Axial turbochargers for the largest medium-speed engines (130 pages)
Summary of Contents for ABB HT603383
Page 1
Turbocharging Operation Manual / A175-M62 HT603383 Document identification Document number HZTL4033 Revision Language English Original Operation Manual Product identification Serial number HT603383 Customer part number Delivery date (yyyy-mm-dd) 2021-06-04 Weight 4600 Operating limits according to rating plate Speed limit in test rig operation only...
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 www.abb.com/turbocharging).
Caution and warning signs are described in chapter Safety. ABB Turbocharging ABB Switzerland Ltd, Turbocharging is identified as ABB Turbocharging in this document. Official service stations of ABB Turbocharging Official service stations are regularly audited and certified by ABB Turbocharging. See also chapter Contact information →5.
Inspect the package for damage. If the package is damaged, the turbocharger must be in- spected by an ABB Turbocharging Service Station and repacked. After every 3 years the following work steps must be performed by an ABB Turbocharging Service Station: ¡...
Safety 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: ¡...
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 po-...
An ABB Turbocharging Service Station should be instructed to carry out this inspection. 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". ¡...
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.
One rating plate (01) each is attached on the left and the right side of the foot of the tur- bocharger. On turbochargers with insulation supplied by ABB, at least one additional rating plate is at- tached to the insulation of the gas outlet casing.
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. Commissioning after taking out of operation...
The lubricating oil pressure must be monitored during operation and the necessary pressure assured at the oil inlet. For monitoring the lubricating oil pressure, ABB Turbocharging recommends installing a manometer "M". If the pressure is controlled electronically, the relevant signals should be triggered at the warning and alarm values.
Agree on a specific service interval with ABB Turbocharging. 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.
Page 51
6 Operation and service / 6.2 Service work 6.2.3 Service work every 8000 ... 16000 hours of operation Checking and assessment of the rotor and the bearing parts must be carried out by an ABB Turbocharging Service Station. Dismantle the turbocharger.
Page 57
Have any heavily contaminated absorption segments and filter rings as well as damaged connecting rods replaced by an ABB Turbocharging Service Station. Fitting the cover grids and absorption segments (see Fig. 26: Cleaning the filter silencer →54)
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. To carry out the cleaning operation checked and recommended by ABB Turbocharging, the following prerequisites must be fulfilled: ¡...
After cleaning operations, a waiting period of at least 5 minutes is required for the tur- bocharger to dry. If the cleaning is unsuccessful after three attempts, we recommend having the turbocharger checked and cleaned by an ABB Turbocharging Service Station in the event of unsatisfactory engine values. Cleaning parameters for each turbocharger compressor...
The use of fuels with poor quality in conjunction with high exhaust gas temperatures can lead to extremely hard deposits on turbine components. ABB Turbocharging recommends the use of fuels with low ash, sulphur, sodium and vana- dium contents. Consequences of contamination: ¡...
Page 67
7.5.3 Cleaning method Cleaning of the turbine and the nozzle ring during operation is carried out by the cleaning method described in the following and is tested and approved by ABB Turbocharging: ¡ Wet cleaning Wet cleaning makes use of various effects. These effects are used with varying levels of in- tensity, depending on the type of contamination: ¡...
Prerequisites: Procedure without automated cleaning The following operating state and the following prerequisites have been tested and ap- proved by ABB Turbocharging for cleaning operations: Set the engine load between 20 … 50 % so that the turbine inlet temperature is between 380 … 430 °C.
7 Periodic maintenance / 7.5 Cleaning turbine and nozzle ring Procedure with automated cleaning The following operating state and the following prerequisites have been tested and ap- proved by ABB Turbocharging for cleaning operations: Set the engine load as follows: ¡...
If there is no drainage system, the amount of water injected can be mon- itored with a flowmeter in the water supply. The permitted amount of water must be de- termined with the help of an ABB Turbocharging Service Station. To be observed during cleaning ¡...
To prevent significant loss of efficiency, specific tolerances must be fulfilled. ¡ If there is any doubt about the extent of the rubbing, contact an ABB Tur- bocharging Service Station. ¡...
Turbochar- Heavy contamination of the turbine Clean (see chapter Periodic mainten- and/or nozzle ring ance →53) Damaged rotor components or bearing Contact ABB Turbocharging Service Station Engine Defect on the connected cylinders in Contact enginebuilder pulse charging Pipes Defects, such as leaks, in the exhaust...
Gradually reduce the engine load. Have the cause clarified and remedied immediately by an ABB Turbochar- ging Service Station. Have parts assessed for damage and, if necessary, replaced by an ABB Turbocharging Service Station. Surging of the turbocharger Possible causes...
The specified tightening torques of the bolted connections must be observed. Tightening torques for assembly devices Unless otherwise described, the screws and nuts of the assembly devices supplied by ABB must be tightened in such a way that they are tight-fitting.
Clearances outside the tolerance Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Tur- bocharging Service Station. Fig. 36: Axial clearance...
Blocked areas on nozzle ring If a nozzle ring is blocked in some areas or is covered by loose parts, it is recommended to appoint an ABB Turbocharging Service Station to inspect the turbine blades and carry out a crack inspection.
9 Disassembly and assembly / 9.10 Fitting the spinner nose cone 9.10 Fitting the spinner nose cone If present: The spinner nose cone (25012) and Loctite®542 are supplied by the ABB service station to- gether with the overhauled cartridge group. CAUTION Total failure of turbocharger...
Clearances outside the tolerance Serious damage to engines or property can be caused by clearances outside the tolerance and excessively worn parts. Have the components assessed and, if necessary, replaced by an ABB Tur- bocharging Service Station. Fig. 64: Axial clearance...
Blocked areas on nozzle ring If a nozzle ring is blocked in some areas or is covered by loose parts, it is re- commended to appoint an ABB Turbocharging Service Station to inspect the turbine blades and carry out a crack inspection.
The permissible turbocharger speed for the unlocked turbocharger may not exceed n . Take note of the rating plate. Bmax After locking the turbocharger, contact an ABB Turbocharging Service Station and find the nearest port. Observe the safety regulations. Follow the directives of the enginebuilder.
A locked rotor must be removed after emergency operation and checked for unbalance (see chapter Removing the cartridge group). The unbalance check must be carried out by an ABB Turbocharging Service Station. Exception The exception concerns customer requirements for test bed runs of new engines at a max- imum engine load of up to 25 %.
If the acid number (TAN) is greater than 2 mg KOH/g, the following mothballing measures are necessary after taking the engine out of operation: Dismantle the turbocharger. The rotor and bearing parts must be dismantled and subsequently refitted by an ABB Tur- bocharging Service Station. Clean all parts.
¡ The casings of the turbocharger remain attached to the engine, the rotor and bearing parts are dismantled by an ABB Turbocharging Service Station and stored separately ¡ The turbocharger is completely removed, either as a whole unit or in individual parts For the measures always necessary for preparing the turbocharger parts for mothballing, see section Taking the engine out of operation for up to 12 months, subsection Preparations...
Designation and part number. Spare parts can be ordered from any ABB Turbocharging Service Station. If different model variants are not taken into account in this document, contact an ABB Turbocharging Service Station. Dispose of placed and unusable parts in an environmentally-friendly and professional manner in accordance with the local regulations.
94007 Hexagon-head screw 90321 Guide stud Table 71: Customer tool set 90009 This tool set can be ordered from any ABB Turbocharging Service Station. The following spe- cifications must be included in the order: ¡ Turbocharger type ¡ Designation and part number of the tool set.