ABB VTR200 (01) PDF Document

The technical specifications for the ABB VTR200, model HT844058, as listed on its rating plate are as follows:

Type: VTR200

Model No.: HT844058

Maximum Speed (nMmax): 583 1/s

Maximum Continuous Speed (nBmax): 0 1/s

Maximum Temperature (t Mmax): 670 °C

Maximum Continuous Temperature (t Bmax): 0 °C

Weight: 245 kg

Year of Manufacture: 2018

The replacement intervals of components for the ABB VTR200 depend on several factors related to its operating conditions. These include:

Load profile: The typical load at which the engine and turbocharger operate.

Turbine inlet temperature: The temperature of the exhaust gas entering the turbine.

Suction air temperature: The temperature of the air entering the compressor.

Turbocharger speed: The rotational speed of the turbocharger.

Frequent load alterations, high temperatures, and high speeds can lower the life of the components. If the operation conditions differ significantly from what is considered normal for the application, it is recommended to request a re-calculation of replacement intervals.

New ABB VTR200 turbochargers can be stored for up to 12 months from the date of delivery in a dry place with average humidity without taking special precautions against corrosion.

If the storage room is affected by vibrations (acceleration > 10m/s²), either the anti-friction bearings have to be checked before taking the turbocharger into service, or the turbocharger must be mothballed from the beginning.

After 12 months, the turbocharger must be mothballed for continued storage.

For the ABB VTR200, the lubricating oil must meet the following specifications:

Viscosity: The viscosity must be within the following limits:

Temperature	Centistoke (mm²/s)	Engler	Redwood No.1	Saybolt Universal
323 K (50 °C) (122 °F)	30-55 cST	4.0-7.3 E	125-225 sec. R1	140-253 S.S.U

Viscosity Grade: This corresponds with the ISO-VG 68 viscosity grade.

Oil Quantity: To fill both bearing spaces, the approximate oil quantity needed for the VTR 200 model is 0.9 dm³.

Oil Change Interval: The oil must be changed at least every 1000 hours in service. The increase of the neutralization factor must not exceed 2 mg KOH/g, and the viscosity must not rise by more than 20%.

The recommended schedule for checks and maintenance on the ABB VTR200 is as follows:

Before taking into service: See § 1.1.0 (Commissioning)

When first taking into service: See § 1.1.1

Daily: See § 1.3

Every 25…75 hours in service: See § 2.0.6 (Cleaning the compressor in service)

After the first 100 hours in service: See § 1.1.2 (Change the oil)

Every 1000 hours in service: See § 1.0 (Check oil quality and change if necessary)

Periodically, according to the plant: See § 2.0 (Cleaning), § 2.6 (Clearances) and § 2.8 (Mothballing)

The ABB VTR200 turbocharger consists essentially of a turbine and a compressor, assembled as a single unit.

The exhaust gas from the diesel engine flows through the gas inlet casing, expands in the nozzle ring, gives up part of its energy to drive the turbine blades and passes via the water-cooled gas outlet casing and an exhaust pipe into the atmosphere.

The air required for the diesel engine passes through a filter and silencer to the inducer and compressor wheel. It is compressed there and finally leaves the turbocharger via the volute of the compressor casing or air outlet casing.

The rotor runs in spring-mounted rolling contact bearings that are readily accessible at both ends of the rotor. For each bearing, there is a lubricating and oil cooling system.

A partition wall with heat insulating intermediate wall and a gas chamber seals the air-side from the gas chamber. Sealing air for the labyrinth glands of the turbine rotor is tapped from the compressor and prevents exhaust from penetrating into the bearing housing.

Before taking a new or overhauled ABB VTR200 into service, follow these commissioning steps:

1. Fill both oil chambers through the appropriate openings up to the upper mark on the oil gauge glass.

2. Note the requirements for oil quality and quantity.

3. Allow the cooling water to circulate.

4. Open the drain plugs if any, and check whether rainwater, condensate, or collected oil has run out from the gas outlet. If this may possibly have done so, fit a drain pipe with a stop-cock.

5. If the turbocharger has an oil flow monitor, consider § 1.4.

As soon as the engine has started, perform the following checks on the ABB VTR200:

Visual Inspection: Make checks by looking through the inspection windows in the bearing space covers that the bearings are supplied with oil.

Connections: Make sure all gas, air, and water pipe connections are perfectly tight.

Performance Data: Measure the turbocharger speed, the charging pressure, turbine temperature before and after the turbine, and compare the readings with the corresponding figures from the shop trial. It is important to record the readings for the different operating conditions.

Cooling Water Temperature: The temperature rise of the cooling water gives an approximation of the heat flow. The rise should be between 8…12 K (°C) for the gas inlet casing and between 8…12 K (°C) for the gas outlet casing.

Cooling Water Type: Only fresh water must be used for cooling. The water outlet temperature must not exceed 353 K (80 °C). Water inlet temperatures below 323 K (50 °C) should be avoided.

After the ABB VTR200 turbocharger has run for 100 hours, the oil should be changed.

To monitor the performance and condition of the ABB VTR200, the following data should be entered into the engine log-book at regular intervals:

General Operation Data:

– Diesel engine output

– Engine speed

– Air inlet temperature

– Pressure drop in the air filter

– Pressure of the charge-air

– Charge-air temperature before compressor and after charge-air cooler

– Cooling-water temperature entering the turbine casings

– Cooling-water temperature leaving the turbine casings

– Gas temperature before turbine

– Quantity, brand, and quality of lube oil used for topping up

Following a Periodical Overhaul, Record:

– State of the oil

– State of the air filter

– State of cooling water spaces

– Which bearings were replaced

– Spare parts used

– Parts and tools ordered as replacements

To put a mothballed ABB VTR200 back into service, follow these steps:

1. Clean the exterior of the turbocharger.

2. Remove the wooden cover plates.

3. Carefully clean the oil spaces, removing the special flange from the bearing housing.

4. Assemble the turbocharger, particularly the damping springs, according to the assembly instructions.

5. Proceed with the standard commissioning procedure.

To clean the air filter of the ABB VTR200:

1. Choose a cleaning agent for the copper mesh based on the type of contamination. Suitable agents include soda solutions with a maximum concentration of 1% or paraffin (kerosene).

2. The filter mesh can be removed for cleaning. It is important to note that cleaning the filter by burning it out is not permitted.

3. For improved filtration, an oil-coated filter mesh can be used. After cleaning, apply a thin coat of oil to the mesh.

4. Replace the filter mesh if it is damaged.

A 5% solution of hydrochloric acid should be used for cleaning and defurring the cooling-water spaces. Follow these instructions carefully:

1. The water outlet at the top should be left open to prevent the build-up of pressure. Because of the risk of explosion, all cleaning operations should be performed in the open where possible. Open flames are strictly prohibited.

2. Depending on the nature and thickness of the scale deposit, allow the cleaning solution to act for 2-6 hours. Light tapping helps to loosen the deposit.

3. Immediately after the acid has been drained off, the cooling-water spaces should be thoroughly rinsed with fresh water and then flushed with water containing 5% soda.

4. Where possible, the cooling-water should be hot.

The specifications for the number of segments and the weight of the copper mesh per filter for the ABB VTR200 (models 200/201-2) are as follows:

Filter Type	Number of segments	kg Copper mesh per filter
K10, K11	2	1.8
K24, K25	2	0.8

The compressor of the ABB VTR200 should be cleaned regularly every 25 to 75 hours of service. The preferred method is water injection. The injected water does not act as a solvent, but the physical impact of the drops on the deposit is what provides the cleaning effect.

Procedure:

1. An inlet pipe is located in the compressor casing or the air inlet casing for water injection.

2. The water should be injected while the engine is running warm and at the highest possible load (e.g., at a high engine speed).

3. A high quantity of water is required for a short period. The injection should last between 4 to 10 seconds. For the VTR 200/201, the recommended water quantity is 0.3 dm³.

4. A hand pump or a measuring vessel can be used for the injection. Ensure that an uncontrolled quantity of water does not enter the turbocharger and the diesel engine.

If using a measuring cup to inject water for cleaning the ABB VTR200 compressor, follow these steps:

1. Loosen the knob and remove cover B.

2. Fill cup A with water up to 1 cm below the rim.

3. Replace cover B and screw the knob tight.

4. Push button C. This opens a valve that admits compressed air from the compressor through a passage, forcing water out of the cup and into the compressor.

The success of the injection can be recognized by the change in charge-air or scavenger pressure, or in the exhaust gas temperature.

If the injection is not successful, it may be repeated after 5 minutes. After a successful injection, the engine should be run loaded for at least 5 minutes. This process is only suitable for cleaning the compressor.

The process for removing and replacing the bearing assemblies on the compressor and turbine ends of the ABB VTR200 involves several detailed steps. The special tools required are marked with green numbers in the diagrams. The sequence of dismantling and fitting is marked in red.

Compressor end dismantling:

1. Remove screw plug and drain off the oil.

2. Remove the bearing space cover.

3. Remove the hex. headed screws and locking washers.

4. Remove the oil suction pipe (part number varies by specific model).

5. Loosen and remove socket screws and locking washers.

6. Remove nipple.

7. Place the fixing tool over the guide bolt and fasten it to the oil slinger.

8. Unscrew the outer ring nut with the box spanner.

9. Remove the locking disc.

10. Unscrew the inner ring nut using the box spanner.

11. For VTR160/161 and VTR200/201: Pull the oil slinger using the extractor.

12. Withdraw the bearing using the extractor.

Turbine end dismantling: The procedure is similar to the compressor end, involving draining oil, removing the cover, screws, oil suction pipe, nipple, and then using fixing tools and extractors to remove the outer ring nut, locking disc, inner ring nut, oil slinger, and the bearing.

Reassembly:

Reassembly is performed in the reverse order of dismantling. It is of utmost importance that before inserting the new bearing assembly, the shaft end is thoroughly cleaned. The bearing space should also be cleaned. When assembling, ensure all parts are clean, use specified lubricants like Molykote DXS, and correctly set the clearances of the damping springs and the axial position of the double ball bearing. Fit parts like the inner ring nut and bearing with the appropriate tools and tighten them securely. After assembly, check that the bearing runs true. Finally, replace the bearing space cover, fill with oil, and ensure all plugs are tight.

The procedure for removing and replacing the rotor depends on the orientation of the ABB VTR200.

For horizontal installation:

1. The turbocharger must not be detached from the motor.

2. Remove the silencer or the air suction branch. Remove the bearing as per the specified procedure.

3. Remove pal-locking nuts and hex-nuts from the stud.

4. Loosen the compressor casing and clear the pulling screws.

5. For VTR200/201 and VTR250/251: Fit slide rods into the gas inlet casing.

6. Screw an eye nut onto the shaft at the compressor end and lift the rotor.

7. Withdraw the rotor.

8. Reassemble in reverse order. The hollow pin determines the position of the partition wall to the gas outlet casing.

For vertical installation:

1. Remove the silencer or air suction branch. Remove the bearing.

2. Put the turbocharger in a vertical position so that the compressor casing is on top.

3. Remove pal-locking nuts and hex-nuts from the stud.

4. Loosen the compressor casing and clear the pulling screws.

5. Screw an eye nut onto the shaft at the compressor end, support the rotor, hoist and withdraw in a perfect vertical plane.

6. Reassemble in reverse order.

Sealing Bushes:

Worn or injured sealing bushes can be prised out with a small drift and replaced. The new bushes should be peened over at the edges until firmly in position.

Turbine Blades:

Broken or bent blades or damping wires must be replaced in accordance with special instructions, and done only by fitters trained by ABB Turbo Systems Ltd.

Nozzle Ring:

Normally the nozzle ring is never removed. If it has to be replaced owing to damage, the rotor must be removed and then the gas outlet casing can be unbolted. Replacement requires specific procedures depending on the VTR model.

As replacements, only spare parts supplied by us or our agents may be used.

The given data in the technical specifications about service life of bearings should be understood as maximum values only. The quality of lubricating oil, as well as service conditions, are directly related to the service life of the bearings. It is highly recommended to check the quality of the lubricating oil very closely. In case the total number of hours mentioned in the service manual are not achieved within 8 years, it is recommended that the bearings are changed.

Should the ABB VTR200 have to be stored or remain out of use for a fairly long period, the mothballing procedure should be employed. Follow these steps:

1. Remove the bearing assemblies.

2. The oil slinger and the nozzle must, under no circumstances, be in a vaseline bath. In such cases, there would be a danger of the fine drilled holes of grease stops becoming blocked.

3. Immerse the bearing assembly for 30 seconds in pure medical vaseline heated to 334…335 K (61…62 °C). Remove and allow to drip. The coating of the vaseline must not be more than 0.1 g and its drip point should be 334…335 K (61…62 °C).

4. Bearings and parts for the bearing assemblies should then be wrapped in waxed paper. They should be packed in a metal box, kept in a dry place.

5. Extension shafts, especially the parts that make contact with the bearings, should be coated with a film of hot vaseline approx. 358 K (85 °C).

6. Reassemble the bearing assemblies by fitting the fixing tool (12 cm) supplied, so that the rotor is fixed in the casing.

7. The bearing space, turbine end, and all other openings in the casings of the turbocharger should be closed with wooden covers using bituminized paper as a seal.

All mothballed turbochargers, including spare parts, should be inspected at regular intervals and protection renewed if necessary.

If the exhaust gas temperature is higher than normal while the output and speed of the diesel engine are normal, possible causes include:

Engine:

– Faults in injection system

– High temperature of incoming air when running without a charge-air cooler

Turbocharger:

– Loss of air, e.g., filter choked with dirt

– Dirty compressor

– Exhaust back-pressure too high

– Turbine badly damaged

Charge-air cooler:

– Dirty, insufficient water, temperature of cooling water too high, insufficient venting

If the charge-air pressure is lower than normal but the output and speed of the engine are unchanged, check for these possible causes:

Engine:

– Air receiver leaking

– Gas leakage between engine and turbine

Turbocharger:

– Pressure-gauge reading wrong or pressure line is leaking

– Dirty air filter, accounting for pressure drop

– Dirty turbocharger

– Labyrinth seals damaged

– Turbine blading damaged

– Exhaust back-pressure too high

If the charge-air pressure is higher than normal while the output and speed of the engine remain unchanged, the possible causes are:

Engine:

– Faults in injection system

– Output of engine higher than expected

Turbocharger:

– Pressure-gauge reading wrong

– Dirty or partly clogged nozzle ring

Vibrations that occur due to the revolution frequencies of the turbocharger rotor can be caused by:

– Unbalance of the rotor as a result of severe dirt on the compressor or the turbine.

– Damaged turbine blading or damping wire.

– Defective bearings.

If you notice unusual noise during run-out, a run-out time that is too short, or a hesitant run-up, the possible causes are:

– Damaged or incorrectly fitted bearings.

– Rotor fouling.

– Turbocharger dirty.

– Foreign bodies inside the turbocharger.

Leakage from the casing of the ABB VTR200 can be caused by:

– Cracks produced by thermal stresses, which might be brought on by:

– Lack of air relief

– Insufficient sealing water

– Excessive furring

A loss of lubricating oil in the ABB VTR200 can be attributed to the following issues:

– Damaged or worn bushes.

– Openings to the balancing passages Y and Z or openings in the dripping water protector (for specific specifications) being stopped up.

– Bearing space covers are untight.

Repeated surging by the turbocharger is typically caused by increased resistance to flow. This can be due to:

– The charge-air cooler being dirty.

– The filter-silencer being dirty or clogged.

– With two-stroke engines, defective non-return valves.

If the cause of surging cannot be found, please notify your local office.

It may be necessary to keep the diesel engine running although the turbocharger is damaged. In this case, the turbocharger must be temporarily stopped. A drawing of the blanking device can be supplied on request.

1. Remove the bearing assemblies from the turbine and compressor side.

2. Extract the rotor.

3. The resultant openings should be closed with the blanking device shown in the diagrams.

4. Tighten up the blanking cover 9102 and fasten it to the cover with tie-bolts 9100 and nuts 9101, with the spring washers 9117 pressed flat.

5. Fix the blanking cover at the compressor end with the screws and nut, ensuring the spring washers are pressed flat.

6. The cooling-water should only be turned off if no gas leakage can be seen from the gas side of the turbine casing, which could harm the operation of the engine.

To lock the compressor end of the ABB VTR200, proceed as follows:

1. Remove the bearing at the compressor end.

2. Place the device sleeve 10709 and the locking device 1070 over the shaft and the guide bolt 50240.

3. Turn the shaft in relation to the guide bolt so that the recesses of the locking part fit on the vis 10703.

4. Lightly tighten screws 10703 first, then screws 10701.

5. Replace the bearing space cover 78.

General Information:

– The bearing at the turbine end must not be removed.

– When the turbocharger is released, the bearing at the turbine end must be replaced. However, if the duration of locking does not exceed more than 60 minutes, which may occur on the engine test bed or during a trial trip, there is no need to replace the bearings.

Additional locking can be performed on the turbine side, but the rotor must be locked at the compressor end before proceeding.