours.
What should be done to remove dirt?
- Avoid the formation of dust.
- Vacuum up dust with a suitable vacuum cleaner.
- Wear a respiratory mask to protect against particles (P1 or P2 mask).
- Lift up the cartridge group and align it horizontally.
- Remove dirt manually using a soft brush or a wire brush.
What should be ensured when cleaning the cartridge group on turbine end?
Make sure that no water or dirt enters the gap between partition wall and turbine.
What should be done after brushing off the dirt?
- Remove all traces of contamination from the turbine.
- After brushing off the dirt, fill the container with clean water and not with salt water.
- Immerse the turbine of the cartridge group in clean water so that any loose dirt comes off.
- Lift up the cartridge group and align it horizontally.
- Clamp the partition wall to the bearing casing.
- Dry the turbine and the gap between the turbine and the partition wall with low-pressure compressed air.
- Lightly spray the turbine and the gap between the turbine and the partition wall with penetrating oil.
- Dispose of dirty water and cleaning agents in accordance with the information in the material safety data sheet.
What are the possible causes and remedies for a delayed start-up when starting?
Possible causes:
- Turbocharger contaminated
- Bearing damaged
- Rotor rubbing
- Foreign object in the turbocharger
Remedy:
- Clean (see chapter Periodic maintenance work →40)
- Contact ABB Turbocharging Service Station
What are the possible causes and remedies for vibrations when starting?
Possible causes:
- Rotor unbalance
- Turbine or compressor damaged
- Bearing damaged
- Vibrations from engine
Remedy:
- Contact ABB Turbocharging Service Station
- Contact enginebuilder
What should be done if there is any doubt about the extent of the rubbing of rotating parts?
- If there is any doubt about the extent of the rubbing, contact an ABB Turbocharging Service Station.
- Have a dimension check carried out by an ABB Turbocharging Service Station.
What should be done if the lubricating oil pressure is too low during operation?
Possible causes:
- Axial clearance of the rotor excessive
- Oil filter heavily contaminated
- Oil pump in lubricating system defective
- Manometer displays incorrectly
Remedy:
- Contact an ABB Turbocharging Service Station
- Clean
- Check/replace
- Replace manometer
What should be done if the speed reduces during operation?
Possible causes:
- Turbine and/or nozzle ring severely contaminated
- Rotor components or bearing damaged
- Defects on the connected cylinders in pulse charging
- Defects, such as leaks, in the exhaust gas pipes or charge air ducts
Remedy:
- Clean (see chapter Periodic maintenance work →40)
- Contact ABB Turbocharging Service Station
- Contact enginebuilder
- Repair
What should be done if the speed increases during operation?
Possible causes:
- Light to medium contamination of the turbine and/or nozzle ring (with 4-stroke application)
Remedy:
- Clean (see chapter Periodic maintenance work →40) or contact an ABB Turbocharging Service Station
What should be done if the exhaust gas temperature is too high during operation with engine performance and engine speed unchanged?
Possible causes:
- Insufficient air, for example, when filter silencer is blocked by contamination
- Compressor/turbine contaminated
- Exhaust gas back pressure too high
- Turbine damaged or eroded
- Malfunction in the injection system
- Cooler contaminated
- Cooling water volume too low
- Inlet temperature of cooling water too high
- Insufficient ventilation
Remedy:
- Clean (see chapter Periodic maintenance work →40)
- Clean or repair boiler or exhaust gas silencer
- Contact ABB Turbocharging Service Station
- Repair or contact manufacturer
- Clean
- Fill
- Check/clean cooling system
- Improve ventilation
What should be done if the charge air pressure is too low during operation with engine performance and engine speed unchanged, suction condition normal?
Possible causes:
- Manometer display not correct
- Supply pipe to manometer not sealed
- Filter silencer contaminated, therefore pressure drop too high
- Compressor end and/or turbine end contaminated
- Compressor/turbine damaged
- Exhaust gas back pressure too high
- Air receiver not sealed
- Gas piping between engine and turbine leaking
- Injection mistimed
- Valve control misadjusted
- Pipes downstream to the compressor outlet not sealed
Remedy:
- Replace manometer
- Repair leak
- Clean (see chapter Periodic maintenance work →40)
- Contact ABB Turbocharging Service Station
- Clean or repair boiler or exhaust gas silencer
- Repair
- Set correctly
- Repair
What should be done if the charge air pressure is too high during operation with engine performance and engine speed unchanged, suction condition normal?
Possible causes:
- Manometer display not correct
- Increased speed due to contamination of nozzle ring
- Malfunction in the injection system
- Injection mistimed
- Engine performance higher than indicated
Remedy:
- Replace manometer
- Clean (see chapter Periodic maintenance work →40) or contact an ABB Turbocharging Service Station
- Repair or contact manufacturer
- Set correctly
- Check engine performance
What should be done in the event of reduced compressor performance/efficiency and therefore engine performance losses?
Possible causes:
- Compressor components severely contaminated by the ventilation gases that have been fed in
- Increased blade vibration, compressor blade damage due to the ventilation gases that have been fed in
- Material of the compressor wheel corroded due to the feeding in of ventilation gases containing corrosive components
- Material of the compressor wheel corroded due to intake air containing exhaust gases or salt
Remedy:
- Clean (see chapter Periodic maintenance work →40) Optimize oil separation
- Correct the feed of ventilation gases according to instructions of enginebuilder
- Prevent exhaust gas leakages in the engine space Clean (see chapter Periodic maintenance work →40)
What should be done if the turbocharger surges continuously or periodically?
- Gradually reduce the engine load.
- Have the cause clarified and remedied immediately by an ABB Turbocharging Service Station.
- Have parts assessed for damage and, if necessary, replaced by an ABB Turbocharging Service Station.
Possible causes:
- Filter silencer or diffuser contaminated
- Heavy contamination deposits in the turbine or in the nozzle ring
- Protective grating in front of the turbocharger contaminated or damaged
- Cooler contaminated
- Charge air duct blocked
Remedy:
- Clean (see chapter Periodic maintenance work →40)
- Clean/replace
- Clean
What should be done for runout noises when stopping?
Possible causes:
- Turbocharger contaminated
- Bearing damaged
- Rotor rubbing
- Foreign object in the turbocharger
Remedy:
- Clean (see chapter Periodic maintenance work →40)
- Check clearances (see chapter Axial clearance A and radial clearance B →73). If clearances are outside the tolerance or if in doubt, contact an ABB Turbocharging Service Station
- Check clearances (see chapter Radial clearances N and R →80). If clearances are outside the tolerance or if in doubt, contact an ABB Turbocharging Service Station
- Dismantle turbocharger (see chapter Dismantling and fitting →58). In case of damage, replace the corresponding parts or contact an ABB Turbocharging Service Station
What should be done if the runout time is too short when stopping?
Possible causes:
- Turbocharger contaminated
- Bearing damaged
- Rotor rubbing
- Foreign object in the turbocharger
Remedy:
- Clean (see chapter Periodic maintenance work →40)
- Check clearances (see chapter Axial clearance A and radial clearance B →73). If clearances are outside the tolerance or if in doubt, contact an ABB Turbocharging Service Station
- Check clearances (see chapter Radial clearances N and R →80). If clearances are outside the tolerance or if in doubt, contact an ABB Turbocharging Service Station
- Dismantle turbocharger (see chapter Dismantling and fitting →58). In case of damage, replace the corresponding parts or contact an ABB Turbocharging Service Station
What should be done if there is no signal or poor signal amplitude of the speed measurement?
Possible causes:
- The speed sensor was accidentally fitted with an additional gasket. An enlarged distance between the sensor tip and the signal-emitting sealing disc reduces the voltage amplitude of the speed signal
- Sensor or cable defective
Remedy:
- Install the speed sensor without the additional gasket (copper ring)
- Contact an ABB Turbocharging Service Station. Order new speed sensor (86505) (refer to chapter Ordering spare parts →89). Replacing the speed sensor →30
What should be done if the measured speed is too high?
Possible causes:
- Sensor tip contaminated, since it is magnetic and can attract metallic particles. This reduces the distance to the signal-emitting sealing disc, which can lead to amplification of the noise component and, hence, to false triggering
Remedy:
- Dismantle the sensor, clean the sensor tip, and fit the sensor back on with the specified tightening torque
What should be done if the measured speed is too low?
Possible causes:
- –
Remedy:
- Contact ABB Turbocharging Service Station
What should be done before and after use with assembly devices?
Assembly devices must be checked for damage.
What should be visually inspected for?
Visually inspect for corrosion, cracks, deformation and wear.
What should be done with damaged assembly devices?
Damaged assembly devices must no longer be used and must be replaced.
What should be done when disassembling the turbocharger?
When disassembling the turbocharger, an oil orifice fitted in the oil inlet must not be removed (see also chapter Removing the cartridge group →69).
What should be done with the threads of studs when removing cartridge group 1?
Treat threads of studs with penetrating oil and leave to take effect.
What should be done with the dimension A, B after the removal and before the installation of the cartridge group?
Measure and record clearances A and B after the removal and before the installation of the cartridge group.
What should be done to obtain a correct measurement?
In order to obtain a correct measurement, elevate the turbine a little.
What should be done with the dial indicator?
Attach the dial indicator and align it for the respective clearance as per the illustration.
What should be done to measure clearance A?
Move the rotor to and fro up to the stop and compare it with the permissible values in the table.
What should be done to measure clearance B?
- Raise the compressor and push the turbine down at the same time.
- Raise the turbine and push the compressor down at the same time.
- Measure clearance B and compare it with the permissible values in the table.
What should be done if the calculated value (PD) lies outside the specified range?
If the calculated value (PD) lies outside the specified range, contact an ABB Turbocharging Service Station.
What should be done to install the nozzle ring?
- Fit the lamellar sealing ring in the correct slot (see detail A1/A2). When doing this, pay attention to correct winding of the lamellar sealing ring (see detail B).
- Secure the lamellar sealing ring with adhesive tape.
- Place the burst ring in the turbine casing.
- Insert the nozzle ring (with the cams facing downwards) into the turbine casing as far as it will go. Align the cams on the nozzle ring with the recesses of the turbine casing. Do not remove the adhesive tape.
- If present: Fit the metal C-ring.
How can the end position of the nozzle ring in the turbine casing be checked?
The end position of the nozzle ring in the turbine casing can be checked via dimension H.
What should be done to measure dimension H?
Measure dimension H as shown in the illustration and compare it with the minimum dimension H in the table.
What should be done with the threads of the studs before installing the cartridge group?
Coat the threads of the studs with high-temperature grease.
What should be done with the fastening strips before assembly when installing the compressor casing?
Thoroughly clean the fastening strips before assembly.
What should be done to measure clearances N and R?
- Push the feeler gauges into the gap such that there is no clearance. The upper direction (N1) and lower direction (N2) must be covered simultaneously.
- Calculate clearance N and compare it with the permissible values in the table.
- Push the feeler gauges into the gap such that there is no clearance. The upper direction (R2) and lower direction (R1) must be covered simultaneously.
- Calculate clearance R and compare it with the permissible values in the table.
What should be done to install air inlets?
- Secure lifting gear to filter silencer.
- Fit a new O-ring to the filter silencer or a new O-ring to the air suction branch.
- Fit the filter silencer or air suction branch with the V-clamp.
- Observe the tightening torque.
What should be done to install the gas outlet flange?
- If present: Insert the metal C-ring into the turbine casing and secure with high-vacuum grease.
- Install the gas outlet flange in the turbine casing.
- Measure radial clearance ® (see chapter Radial clearances N and R).
What should be done to install the gas outlet casing?
- Insert a new gasket into the gas outlet casing.
- Coat the threads of the studs with high-temperature grease.
- Attach the lifting gear to the gas outlet casing and position the gas outlet casing in the correct position on the turbine casing.
- If present: Fit the support.
- Fit the hexagon nuts. Observe the tightening torque.
What emergency repair options exist if the engine has to be brought back into operation again as quickly as possible in the event of a turbocharger defect?
- If present: Installing the replacement turbocharger →85.
- If present: Installing the replacement cartridge group →85.
What does ABB Turbo Systems recommends to enable to quickly put an engine back into operation after a turbocharger has sustained damage?
To enable you to quickly put an engine back into operation after a turbocharger has sustained damage, ABB Turbo Systems recommends having a replacement turbocharger or appropriate spare parts available in storage. The defective turbocharger can be removed and the replacement turbocharger installed within a short period of time.
What should be done to install the replacement turbocharger?
- Remove defective turbocharger (see chapter Removing and Installing →8).
- Install replacement turbocharger (see chapter Removing and Installing →8).
- Send the defective turbocharger to an ABB Turbocharging Service Station for inspection and repair.
What does ABB Turbo Systems recommends to enable to quickly put an engine back into operation after a turbocharger has sustained damage?
To enable you to quickly put an engine back into operation after a turbocharger has sustained damage, ABB Turbo Systems recommends having a replacement cartridge group available in storage. The defective cartridge group can be removed and the replacement cartridge group installed within a short period of time. A replacement cartridge group is ready for use immediately and includes the complete bearing casing with bearing and a balanced rotor.
What should be done to install the replacement cartridge group?
- Remove defective cartridge group (see chapter Dismantling and fitting →58).
- Install replacement cartridge group (see chapter Dismantling and fitting →58).
- Send the defective cartridge group to an ABB Turbocharging Service Station for inspection and repair.
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