ABB A135-M65 (01) PDF MANUAL


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PDF Content Summary: ABB Turbocharging Operation Manual A135-M65 HT593033 English Original Operation Manual Chapter Document-ID 1 Introduction HZTL4005_EN_F 2 Safety HZTL4022_EN_E 3 Safety data sheet HT593033 4 Product description HZTL4031_EN_H Operating limits and replacement intervals The recommended replacement intervals and the corresponding operating limits in chapter 3 are jointly defined with the enginebuilder. This information is specific to the product. Non-observance of the recommended replacement intervals and the operating limits increases the risk of unpre- dictable component failures. Operation Manual / 1 Introduction Table of contents Introduction 1 Introduction............................................................................................................ 2 1.1 Purpose of the manual.................................................................................................. 2 1.2 Symbols, definitions...................................................................................................... 3 1.3 Storage of new turbochargers and spare parts...................................................... 5 1.4 Contact information...................................................................................................... 7 © Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017 Operation Manual / 1 Introduction 1 Introduction / 1.1 Purpose of the manual 1 Introduction 1.1 Purpose of the manual © Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017 Fig. 1: Serial number (01) on the rating plate This Operation Manual belongs to the turbocharger with the identical serial number (01), see chapter 3 (Safety data sheet) 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. Operation Manual / 1 Introduction 1 Introduction / 1.2 Symbols, definitions 1.2 Symbols, definitions Symbols The following symbols are used in this document: ▶ Indicates 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. ABB Turbo Systems ABB Turbo Systems Ltd is identified as ABB Turbo Systems in this document. Official service stations of ABB Turbo Systems Official service stations are identified in this document as ABB Turbocharging Service Sta- tions. They are regularly audited and certified by ABB Turbo Systems. Also see chapter Con- tact information →7. © Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017 Operation Manual / 1 Introduction 1 Introduction / 1.2 Symbols, definitions 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 Pictogram Meaning

Oil free, grease free and dry Table 1: Definition of pictograms Apply other paste in accord- ance with specifications Dispose of in an environmentally compatible, professional way and in compliance with locally applic- able regulations

© Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017

Tighten with specified torque Tighten over specified tighten- ing angle Hand-tight, tighten without tools Oil Apply screw locking paste (e.g. Loctite) Apply high-temperature grease Affix Measure Note Visually inspect Please note text for numbered work step See document

Operation Manual / 1 Introduction 1 Introduction / 1.3 Storage of new turbochargers and spare parts 1.3 Storage of new turbochargers and spare parts Storage of new turbochargers and spare parts for 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, indicated by the VCI la- bel on the package. © Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017 Fig. 2: Volatile Corrosion Inhibitor (VCI) Only dry rooms with 40...70 % atmospheric humidity, in which no water condensation can form, are suitable as storage locations. Storage of new turbochargers and spare parts for more than 6 months Wear safety gloves to protect against mechanical hazards. Every 6 months, the following mothballing measures are required: ▶ Open package. ▶ Remove 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 http://www.branopac.com. ▶ Old VCI corrosion protection emitters must be disposed of in an environmentally compat- ible, professional way and in compliance with locally applicable regulations. ▶ Close package. The more tightly the package is sealed, the longer the protection dura- tion. 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: ▶ 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. Operation Manual / 1 Introduction 1 Introduction / 1.3 Storage of new turbochargers and spare parts Long-term storage of replacement turbochargers or spare parts The turbochargers or cartridge groups will be prepared for long-term storage if requested in the purchase order. The package is equipped with a hygrometer (see illustration). © Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017 Fig. 3: Package with hygrometer Every 6 months, the following measures are required: ▶ Check the hygrometer (02) in the sight-glass. There is an opening (01) in the wooden crate to enable you to perform this check. If the 70% indicator field has changed colour, the maximum admissible atmospheric humidity has been exceeded. In this case, the tur- bocharger 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. After every 3 years, the following steps must be carried out by an ABB Turbocharging Service Station: ▪ Checking the component ▪ Replacing the desiccant ▪ Repackaging the component. NOTICE Replacement components which are ready for operation If the 70% field of the hygrometer (02) has not changed colour and the pack- age 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. Unpackaging replacement turbochargers or spare parts Once the material has been unpackaged from the VCI package, the corrosion protection is no longer effective. To prevent condensation, the temperature of the package contents must be the same as the ambient temperature. Operation Manual / 1 Introduction 1 Introduction / 1.4 Contact information 1.4 Contact information Contact information for the ABB Turbocharging Service Stations is available online. ▶ Scan the QR code to access our website. ABB Turbo Systems Ltd Bruggerstrasse 71a CH-5401 Baden Switzerland http://www.abb.com/turbocharging © Copyright 2017 ABB. All rights reserved. HZTL4005_EN Revision F May 2017 Operation Manual / 2 Safety / A130 - A155 Table of contents Safety 1 Safety ...................................................................................................................... 2 1.1 Introduction.................................................................................................................... 2 1.2 CE conformity................................................................................................................. 2 1.3 Definition of mandatory signs.................................................................................... 3 1.4 Definition of safety instructions ................................................................................ 3 1.5 Intended use .................................................................................................................. 4 1.6 Deflagration on gas engines ....................................................................................... 5 1.7 Warning plates on the turbocharger......................................................................... 6 1.8 Turbocharger rating plate............................................................................................ 7 1.9 Periodic check of the pressure vessels..................................................................... 8 1.10 Lifting of loads.............................................................................................................. 9 1.11 Prerequisites for operation and maintenance....................................................... 10 1.12 Hazards during operation and maintenance ......................................................... 11 1.13 Safe operation.............................................................................................................. 13 1.14 Safe maintenance ........................................................................................................ 15 © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017 Operation Manual / 2 Safety / A130 - A155 1 Safety / 1.1 Introduction 1 Safety 1.1 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 manual (Definition of safety instructions →3) must also be observed. 1.2 CE conformity Information ABB turbochargers comply with the Machinery Directive 2006/42/EC and are partly com- pleted machinery as defined by Article 2 g in this directive. © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017 Operation Manual / 2 Safety / A130 - A155 1 Safety / 1.3 Definition of mandatory signs 1.3 Definition of mandatory signs To be worn at all times

Safety footwear to protect against mechanical hazard and risk of falling Table 1: Personal protective equipment to be worn at all times To be worn specific to the respective task Ear protection Safety helmet Protective clothing

Table 2: Personal protective equipment to be worn specific to the respective task 1.4 Definition of safety instructions © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017 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. ▶ Warning 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. ▶ Caution signs must always be observed.

Safety glasses Safety gloves to protect against - Mechanical hazard - Chemical hazard - Thermal hazard Safety goggles Respiratory mask to protect against - Dusts - Gases

Operation Manual / 2 Safety / A130 - A155 1 Safety / 1.5 Intended use 1.5 Intended use Use on internal combustion engines in general ABB turbochargers are intended for turbocharging 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. ABB accepts no liability and rejects all warranty claims for any non-intended uses. [1] Euromot = The European Association of Internal Combustion Engine Manufacturers [2] Directive 94/9/EC concerning equipment and protective systems intended for use in potentially 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. ▶ Only operate the turbocharger within the operating limits. ▶ Only 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 © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017 Operation Manual / 2 Safety / A130 - A155 1 Safety / 1.6 Deflagration on gas engines 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. ABB excludes any liability for damage resulting from unauthorized modifications to the tur- bocharger or improper operation. 1.6 Deflagration on gas engines ABB turbochargers can tolerate a deflagration with a transient pressure increase of 12 bar. After a deflagration event ABB Turbo Systems recommends verifying the following points on the turbocharger: ▪ Position of the turbine and compressor casings to the bearing casing ▪ Shifting of the bearing casing in relation to the bracket ▪ Cracks in casings If during external inspection anomalies are found or if a particularly strong deflagration event has taken place, it is also 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. © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017 Operation Manual / 2 Safety / A130 - A155 1 Safety / 1.7 Warning plates on the turbocharger 1.7 Warning plates on the turbocharger Warning plates are attached to the turbocharger, which must be observed. The warning plates must always be present in the intended locations and must be legible. © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017 Fig. 1: Warning plate 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. Turbochargers supplied to the enginebuilder without insulation must be equipped later with warning plates on the insulation. This is the responsibility of the enginebuilder. Operation Manual / 2 Safety / A130 - A155 1 Safety / 1.8 Turbocharger rating plate 1.8 Turbocharger rating plate © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017 Fig. 2: 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 Operation Manual / 2 Safety / A130 - A155 1 Safety / 1.9 Periodic check of the pressure vessels 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 a case, we recommend that you contact the nearest official service station of ABB Turbo Systems. 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. Locations of the rating plates The locations of the rating plates are defined in the Operation Manual, Chapter 4 Product description. 1.9 Periodic check of the pressure vessels The pressure vessels used by ABB Turbocharging, such as those for wet or dry cleaning, are so-called "simple pressure vessels". ▪ The locally applicable legal regulations regarding periodic checks of the pressure vessels must be observed. ▪ The operating company is responsible for the safe operation of the pressure vessel. © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017 WARNING Danger due to 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. Operation Manual / 2 Safety / A130 - A155 1 Safety / 1.10 Lifting of loads 1.10 Lifting of loads © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017 Fig. 3: Attachment of loads on the crane hook Fig. 4: Attachment angle If there are two or more suspension points, the attachment angle of 45° must not be ex- ceeded. This prevents excessive loading due to diagonal pull. ▶ Before looping around the components of the turbocharger, let them cool down (max- imum 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. WARNING Suspended loads Loads that are not attached according to regulations can cause injury to personnel or fatal accidents. ▶ 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. Wear safety gloves to protect against mechanical hazards. Wear safety helmet. Operation Manual / 2 Safety / A130 - A155 1 Safety / 1.11 Prerequisites for operation and maintenance 1.11 Prerequisites for operation and maintenance Responsibility of the operating company In awareness of its responsibility, the operating company must ensure that only authorised 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. The safety-conscious work of the personnel and adherence to the Operation Manual must be checked periodically. Suitable working materials and personal protective equipment must be kept in a perfect condition. Only authorised personnel may remain in the vicinity of the turbocharger when the engine is running. Competence of personnel The turbocharger must only be operated and serviced by trained and authorised personnel. Basic mechanical training is a prerequisite. Modifications to the turbocharger Modifications to the turbocharger must be approved by ABB Turbo Systems. WARNING Use original parts Operation of the turbocharger with non-original parts can impair the safety of the turbocharger and can cause serious damage to property and injury to personnel. ▶ Only use original parts from ABB Turbo Systems. Original parts and accessories are specially designed by ABB Turbo Systems for the ABB tur- bochargers. ABB accepts no liability for any damage resulting from the use of non-original parts and cor- responding accessories. © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017 Operation Manual / 2 Safety / A130 - A155 1 Safety / 1.12 Hazards during operation and maintenance 1.12 Hazards during operation and maintenance Noise hazards The turbocharger's noise emission during operation is influenced by its installation and op- erating conditions. A noise level exceeding 85 dB(A) is harmful. Wear ear protection. Hazards due to hot surfaces Surfaces of the turbocharger, attached parts and operating fluids (lubricating oil) get hot during operation. The surface temperature depends on the efficacy of the existing insula- tion. The temperature may rise to a level that can cause burns. © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017 WARNING Danger due to noise Exposure to noise can harm the hearing system, impair health and the psy- chological state and may lead to lack of attention and irritation. ▶ When the engine is running, always wear ear protection. ▶ Always wear ear protection if the sound pressure level exceeds 85 dB(A). WARNING Danger of burns Touching hot surfaces or contact with hot operating fluids can cause burns. ▶ Do not touch hot surfaces. Observe the warning plate on the turbochar- ger. ▶ Wear heat-resistant safety gloves and protective clothing. ▶ Wait for the turbocharger to cool down before carrying out any work. Wear safety gloves to protect against thermal hazards. Operation Manual / 2 Safety / A130 - A155 1 Safety / 1.12 Hazards during operation and maintenance © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017 Wear safety gloves to protect against thermal hazards. Hazards due to rotating parts Wear safety gloves to protect against mechanical hazards. Hazards due to electrical installations (if present) WARNING Hot surfaces on the non-insulated turbocharger Non-insulated turbochargers can cause serious injuries to personnel (burns). The turbocharger is supplied with or without insulation in accordance with the purchase order received from the enginebuilder. If supply is without in- sulation, 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 en- ginebuilder to protect against hot turbocharger surfaces is compulsory. WARNING Physical hazards Contact with rotating parts can cause severe injury. 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. ▶ Operate the turbocharger in compliance with the specifications. ▶ Secure the rotor against unintentional rotation during maintenance. WARNING Dangers during work on electrical installations Electrical installations use voltages that can lead to severe injury to person- nel or accidents resulting in fatalities. At the same time, electrical or electronic components and parts can also be damaged or destroyed. ▶ Only specially trained personnel should perform work on, or with, elec- trical components. ▶ Observe national regulations. Operation Manual / 2 Safety / A130 - A155 1 Safety / 1.13 Safe operation © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017 WARNING Absence of grounding on electrical installations Missing or incorrectly fitted grounding conductors can lead to severe injury to personnel or accidents resulting in fatalities. Electric shock or elevated electromagnetic disturbances can damage or des- troy electrical and electronic components. ▶ 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. 1.13 Safe operation Mechanical hazards during operation During standard operation, no mechanical hazards are caused by the turbocharger itself if it has been properly installed. Safety 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 commission- ing. ▶ Check turbocharger for recognisable 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 at- tention to the risks that may occur as a consequence of this energy input. Operation Manual / 2 Safety / A130 - A155 1 Safety / 1.13 Safe operation © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017 Fig. 5 Variant A Insulation (01) with integrated burst protection from ABB Turbo Systems. Variant B Burst protection (03) and insulation (02) from ABB Turbo Systems. Variant C Burst protection (03) from ABB Turbo Systems with appropriate insulation from the enginebuilder. WARNING Burst protection and insulation Operation without burst protection and insulation or with the wrong com- bination of burst protection and insulation can cause serious injuries to per- sons or even fatal accidents. ▶ Only operate the turbocharger with burst protection fitted and insulation fitted in one of the following, permitted variants. Operation Manual / 2 Safety / A130 - A155 1 Safety / 1.14 Safe maintenance 1.14 Safe maintenance Occupational safety WARNING Risk of falling When working on the turbocharger, there is a risk of falling. ▶ 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. © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017 WARNING Injuries to persons Severe injuries to personnel or fatal accidents can be caused by mechanical influences as a consequence of hazardous and inadequate operational pro- cedures or non-compliance with safety and health standards. ▶ When working on the turbocharger always wear safety footwear and pro- tective 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 acci- dents. ▶ Only perform operations that are described in this manual. ▶ Only perform operations for which you have received instruction or train- ing. Wear safety footwear to protect against mechanical hazard and risk of fall- ing. Wear protective clothing. Operation Manual / 2 Safety / A130 - A155 1 Safety / 1.14 Safe maintenance 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 tur- bocharger. ▶ Wear personal protective equipment (PPE) for welding operations. Safety during cleaning If cleaning agents or solvents are used for cleaning, the corresponding material safety data sheet and the safety instructions in section Hazards due to operating materials and supplies must be observed. ▶ 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. Safety during disassembly, assembly, maintenance and repair ▶ Observe the procedures for set-up, service and inspection work and the inspection inter- vals. ▶ Inform the operating staff before starting any service or repair work. Make sure the en- gine 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 en- sured. CAUTION Mechanical operations on the turbocharger Components of the turbocharger can be damaged or destroyed as a result of improper procedures. ▶ Only perform operations that are described in this manual. ▶ Only perform operations for which you have received instruction or train- ing. Safety 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. © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017 Operation Manual / 2 Safety / A130 - A155 1 Safety / 1.14 Safe maintenance Mechanical hazards when working on the turbocharger WARNING Mechanical hazards Severe injuries to personnel or fatal accidents can be caused by mechanical influences as a consequence of hazardous and inadequate operational pro- cedures. ▶ Observe the general rules for occupational safety and prevention of acci- dents. ▶ Ensure workplace safety. ▶ Only perform operations that are described in this chapter. ▶ Only perform operations for which you have previously received instruc- tion or training. Hazards due to operating materials and supplies Operating materials and supplies are substances required for the operation of the tur- bocharger or for the performance of maintenance work. Oils, greases, coolants, detergents and solvents, acids and similar substances can be classified as hazardous substances. © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017 WARNING Physical hazards due to rotating parts The rotor can rotate due to the stack draught alone. Contact with rotating parts can cause severe injury. ▶ Secure rotor against turning. WARNING Handling operating materials and supplies Swallowing or inhaling vapours of operating materials and supplies or con- tact with them may be harmful to health. ▶ 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 operat- ing materials and supplies. ▶ Wear personal protective equipment (PPE) according to the material safety data sheet. ▶ Comply with local legislation. Wear safety goggles. Wear safety gloves to protect against chemical hazards. Wear a respiratory mask to protect against gases. Operation Manual / 2 Safety / A130 - A155 1 Safety / 1.14 Safe maintenance © Copyright 2017 ABB. All rights reserved. HZTL4022_EN Revision E May 2017 CAUTION Environmental hazard Improper handling of operating materials and supplies can lead to environ- mental damage. ▶ Observe the information in the material safety data sheet for the operat- ing materials and supplies. ▶ Comply with local legislation. Hazards due to the handling of insulation materials WARNING Danger of fire or explosion Flammable and combustible operating materials and supplies can catch fire or resulting vapours can lead to an explosion. ▶ Observe the information in the material safety data sheet for the operat- ing 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. WARNING Danger from insulation materials Dust or fibres from insulation materials can have adverse effects on the health or cause irritations. Unsuitable and combustible insulation materials are a fire hazard. ▶ 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 com- patible manner in compliance with the legal regulations. Wear safety goggles. Wear a respiratory mask to protect against dusts. Wear safety gloves to protect against chemical hazards. Operation Manual / A135-M65 / Safety data sheet Page 1 / 1 Safety data sheet A135-M65 HT593033 © Copyright 2020 ABB. All rights reserved. HT593033 February 2020 A135-M65 HT593033 893 630 873 600 150634-18013 300 8 50 50 2020 Operation Manual / 4 Product description / A130-M.. - A145-M.. Table of contents Product description 1 Introduction............................................................................................................ 3 1.1 Essential information.................................................................................................... 3 1.2 Registered trademarks................................................................................................. 3 1.3 Related documents........................................................................................................ 3 1.4 Layout and function of the turbocharger................................................................ 4 1.5 Warning plates on the turbocharger......................................................................... 6 1.6 Locations of the rating plates..................................................................................... 7 2 Removing and Installing........................................................................................ 8 2.1 Turbocharger weight and transportation ............................................................... 8 2.2 Removing the turbocharger........................................................................................ 9 2.3 Installing the turbocharger........................................................................................ 14 3 Commissioning .................................................................................................... 22 3.1 Oil supply....................................................................................................................... 22 3.2 Inspection procedures............................................................................................... 24 3.3 Commissioning after taking out of operation...................................................... 26 4 Monitoring operation.......................................................................................... 27 4.1 Oil pressure, oil temperature..................................................................................... 27 4.2 Exhaust gas temperature before turbine .............................................................. 29 4.3 Turbocharger speed................................................................................................... 30 5 Operation and service......................................................................................... 33 5.1 Noise emission............................................................................................................ 33 5.2 Service work................................................................................................................. 35 5.3 Expected replacement intervals .............................................................................. 39 5.4 Stopping the engine.................................................................................................... 41 6 Periodic maintenance work................................................................................ 42 6.1 Foreword to maintenance......................................................................................... 42 6.2 Cleaning the compressor during operation.......................................................... 43 6.3 Cleaning the turbine during operation................................................................... 46 6.4 Cleaning components mechanically ....................................................................... 50 7 Eliminating malfunctions.................................................................................... 60 7.1 Malfunctions when starting...................................................................................... 60 7.2 Malfunctions during operation................................................................................. 61 7.3 Turbocharger is surging............................................................................................ 64 7.4 Malfunctions when stopping.................................................................................... 65 7.5 Speed measurement system.................................................................................... 66 © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Operation Manual / 4 Product description / A130-M.. - A145-M.. Table of contents 8 Dismantling and fitting....................................................................................... 67 8.1 Introduction................................................................................................................. 67 8.2 Weights of individual parts....................................................................................... 70 8.3 Removing the air inlets............................................................................................... 71 8.4 Removing the gas outlet casing ............................................................................... 72 8.5 Removing the gas outlet flange................................................................................ 73 8.6 Removing the compressor casing........................................................................... 76 8.7 Pressing off the casing.............................................................................................. 78 8.8 Removing the cartridge group................................................................................. 79 8.9 Removing the nozzle ring........................................................................................... 81 8.10 Installing the cartridge group on the service support........................................ 82 8.11 Measuring clearance A and B.................................................................................... 83 8.12 Nozzle ring compression PD..................................................................................... 84 8.13 Installing the nozzle ring ........................................................................................... 85 8.14 Installing the cartridge group .................................................................................. 86 8.15 Installing the compressor casing ............................................................................ 89 8.16 Measuring radial clearances N and R ....................................................................... 91 8.17 Installing the air inlets ............................................................................................... 92 8.18 Installing the gas outlet flange ................................................................................ 93 8.19 Fitting the insulation of the turbine casing .......................................................... 94 8.20 Installing the gas outlet casing................................................................................ 95 8.21 Table of tightening torques...................................................................................... 97 9 Taking out of operation at short notice........................................................... 99 9.1 Possible emergency repairs...................................................................................... 99 9.2 Installing the replacement turbocharger............................................................. 100 9.3 Installing the replacement cartridge group ........................................................ 100 9.4 Fitting the cover plate............................................................................................... 101 9.5 Cover plate drawing................................................................................................. 102 10 Mothballing the turbocharger.......................................................................... 103 10.1 Taking the engine out of operation for up to 12 months ................................. 103 10.2 Taking the engine out of operation for more than 12 months........................ 104 11 Disposing of turbocharger components ........................................................ 105 12 Spare parts ......................................................................................................... 106 12.1 Ordering spare parts................................................................................................ 106 12.2 Required customer spare part set (97070).......................................................... 106 12.3 View of turbocharger with part numbers............................................................ 108 12.4 View of turbine cleaning device .............................................................................. 110 Figures.................................................................................................................. 111 Tables ................................................................................................................... 113 © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Operation Manual / 4 Product description / A130-M.. - A145-M.. 1 Introduction / 1.1 Essential information 1 Introduction 1.1 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 ABB Turbocharging Service Station if you have any questions regarding a design variant (see Contact information at http://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. 1.2 Registered trademarks The trademarks of outside companies are used in this document. These are marked with the ® symbol. 1.3 Related documents Chapter Document number Operation Manual / 1 Introduction HZTL4005 Operation Manual / 2 Safety HZTL4022 Operation Manual / 3 Safety data sheet *) Serial number of the turbocharger Table 1: Related documents *) This chapter is only available in serialised operation manuals. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Operation Manual / 4 Product description / A130-M.. - A145-M.. 1 Introduction / 1.4 Layout and function of the turbocharger 1.4 Layout and function of the turbocharger © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Fig. 1: 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 Operation Manual / 4 Product description / A130-M.. - A145-M.. 1 Introduction / 1.4 Layout and function of the turbocharger 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). 1.4.1 Function of the compressor wheel cooling © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Fig. 2: 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 (01). In addition, the turbocharger version with compressor wheel cooling is indicated by the tur- bocharger type (M6..) on the rating plate. Operation Manual / 4 Product description / A130-M.. - A145-M.. 1 Introduction / 1.5 Warning plates on the turbocharger 1.5 Warning plates on the turbocharger Warning plates are affixed at the following locations: © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Fig. 3: Warning plate locations If warning plates are not present in the designated locations or not readable, proceed as fol- lows: ▶ 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. Turbochargers supplied to the enginebuilder without insulation must be equipped later with warning plates on the insulation. This is the responsibility of the enginebuilder. Operation Manual / 4 Product description / A130-M.. - A145-M.. 1 Introduction / 1.6 Locations of the rating plates 1.6 Locations of the rating plates © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Fig. 4: 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. Operation Manual / 4 Product description / A130-M.. - A145-M.. 2 Removing and Installing / 2.1 Turbocharger weight and transporta- tion 2 Removing and Installing 2.1 Turbocharger weight and transportation Lifting gear with a sufficient load limit must be used for transporting the turbocharger. The weight specified below applies to the heaviest variant possible. Depending on the specifica- tion, the weight specified on the rating plate may be lower than the standard value specified here. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Fig. 5: Suspension of complete turbocharger unit A Turbocharger with oil-cooled bearing casing B Turbocharger with water-cooled bearing casing C Complete turbocharger unit with gas outlet casing Product Weight of complete turbocharger unit [kg] A130-M 210 A135-M 300 A140-M 500 A145-M 850 Table 2: Weight of complete turbocharger unit Operation Manual / 4 Product description / A130-M.. - A145-M.. 2 Removing and Installing / 2.2 Removing the turbocharger 2.2 Removing the turbocharger ▶ Disconnect all pipes according to the instructions of the enginebuilder. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Fig. 6: Turbine cleaning nozzle ▶ If present: Loosen the turbine cleaning connection. The cleaning nozzle (51301) must be replaced after each removal procedure. If the clean- ing nozzle is not to be replaced, the screw connection (01) must not be loosened during disassembly. Operation Manual / 4 Product description / A130-M.. - A145-M.. 2 Removing and Installing / 2.2 Removing the turbocharger The gas outlet casing (61001) 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. ▶ If present: Loosen and remove the compressor wheel cooling connection. Close the com- pressor wheel cooling opening with a screw plug (01). ▶ If present: Disconnect the plug to the speed sensor (86505) and secure the rolled-up cable on the turbocharger. This protects the plug from being crushed. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Fig. 7: Removing the turbocharger A Oil-cooled bearing casing D Clamping nut B Water-cooled bearing casing E Standard nut C Position of expansion sleeves ▶ Apply penetrating oil to thread of stud (02) and nut and let it work in. Do not oil the pressure screws of the clamping nut (D). ▶ If present: Detach the support (61301) from the engine support. Depending on the bracket version (04), two positioning pins (05) 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. Operation Manual / 4 Product description / A130-M.. - A145-M.. 2 Removing and Installing / 2.2 Removing the turbocharger Version with water cooling CAUTION Freezing of the cooling water in the bearing casing If cooling water freezes in the bearing casing, this can lead to severe dam- age. ▶ For transport and storage of the turbocharger, drain the cooling water from the bearing casing via one of the two bottom openings of the water connections. 2.2.1 Fastening of the turbocharger Depending on the type and version, the turbocharger can be fastened in different ways. The appropriate procedure must be chosen to undo the connection. Oil-cooled bearing casing (A) ▶ Attach lifting gear to the suspension eye. ▶ Loosen and remove nuts (E). If clamping nut (D) is present: Loosen in accordance with chapter Loosening the clamping nut →12. ▶ Positioning the turbocharger for storage →13. Water-cooled bearing casing (B) ▶ 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 (E). If clamping nut (D) is present: Loosen in accordance with chapter Loosening the clamping nut →12. ▶ Positioning the turbocharger for storage →13. Hydraulic loosening (round special nut) ▶ Attach lifting gear to the suspension eye. ▶ Loosen the round special nut with a hydraulic tool according to the instructions of the en- ginebuilder. ▶ Positioning the turbocharger for storage →13. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Operation Manual / 4 Product description / A130-M.. - A145-M.. 2 Removing and Installing / 2.2 Removing the turbocharger 2.2.2 Loosening the clamping nut CAUTION Do not clean pressure screws The pressure screws are equipped with a permanent sliding layer that must not be removed. In case of non-compliance, it cannot be ensured that the necessary tension force is reached. ▶ Do not clean pressure screws. ▶ Do not lubricate pressure screws. If a screw jams, the previously loosened screw must be tightened again a little. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Fig. 8: Loosening the clamping nut 1. Working in a circle, break loose each pressure screw (≤ 20°). 2. Working in a circle, loosen each pressure screw by 45° in 4 rounds. 3. Working in a circle, loosen each pressure screw by 90° in 1...5 rounds until all of the pres- sure screws have been relieved. ▶ Loosen clamping nut by hand. CAUTION Incorrect procedure can make loosening impossible If individual pressure screws are fully relieved, the pressure screws can be- come compressed, making it impossible to loosen them. ▶ Comply with the following steps for loosening the pressure screws. Operation Manual / 4 Product description / A130-M.. - A145-M.. 2 Removing and Installing / 2.2 Removing the turbocharger 2.2.3 Positioning the turbocharger for storage © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Fig. 9: Turbocharger centre of gravity 01 Centre of gravity ▶ 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. WARNING Risk of tipping If the turbocharger is not positioned stably, it may tip over. This can result in serious personal injury. ▶ 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 centre of gravity into account. Operation Manual / 4 Product description / A130-M.. - A145-M.. 2 Removing and Installing / 2.3 Installing the turbocharger 2.3 Installing the turbocharger 2.3.1 Inserting gaskets CAUTION Inserting the gaskets Gaskets that are forgotten, damaged or improperly inserted will lead to oil leaks. ▶ Always use new gaskets and insert them carefully into the slot. The oil is supplied (02) and drained (03) through the bracket (01). The necessary sealing is provided by O-rings. The O-rings are not included in the ABB Turbo Systems scope of delivery. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Fig. 10: Inserting gaskets into the bracket 01 Bracket 04 Slot for O-ring 02 Oil supply 05 O-rings 03 Oil drain 06 Pin (optional) Pin (06) as installation safety device Turbochargers can have an oil inlet either on their right or left side; the oil inlet position can be different for the turbocharger fitted on the left and on the right engine bank. A pin can be installed in every support as an installation safety device to prevent inadvertent incorrect fitting. This pin fits into the respective slot on the foot of the bearing casing. In- structions of the enginebuilder must be observed. Operation Manual / 4 Product description / A130-M.. - A145-M.. 2 Removing and Installing / 2.3 Installing the turbocharger 2.3.2 Fitting threaded rods © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Fig. 11: Inserting the threaded rods 1. Lightly oil the surfaces of the threaded rods (02) to be screwed in. 2. Screw the threaded rods into the bracket with the aid of locknuts (01). 3. Remove nuts (01) again. Requirements for the threaded rods Fig. 12: Requirements for threaded rods Product Diameter Threaded rod [mm] Material Thread length Oil-cooled DIN / ISO 898 L1 [mm] L2 [mm] (Part 1) Water-cooled L2 [mm] A130 Ø 16 / M16 10.9 / 12.9 ≥ 30 250 250 A135 Ø 20 / M20 10.9 / 12.9 ≥ 30 270 325 A140 Ø 24 / M24 10.9 / 12.9 ≥ 70 350 ... 360 410 ... 420 A145 Ø 30 / M30 10.9 / 12.9 ≥ 80 415 ... 425 -- Table 3: Requirements for threaded rods Fastening material, scope of delivery The threaded rods and nuts for fastening the turbocharger on the bracket are not included in the ABB Turbo Systems scope of delivery. The clamping nuts are included in the ABB Turbo Systems scope of delivery. Operation Manual / 4 Product description / A130-M.. - A145-M.. 2 Removing and Installing / 2.3 Installing the turbocharger 2.3.3 Placing the turbocharger on the bracket © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Fig. 13: Placing the turbocharger on the bracket A Oil-cooled bearing casing C Fixing with clamping nut B Water-cooled bearing casing D Fixing with standard nut ▶ Make sure that covers of the oil and water connections are removed. 1. Make sure that the gaskets (03) are not damaged and are positioned correctly in the slots. 2. Clean the contact surfaces of the expansion bushes (42190) in the bearing casing. 3. Clean the expansion bushes (42190). 4. Attach the lifting gear to the suspension eye of the bearing casing (A/B) and loop around the gas outlet casing (61001). If the gas outlet casing is already fitted in the exhaust gas pipe, the attachment of the lifting gear on the bearing casing is sufficient. 5. Position the turbocharger on the bracket (04) and align it. Pay attention to the position- ing pins (05) in the bracket. 6. When fixing with a standard nut (D), fit expansion bushes (42190) in the correct position in the slot (only relevant for older, water-cooled versions). Safeguard against wrong fitting (only for water-cooled bearing casings) Depending on the bracket version (04), two positioning pins (05) 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. Operation Manual / 4 Product description / A130-M.. - A145-M.. 2 Removing and Installing / 2.3 Installing the turbocharger ▶ Observe the instructions for the fastening variant at hand. ▪ Fastening the turbocharger with a standard nut →17 (A130 - A140) ▪ Fastening the turbocharger with a clamping nut →18 (A140 and A145) 2.3.4 Fastening the turbocharger with a standard nut ▶ Fit the nuts and tighten them according to variant 1 or 2 in the table below. Product Through hole in bearing casing [mm] Fixing screws [mm] Variant 1: Tightening torques [Nm] **) Variant 2: Hy- draulic pre-ten- sioning forces [kN] A130 Ø 17 M16 280 110 A135 Ø 21 M20 560 175 A140 Ø 25 M24 960 250 Table 4: Tightening torque for standard nuts **) When the turbocharger is mounted on the engine support, the bolt threads and screw heads must be lightly oiled (assumed friction coefficient μ = 0.12 for tightening torque) ▶ Remove the lifting gear. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Operation Manual / 4 Product description / A130-M.. - A145-M.. 2 Removing and Installing / 2.3 Installing the turbocharger 2.3.5 Fastening the turbocharger with a clamping nut Preparations for tightening the clamping nut CAUTION Do not clean pressure screws (04) The pressure screws are equipped with a permanent sliding layer that must not be removed. Do neither clean nor lubricate the pressure screws. In case of non-compli- ance, it cannot be ensured that the necessary tension force is reached. ▶ Do not clean pressure screws. ▶ Do not lubricate pressure screws. In order to correctly fit the clamping nuts, the pressure screws (04) must not protrude from the clamping nuts (03) in the direction of the thrust washer (02). ▶ Make sure the pressure screws do not protrude in the direction of the thrust washer. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Fig. 14: Preparing the clamping nut for the tightening procedure 1. Check whether the expansion bushes (42190) with recess are correctly positioned and do not touch the flange of the core hole cover (A). 2. Clean the thread of the bolt (01) and the contact surface. 3. Lightly oil the bolt thread. 4. Position the thrust washer (02) in place. 5. Tighten clamping nut (03) by hand. 6. Unscrew clamping nut (03) by 1⁄4 of a turn (90°). The distance between the thrust washer and the clamping nut is now about 1 mm. Operation Manual / 4 Product description / A130-M.. - A145-M.. 2 Removing and Installing / 2.3 Installing the turbocharger Tightening pressure screws © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Fig. 15: Tightening pressure screws Product Fixing screw [mm] Tightening torques [Nm] A140 M24 35 A145 M30 45 Table 5: Torque-controlled tightening of the pressure screws 1. Screw in pressure screws crosswise by hand until reaching the stop. 2. Tighten pressure screws crosswise to 50 % of the tightening torque specified in the table. 3. Tighten pressure screws crosswise to 100 % of the tightening torque specified in the table. 4. Work in a circle to tighten all pressure screws to 100 % of the tightening torque specified in the table. 5. Tighten pressure screws to 100 % in 5 ... 7 rounds until the required residual tightening angle of < 20° is achieved. Operation Manual / 4 Product description / A130-M.. - A145-M.. 2 Removing and Installing / 2.3 Installing the turbocharger 2.3.6 Connecting the turbocharger © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Fig. 16: Connecting the speed sensor ▶ Connect cable to speed sensor (86515). ▶ Connect all gas, water and air lines according to the instructions of the enginebuilder. Version with water-cooled bearing casing ▶ Fit the water pipes according to the instructions of the enginebuilder. Version with compressor wheel cooling Fig. 17: Connecting the compressor cooling air intake ▶ Remove the screw plug on the connection for the compressor wheel cooling (06) and fit the cooling air line. CAUTION Failure of compressor wheel cooling Any prolonged failure of the compressor wheel cooling will shorten the re- placement interval of the compressor wheel. ▶ Make sure there is an uninterrupted supply of cooling air during opera- tion. Operation Manual / 4 Product description / A130-M.. - A145-M.. 2 Removing and Installing / 2.3 Installing the turbocharger 2.3.7 Attaching the support © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Fig. 18: Attaching the support ▶ If present: Attach support (61301) to engine support or to a connecting piece. Operation Manual / 4 Product description / A130-M.. - A145-M.. 3 Commissioning / 3.1 Oil supply 3 Commissioning 3.1 Oil supply 3.1.1 Introduction In all operating states, a functioning and carefully executed oil supply is an important pre- requisite for trouble-free operation of the turbocharger. The lubrication of the turbocharger is usually carried out with oil from the engine oil circula- tion. ▶ Comply with the enginebuilder's specifications regarding the selection of lubricating oil and the oil change intervals. 3.1.2 Pre-lubrication Pre-lubrication must be carried out as follows: ▶ 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. 3.1.3 Oil filtering Filtering the lubricating oil with a filter mesh width of ≤ 0.034 mm is sufficient for this tur- bocharger. 3.1.4 Oil pressure Comply precisely with the oil pressure before the turbocharger for trouble-free operation. The admissible values are specified in chapter Monitoring operation →27. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Operation Manual / 4 Product description / A130-M.. - A145-M.. 3 Commissioning / 3.1 Oil supply 3.1.5 Oil orifice in the bearing casing © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Fig. 19: Oil orifice 01 Bearing casing 02 Oil orifice 03 Circlip With an oil inlet pressure of more than 3 bar of overpressure (with engine under load) up- stream of the turbocharger, the bearing casings are equipped with an orifice at the oil inlet as standard. Operation Manual / 4 Product description / A130-M.. - A145-M.. 3 Commissioning / 3.2 Inspection procedures 3.2 Inspection procedures 3.2.1 Introduction Inspection procedures include preventative visual controls, monitoring and measuring work before and during commissioning. Inspection procedures enable changes to the turbochar- ger to be detected. Machine damage can be prevented. 3.2.2 Checks before commissioning Filter mat (if available) ▶ Check for damage and contamination. Lubricating system CAUTION Contaminated oil Serious damage to engine or property can be caused by dirt and solid ma- terial particles in the oil. ▶ For the initial commissioning phase and after all service work, flush the complete lubricating system with warm oil. ▶ Use special running-in filters when running in the engine and after all ser- vice work on the lubricating system. ▶ Check that the oil filter is clean before commissioning. ▶ Check the oil pressure in the oil supply pipes. Warning plates ▶ Check whether warning plates are present and legible. ▶ Check whether the protective sheets have been removed from new warning plates. Version with compressor wheel cooling: CAUTION Failure of compressor wheel cooling Any prolonged failure of the compressor wheel cooling will shorten the re- placement interval of the compressor wheel. ▶ Make sure there is an uninterrupted supply of cooling air during opera- tion. ▶ Check whether the compressor wheel cooling is fitted on the bearing casing. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Operation Manual / 4 Product description / A130-M.. - A145-M.. 3 Commissioning / 3.2 Inspection procedures Version with water-cooled bearing casing CAUTION Failure of bearing casing cooling Any prolonged failure of the water cooling will shorten the lifetime of the turbocharger. ▶ Make sure that an uninterrupted supply of cooling water is provided dur- ing operation. ▶ Check whether the water pipes are fitted on the bearing casing. 3.2.3 Checks after commissioning (engine in idle mode) Lubricating system ▶ Keep to the lubricating oil pressure at the inlet. ▶ Keep to the lubricating oil temperature at the inlet. ▶ Refer to chapter Monitoring operation →27 for admissible values. Leaktightness of pipes WARNING Risk of burning from hot gas Escaping gases are hot and will lead to serious burns in the event of contact. ▶ Check all pipes for leaks in accordance with the enginebuilder’s instruc- tions. 3.2.4 Checks 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 operat- ing conditions indicate a malfunction (see chapter Eliminating malfunctions →60). Lubricants and pastes used during assembly can liquefy or vaporise and escape as oily fluids during the initial hours of operation. Continual escape of an oily fluid indicates an oil leak. If there is a leak, contact an ABB Turbocharging Service Station. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Operation Manual / 4 Product description / A130-M.. - A145-M.. 3 Commissioning / 3.3 Commissioning after taking out of operation 3.3 Commissioning after taking out of operation If present ▶ Remove cover plates (blind flanges) from the compressor casing, the gas inlet and the gas outlet. ▶ Remove the screw plugs on the water connections and fit the water pipe. Version with compressor wheel cooling: ▶ Remove the screw plug on the cooling air connection and fit the cooling air line. General ▶ Check the exhaust gas pipe before and after the turbine for combustion residues or wa- ter residues and clean it. Remove any foreign objects that may be present. ▶ Check and clean filter silencer or air supply line, and remove any foreign objects that may be present. ▶ Put engine-side oil circulation to the turbocharger into operation. ▶ Prepare the turbocharger for operation (see Checks before commissioning →24). ▶ The turbocharger is now ready for operation. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Operation Manual / 4 Product description / A130-M.. - A145-M.. 4 Monitoring operation / 4.1 Oil pressure, oil temperature 4 Monitoring operation 4.1 Oil pressure, oil temperature Lubricating oil pressure, oil inlet 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. CAUTION Assuring lubricating oil pressure Serious damage to the engine or property can result from a missing or insuf- ficient lubricating oil supply. ▶ The lubricating oil pressure must be monitored during operation and the necessary pressure assured at the oil inlet. Status for operation Pressure at oil inlet upstream of the turbocharger [bar] Overpressure Normal operation 2.0 < poil ≤ 4.5 *) Engine start: Cold oil, admissible for a maximum of 15 minutes < 8.0 Engine idling, admissible for a maximum of 1 hour 0.5 < poil ≤ 2.5 Pre-lubrication and post-lubrication (engine stopped) 0.5 < poil ≤ 1.0 Warning signal: (n ≥ 0.5 x nBmax) < 1.25 Alarm signal: Not admissible. Stop the engine immediately. < 0.6 Table 6: Lubricating oil pressure at oil inlet before turbocharger *) Depending on use of an oil orifice in accordance with the enginebuilder’s specifications. 01 Turbocharger contact surface 02 Oil inlet 03 Oil outlet P Oil pressure measuring point T Oil temperature measuring point 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. *) If the drain pipe is vented, the lubricating oil temperature measuring point can be installed at the outlet in the vent tank. Otherwise the measurement should be taken in the drain pipe as close to the turbocharger as possible. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Operation Manual / 4 Product description / A130-M.. - A145-M.. 4 Monitoring operation / 4.1 Oil pressure, oil temperature Lubricating oil temperature at the inlet CAUTION Machine damage If the oil temperature at the oil inlet exceeds the admissible range, this may lead to engine damage. ▶ Observe oil temperature at the oil inlet according to the following table. Status for operation Oil temperature at the inlet Toil,inlet Admissible 30 ... 105 °C Temporarily admissible (< 1 h) → alarm > 105 °C Not admissible → stop engine > 110 °C Not admissible → do not start engine (before start: preheat oil) < 30 °C Table 7: Lubricating oil temperature at the inlet Lubricating oil temperature at the outlet The oil temperature at the outlet is mainly dependant on: ▪ Lubricating oil temperature and pressure at the oil inlet ▪ Engine load and turbocharger speed ▪ Exhaust gas temperature The maximum admissible oil temperature at the outlet is listed in the following table. The specified oil outlet temperature is to be considered as alarm value for the turbocharger op- eration and must be monitored according to the current regulations. Status for operation Oil temperature at the outlet Toil,outlet Admissible ≤ 160 °C Temporarily admissible → alarm > 160 °C Not admissible → stop engine > 180 °C Admissible ≤ Toil,inlet + 55 K Temporarily admissible → alarm > Toil,inlet + 55 K Table 8: Lubricating oil temperature at the outlet If the turbocharger was operated for a longer period of time outside of the admissible range, ABB Turbo Systems recommends to have the turbocharger inspected by an ABB Tur- bocharging Service Station. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Operation Manual / 4 Product description / A130-M.. - A145-M.. 4 Monitoring operation / 4.2 Exhaust gas temperature before turbine 4.2 Exhaust gas temperature before turbine CAUTION Factors influencing replacement intervals Operation above the operating limits defined on the rating plate can shorten the recommended replacement intervals considerably. ▶ 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. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Operation Manual / 4 Product description / A130-M.. - A145-M.. 4 Monitoring operation / 4.3 Turbocharger speed 4.3 Turbocharger speed 4.3.1 Introduction A speed measuring system enables the constant monitoring of the turbocharger speed. CAUTION Do not strain cables If you pull the speed measurement cables too hard, contacts can be pulled out. ▶ Do not strain the speed measurement cables by pulling. 4.3.2 Layout and overview © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Fig. 20: Layout and overview of speed measurement system 86505 Speed sensor 42188 Screw plug 86515 Cable connector 42189 Gasket 86526 F/I converter 01 Plug with integrated voltage limiter 86528 Tachometer *) Installation variant for speed sensor 32109 Sealing disc with cams Operation Manual / 4 Product description / A130-M.. - A145-M.. 4 Monitoring operation / 4.3 Turbocharger speed 4.3.3 Speed differences with several turbochargers per engine The speeds of all turbochargers on an engine vary only slightly from each other in standard operation. The difference between the highest and the lowest turbocharger speed must not be more than 3 %, relative to the speed limit nBmax. If this permissible range of difference is exceeded, the following steps must be carried out: ▶ Reduce the engine performance immediately to the point at which the maximum tur- bocharger 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. 4.3.4 Malfunctions on the speed measurement system In the case of malfunctions of the speed measurement system, refer to the chapter entitled Troubleshooting/Speed measurement system →66. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Operation Manual / 4 Product description / A130-M.. - A145-M.. 4 Monitoring operation / 4.3 Turbocharger speed 4.3.5 Replacing the speed sensor Wear safety gloves to protect against thermal hazards. The speed sensor supplied by ABB is equipped with a sealing lip and an O-ring. No additional gasket is required during assembly. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Fig. 21: Replacing the speed sensor Part number A130 A135 A140 A145 86505 M12 x 1.5 15 Nm M12 x 1.5 15 Nm M12 x 1.5 15 Nm M12 x 1.5 15 Nm Table 9: Tightening torque (86505) ▶ Reduce the engine performance to idling and then stop the engine. Pay attention to post- lubrication (Stopping the engine →41). ▶ 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. WARNING Hot speed sensor Danger of burns. The speed sensor can reach temperatures of more than 100 °C during operation. ▶ Wear safety gloves when disassembling the speed sensor. Operation Manual / 4 Product description / A130-M.. - A145-M.. 5 Operation and service / 5.1 Noise emission 5 Operation and service 5.1 Noise emission Wear ear protection. The emission sound pressure level (A-weighted) is measured at a distance of 1 meter from the turbocharger. The highest value of the emission sound pressure level1) reaches a maximum of 105 dB(A) near the filter silencer. The following prerequisites must be fulfilled with regard to the tur- bocharger to observe this limit value: ▪ Air-inlet system has been fitted ▪ All standard, noise-reducing measures2) have been fitted ▪ Bellows at the air outlet has been acoustically insulated by the enginebuilder (see Fig. 22: Noise insulation, bellows →34). The enginebuilder is responsible for insulating the charge air/scavenging air line and the charge air cooler. 1) Directive 2006/42/EC, 1.7.4.2 / u / Paragraphs 5 + 7 : A-weighted emission sound pressure level 2) The enginebuilder must provide acoustically equivalent measures in case of deviating in- sulation versions © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 WARNING Danger due to noise Exposure to noise can harm the hearing system, impair health and the psy- chological state and may lead to lack of attention and irritation. ▶ When the engine is running, always wear ear protection. ▶ Always wear ear protection if the sound pressure level exceeds 85 dB(A). Operation Manual / 4 Product description / A130-M.. - A145-M.. 5 Operation and service / 5.1 Noise emission Suggestion for noise insulation, bellows © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Fig. 22: Noise insulation, bellows 01 Compressor casing 02 Bellows 03 Charge air duct / scavenging air duct 04 Insulation cushion 05 Insulation mat (at least 15 mm) 06 Sheet metal cover Operation Manual / 4 Product description / A130-M.. - A145-M.. 5 Operation and service / 5.2 Service work 5.2 Service work Service work includes visual controls, monitoring, measuring and inspection as well as func- tional checks. Service work enables the detection and rectification of changes to the tur- bocharger and ensures full operability of the turbocharger. CAUTION Shortened service intervals Exceptional stresses such as several starts/stops per day, harsh environ- mental conditions, poor fuel quality or high system vibrations can lead to untimely machine damage even if the prescribed service intervals are ob- served. ▶ Agree on a shortened service interval with ABB Turbo Systems. To prevent machine damage caused by ageing and downtime, we recommend having an in- spection carried out by an ABB Turbocharging Service Station no later than 5 years after the last service. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 CAUTION Service intervals Any service work on the turbocharger that is omitted or performed too late can cause excessive contamination, wear and operating failures. ▶ Carry out the service work at the specified time intervals. Operation Manual / 4 Product description / A130-M.. - A145-M.. 5 Operation and service / 5.2 Service work 5.2.1 Service work every 25 ... 50 hours CAUTION Unknown operational changes Impairment to the degree of a possible operating failure can be the con- sequence. ▶ Have any unknown causes clarified by an ABB Turbocharging Service Sta- tion. ▶ 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. 5.2.2 Service work at 100 hours after commissioning ▶ Clean or replace the oil filter located in the supply pipe to the turbocharger while the en- gine is stopped. 5.2.3 Service work according to instructions of enginebuilder ▶ Clean or replace the oil filter located in the supply pipe to the turbocharger while the en- gine is stopped. 5.2.4 Service work according to data on the rating plate (Usually after 8000 ... 12000 operating hours) The rotor and bearing parts must be checked and assessed by an ABB Turbocharging Service Station. The following work can be carried out as preparation. ▶ 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. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Operation Manual / 4 Product description / A130-M.. - A145-M.. 5 Operation and service / 5.2 Service work 5.2.5 Other service work If a protective grid is installed in the gas outlet casing (61001) by ABB Turbo Systems: © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Fig. 23: Replacing the protective grid ▶ Remove the protective grid (61205) after 50000 hours and replace it with a new protect- ive grid. Operation Manual / 4 Product description / A130-M.. - A145-M.. 5 Operation and service / 5.2 Service work 5.2.6 Entries in the engine logbook The monitoring of the engine system enables conclusions to be drawn on the behaviour of the turbocharger. The following operating data and measured values must be entered regularly in the engine logbook of the enginebuilder: ▪ Rating 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. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Operation Manual / 4 Product description / A130-M.. - A145-M.. 5 Operation and service / 5.3 Expected replacement intervals 5.3 Expected replacement intervals Rotating components The recommended replacement intervals of the compressor and turbine wheels are spe- cified with the aid of the safety concept for rotating parts (SIKO) and dependent on the op- erating conditions. These intervals are shown on the rating plate of the turbocharger. Non-rotating components Depending on the system-specific operating conditions, a differentiation must be made between the intervals to be expected for: ▪ replacing the bearing parts and ▪ replacing the non-rotating components exposed to hot gas. A decisive role is played by various influencing parameters which, in extreme cases, can drastically reduce the replacement interval of these parts. During the prescribed periodic service work, the individual parts are examined for wear and replaced if necessary. Expected replacement intervals [h] GAS / MDO HFO Turbine casing 25000 ... 50000 25000 ... 50000 Nozzle ring 25000 ... 50000 10000 ... 25000 Gas outlet flange 25000 ... 50000 25000 Heat shield 25000 ... 50000 25000 Rotor components See rating plate data Bearing parts 12000 ... 24000 12000 ... 24000 Other casings 50000 50000 Table 10: Expected replacement intervals GAS = Natural Gas MDO = Marine Diesel Oil HFO = Heavy Fuel Oil The specified values are guideline values and not guaranteed values, see Influencing para- meters. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Operation Manual / 4 Product description / A130-M.. - A145-M.. 5 Operation and service / 5.3 Expected replacement intervals Influencing parameters The specified values are guideline values and are not guaranteed. The actual values can devi- ate considerably from the guideline values, for example, due to the following influences: ▪ Fuel quality and fuel treatment ▪ Load profile (thermal cycling, also number of starts/stops, emergency shutdowns, oper- ating point) ▪ Gas inlet temperature ▪ Frequency and execution of cleaning process during operation ▪ Turbocharger specification. ▪ System-specific operating conditions (combustion quality, exhaust gas composition) For bearing parts ▪ Lubricating oil quality (oil filtering, oil condition, oil monitoring) ▪ Load profile (speed, pressure conditions, temperature) ▪ Number of starts/stops ▪ Unbalance of the rotor (degree of contamination). © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Operation Manual / 4 Product description / A130-M.. - A145-M.. 5 Operation and service / 5.4 Stopping the engine 5.4 Stopping the engine CAUTION Residual heat in the turbocharger If the residual heat in the turbocharger is not adequately dissipated, it may damage the engine. ▶ Adequate cooling of the turbocharger must be ensured after stopping the engine. ▶ Run the engine for 5 ... 10 minutes at idling speed before stopping it. ▶ Observe the oil pressure specified for engine idling (see Table 6: Lubricating oil pressure at oil inlet before turbocharger →27). ▪ Post-lubricate water-cooled bearing casings until the rotors come to a standstill. Deac- tivate post-lubrication as soon as the rotor comes to a standstill. Deviating procedures must be coordinated with ABB Turbo Systems. ▪ For oil-cooled bearing casings, post-lubricate for 20 minutes if the turbine inlet temper- ature (tTE) exceeds the following values when the engine is stopped: – 550 °C with insulated casing – 600 °C with non-insulated casing At temperatures below the specified values, post-lubrication must be ensured until the rotors come to a standstill. ABB Turbo Systems recommends post-lubrication for 10 minutes. ▶ Observe the oil pressure specified for post-lubrication (see Table 6: Lubricating oil pres- sure at oil inlet before turbocharger →27). © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Operation Manual / 4 Product description / A130-M.. - A145-M.. 6 Periodic maintenance work / 6.1 Foreword to maintenance 6 Periodic maintenance work 6.1 Foreword to maintenance Maintenance work includes regular visual controls and cleaning operations which are inten- ded to ensure the trouble-free functioning of the turbocharger. To allow you to observe the standard service intervals and to maintain a high turbocharger efficiency, ABB Turbo Systems recommends that the cleaning procedure be carried out dur- ing operation. This allows the thermal load of the engine to be kept low while ensuring max- imum fuel efficiency. Maintenance inter- val Maintenance work Operating status 24 ... 72 h 1) Cleaning the compressor during operation Engine load 50 ... 85 % →43 50 ... 200 h 1) Cleaning the turbine during operation →46 Engine load 20 ... 40% (guideline value) Similar to the service interval (usually every 8000 ... 12000 h) 2) Cleaning components mechanically →50 Engine stopped Table 11: Maintenance table [h] = Hours of operation 1) If the maintenance intervals are incompatible with operation of the engine, contact ABB Turbo Systems. 2) ABB Turbo Systems recommends having mechanical cleaning carried out by an ABB Tur- bocharging Service Station during the service work. Otherwise, only carry out mechanical cleaning if cleaning during operation is not sufficient to achieve the thermal load and the rating of the engine. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Operation Manual / 4 Product description / A130-M.. - A145-M.. 6 Periodic maintenance work / 6.2 Cleaning the compressor during operation 6.2 Cleaning the compressor during operation 6.2.1 Introduction Approval by enginebuilder The following instructions for wet cleaning only apply to cleaning with pure water and under the precondition that the enginebuilder approves the process. Options and limits Periodic cleaning during operation delays any major increase in contamination. The cleaning method is suitable as long as the contamination has not progressed far. Very heavily con- taminated components can no longer be cleaned using this method. In this case, ABB Turbo Systems recommends having the contaminated components cleaned mechanically by an ABB Turbocharging Service Station. Periodic cleaning during operation is not a substitute for the service work during which the turbocharger is completely dismantled and cleaned. Cause and consequences of contamination The contamination of the compressor stage depends on the degree of purity of the air that is sucked in. Deposits can form in the flow channels if salt, oil mist, exhaust gas or dust are sucked in with the air. Consequences of contamination: ▪ Impaired compressor efficiency ▪ Elevated exhaust gas temperatures ▪ Increased fuel consumption ▪ Increased rotor unbalance 6.2.2 Cleaning interval The time period between the periodical cleaning cycles depends greatly on the operating conditions. Cleaning should normally be done every 24 ... 72 hours of operation. If the specified cleaning intervals are incompatible with operation of the engine, contact ABB Turbo Systems. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Operation Manual / 4 Product description / A130-M.. - A145-M.. 6 Periodic maintenance work / 6.2 Cleaning the compressor during operation 6.2.3 Cleaning method Cleaning method and operating state The compressor is cleaned during operation using the wet cleaning method. It is carried out at an engine load of 50 ... 85 %. This cleaning method has been tested and approved by ABB Turbo Systems. V-engines On V-engines with several turbochargers per engine, parallel cleaning of both turbochargers is recommended. This cleaning process is faster and reduces the risk of surging of the tur- bocharger. Sequential charging With sequential charging, it must be made sure especially after operating periods in the lower range of performance that both turbocharger compressors are cleaned. 6.2.4 Function and safety of wet cleaning © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 CAUTION Volume of water Uncontrolled volumes of water can damage the turbocharger and the en- gine. ▶ Never connect the water connection directly to a water pipe or a bigger metering container than the one specified by ABB Turbo Systems. WARNING Danger due to pressure vessels Personal injury can occur if the locally applicable legal regulations on peri- odic inspections of the pressure vessels are not complied with. ▶ The locally applicable legal regulations regarding periodic checks of the pressure vessels must be observed. ▶ Do not use pressure vessels that are defective. CAUTION Corrosion and deposits when cleaning Salt water and cooling water treatment substances damage and adversely affect turbocharger parts. ▶ Never use salt water, but only pure water for cleaning. Operation Manual / 4 Product description / A130-M.. - A145-M.. 6 Periodic maintenance work / 6.2 Cleaning the compressor during operation © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 72000 Compressor casing 27000 External water pressure vessel 27005 Sealing plug 01 Water pipe to filter silencer or air suction branch 02 Pressurized air inlet pipe 03 Valve activator Pressurized air from the compressor casing (72000) of the turbocharger passes through the pipe (02) to the water pressure vessel (27000). As soon as the valve activator (03) is activ- ated, water is pressed into the pipe (01) and routed to the filter silencer or air suction branch. The water does not act as a solvent. The coating is removed by the mechanical action of the impacting droplets. 6.2.5 Carrying out wet cleaning of the compressor Fig. 24: Carrying out wet cleaning of compressor Engine load Filling amount of water pressure vessel [dm3] Water injection period [s] 50 ... 85 % 0.4 5 ... 30 10 Table 12: Parameters for wet cleaning of compressor ▶ Remove sealing plug (27005). ▶ Fill container with 0.4 dm3 of pure water. ▶ Screw in sealing plug (27005) again. ▶ Push the valve activator (03) against the spring and hold for 10 ... 15 seconds until the en- tire volume of water is injected. ▶ Continue to operate the engine for at least five minutes to ensure that all of the water is flushed out of the system. Not more than three cleaning cycles should be conducted consecutively. Before repeating the process, continue to operate the engine for at least five minutes to ensure that all of the water is flushed out of the system. Water temperature [°C] Operation Manual / 4 Product description / A130-M.. - A145-M.. 6 Periodic maintenance work / 6.3 Cleaning the turbine during opera- tion 6.3 Cleaning the turbine during operation 6.3.1 Introduction Approval by enginebuilder The following instructions for wet cleaning only apply to cleaning with pure water and under the precondition that the enginebuilder approves the process. Options and limits Periodic cleaning during operation delays any major increase in contamination. The cleaning method is suitable as long as the contamination has not progressed far. Very heavily con- taminated components can no longer be cleaned using this method. In this case, ABB Turbo Systems recommends having the contaminated components cleaned mechanically by an ABB Turbocharging Service Station. Periodic cleaning during operation is not a substitute for the service work during which the turbocharger is completely dismantled and cleaned. Cause and consequences of contamination ABB Turbo Systems recommends the use of fuels with low ash, sulphur, sodium and vana- dium contents. Operating states with incomplete combustion also increase the tendency to form deposits and must be avoided. The combustion of heavy fuel oil (HFO) in diesel engines causes contamination of the tur- bine stage. Poor quality fuel in conjunction with high exhaust gas temperatures can lead to extremely hard deposits on turbine components. Consequences of contamination: ▪ Low turbine efficiency ▪ Elevated exhaust gas temperatures ▪ Increased charging and ignition pressures with increasing turbocharger speed ▪ Lower engine performance. Possible damage to turbocharger: ▪ After the engine is stopped the rotor may become stuck in contamination deposits ▪ Damage to turbine heads with blade breaks. 6.3.2 Cleaning interval The time period between the periodical cleaning cycles depends greatly on the operating conditions. Cleaning should normally be done every 50 to 200 hours of operation. If the specified cleaning intervals are incompatible with operation of the engine, contact ABB Turbo Systems. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Operation Manual / 4 Product description / A130-M.. - A145-M.. 6 Periodic maintenance work / 6.3 Cleaning the turbine during opera- tion 6.3.3 Cleaning method The turbine components are cleaned during operation using the wet cleaning method. This cleaning method is tested and approved by ABB Turbo Systems. The precondition for wet cleaning is that the enginebuilder approves the process and these regulations are observed. V-engines On V-engines with several turbochargers per engine, parallel cleaning of both turbochargers is recommended. This cleaning process is faster and reduces the risk of surging of the tur- bocharger. 6.3.4 Function and safety of wet cleaning CAUTION Corrosion and deposits when cleaning Salt water and cooling water treatment substances damage and adversely affect turbocharger parts. ▶ Never use salt water, but only pure water for cleaning. To clean the turbine stage during operation, water is injected before the nozzle ring. Based on an injection phase of 10 minutes, this cleaning procedure uses the principle of water solu- bility of dirt deposits. To prevent corrosion of the inside surfaces of the casings, the engine must be continued to be operated for 10 minutes after a wet cleaning. The exhaust gas temperature downstream of the turbocharger can drop by up to 180 °C during cleaning. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Operation Manual / 4 Product description / A130-M.. - A145-M.. 6 Periodic maintenance work / 6.3 Cleaning the turbine during opera- tion 6.3.5 Prerequisites Characteristic/component Conditions Engine load (guideline value) 20 ... 40 % *) Turbine inlet temperature TTE before water injection 350 ... 430 °C Stabilisation phase after TTE has been reached 10 minutes Stabilisation phase after turbine cleaning 10 minutes Water supply ensured Water pressure (overpressure compared to atmosphere) pWT 1.5 bar Water temperature 5 ... 30 °C Table 13: Turbine wet cleaning, recommended operating state *) The temperature at the turbine inlet can be up to 100 °C higher than the exhaust gas tem- perature after the cylinder. This must be taken into account when setting the operating point before cleaning. If necessary, the engine performance must be reduced to meet these conditions. The clean- ing cycle can be started when the above conditions are fulfilled. 6.3.6 Carrying out wet cleaning of the turbine © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 CAUTION Inadmissible thermal stress and flooding of the turbine Smaller amounts of water can lead to an inadequate cleaning result. Larger amounts of water lead to inadmissible thermal stress on the turbine com- ponents and can cause flooding of the turbine. ▶ It is imperative that turbine cleaning parameters are observed. CAUTION Maximum temperature at turbine inlet during cleaning During cleaning, the temperature at the turbine inlet will rise and may strain the material significantly. ▶ Make sure the maximum temperature at the turbine inlet is not exceeded during cleaning. Operation Manual / 4 Product description / A130-M.. - A145-M.. 6 Periodic maintenance work / 6.3 Cleaning the turbine during opera- tion © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 Fig. 25: Carrying out wet cleaning of turbine ▶ Fulfil prerequisites. ▶ Ensure that the water supply (01) is guaranteed. ▶ Open the stop valve (02) and set the required water pressure at the manometer (3) (see cleaning parameters in the table (see Table 13: Turbine wet cleaning, recommended oper- ating state →48)). If cleaning an optional parameters flowmeter in the (04) table is present, (see Table set 14: the Wet water cleaning volume of flow turbine, VW on parameters the basis of the →49). ▶ Close the stop valve (02) after 10 minutes. ▶ Wait for 10 minutes; do not change the load during this stabilisation phase. If the cleaning result is unsatisfactory or there is water leakage, contact an ABB Turbochar- ging Service Station. Product Temperature be- fore turbine before cleaning [°C] Maximum temper- ature before tur- bine during clean- ing [°C] Water volume flow VW [dm3/min] 1) Injection time [min] A130 350 ... 430 530 4.0 10 A135 350 ... 430 530 5.5 10 A140 350 ... 430 530 8.5 10 A145 350 ... 430 530 12.0 10 Table 14: Wet cleaning of turbine, parameters 1) Corresponds to a water pressure pWT of 1.5 bar (overpressure compared to atmosphere) Operation Manual / 4 Product description / A130-M.. - A145-M.. 6 Periodic maintenance work / 6.4 Cleaning components mechanically 6.4 Cleaning components mechanically 6.4.1 Preparation CAUTION Selection of cleaning tools Turbocharger components are sensitive and easily sustain mechanical dam- age. The use of needle descalers (for example) or other striking tools dam- ages the components. Depending on the specification, nozzle rings or tur- bine casings may have protective coatings which can also be damaged. ▶ Use only soft tools such as rags, brushes or wire brushes. ▶ In case of heavy contamination, the cleaning methods described in this chapter (such as soaking, for example) can be repeated until a satisfact- ory result is achieved. The disassembly and assembly of the components is described in chapter Fitting and dis- mantling. ▶ Contaminated water and cleaning agents must be disposed of in an environmentally compatible, professional way and in compliance with locally applicable regulations. © Copyright 2019 ABB. All rights reserved. HZTL4031_EN Revision H March 2019 CAUTION Component damage and corrosion If mechanical cleaning is carried out incorrectly, this can lead to damage and corrosion on the components. ▶ Pay attention to the specifications in this chapter pertaining to mechan- ical cleaning.


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