Operation Manual ABB Turbo Systems LtdABB Turbocharging ABB Turbo Systems Ltd CH 5401 Baden Type TPS 50B01 HT843860 n Mmax 840 t Mmax 750 n Bmax 800 t Bmax 710 1/s °C 00270 10 50 50 Year 2018 made in Switzerland Application according to the Operation Manual kg HZTL2401 English TPS 50B01 Original Operation Manual
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Transcript
Operation Manual
ABB Turbocharging ���
ABB Turbo Systems LtdCH 5401 Baden
Type TPS 50B01 HT843860
nMmax 840 t Mmax 750
nBmax 800 t Bmax 7101/s °C
00270 10 50 50
Year 2018made in Switzerland
Application according tothe Operation Manual
kg
HZ
TL2
401
Eng
lish
TPS 50B01
Orig
inal
Ope
ratio
n M
anua
l
Operating condition and replacement intervals
The operational limits for the turbocharger nBmax, tBmax, nMmax, tMmax, inspection- and replacement intervals for the compon-ents concerned on the rating plate are valid for the operational mode and compressor inlet condition, which has been agreed upon between the engine builder and ABB.
Note: Replacement intervals of components depends on the load profi le, turbine inlet temperature, suction air temperature and turbocharger speed. In case the operation conditions differs signifi cantly from what is considered to be normal for the cur-rent application, it is recommended to contact ABB for a re-calculation of replacement intervals. Frequent load alterations, high temperatures and high speed lower the life of components.
Unless otherwise agreed, the application limits nMmax, tMmax are valid for the test operation for a limited time.
This operation manual enables you to familiarize yourself with the turbo-charger supplied by ABB Turbo Systems and to use it as intended.
The operation manual provides important information in order that the tur-bocharger can be operated safely, correctly and efficiently.
The operation manual complements and expands existing national regula-tions concerning work safety and accident prevention.
Target group
The operation manual is intended for engineers, mechanics and service-men who are responsible for operating the engine and the turbocharger installed on it.
Availability of operation manual
An operation manual must be available at all times at the place where the turbocharger is used.
Everyone who operates or works on the turbocharger must have first read and understood the operation manual.
Contact address
ABB Turbo Systems AG Bruggerstrasse 71a CH-5401 Baden Switzerland www.abb.com/turbocharging
After-sales service
The Contact Information brochure contains an overview of official ABB Turbo Systems service stations worldwide.
The turbocharger is a turbomachine consisting of the following main com-ponents:
turbine compressor
These are mounted on a common shaft.
The exhaust gas from the diesel or gas engine flows through the gas inlet casing (9) and nozzle ring (8) to the turbine (7).
The turbine (7) uses the energy contained in the exhaust gas to drive the compressor wheel (11). The compressor draws in fresh air, compresses it and then forces it into the engine's cylinders.
The exhaust gas escapes into the ambient air through the exhaust gas pi-pe, which is connected to the gas outlet flange (6).
The air, which is necessary for operation of the diesel or gas engine and which is compressed in the turbocharger, is drawn into the compressor wheel (11) through the suction branch or filter silencer or through an axial suction pipe. It then passes through the diffuser (2) and leaves the turbo-charger through the outlet on the compressor casing (1).
The rotor runs in two radial bearings (4/5) which are located in the bearing flange between the compressor and the turbine. The axial thrust bearing (3) is located at the compressor end.
The radial bearings are connected to a central lubricating oil duct which is fed with oil from the engine's lubricating oil circuit. The oil outlet is always at the lowest point of the bearing casing (10).
This turbocharger supplied by ABB Turbo Systems has been developed for use on diesel engines to generate the volume of air and the charg-ing pressure required to operate the engine. The engine manufacturer has provided ABB Turbo Systems with infor-mation regarding the intended purpose of the engine, from which the operating parameters specific to the turbocharger (such as rotating speeds, temperatures, replacement periods / exchange intervals) have been derived and are indicated on the rating plate. If it is used in conjunction with a gas engine, the engine must not be in-stalled in a potentially explosive environment, and precautionary meas-ures must be taken to ensure that the machine room as a whole is clas-sified as not potentially explosive. Any other use will be regarded as a special application which must first be discussed with ABB Turbo Systems. The manufacturer accepts no liability for other applications. If it is used otherwise, ABB Turbo Sys-tems reserves the right to reject all claims under the warranty.
This turbocharger was built according to state-of-the-art technology and is operationally safe according to recognised safety regulations.
Improper operation and maintenance of the turbocharger can result in danger to life and limb of the user or third parties. In addition, improper use may cause damage to the machine. The machine may be operated only by trained personnel.
Use of the turbocharger as intended also includes observance of the in-stallation / fitting, disassembly / removal, operating, maintenance / servic-ing and repair conditions specified by the manufacturer. Disposal regula-tions set down by local authorities must be observed.
The turbocharger may be installed only when in technically perfect condi-tion while observing the instructions given in the engine builder's manual. It may be used only for the intended purpose and operated in compliance with the operation manual.
Malfunctions which could affect safety must be eliminated immediately.
The manufacturer accepts no liability for any damage resulting from unau-thorised alterations to the turbocharger.
In addition to this manual, the general, statutory regulations applicable in the respective country for the prevention of accidents and the protection of the environment must be observed.
This also applies to the provision and wearing of personnel protection equipment.
The safety and risk consciousness of the personnel working on and with the turbocharger must be checked regularly with reference to this manual.
The turbocharger must be shut down immediately by stopping the en-
gine in the event of alterations affecting safety or of corresponding op-erating behaviour. The fault must be reported to the person or depart-ment responsible.
Additions and alterations to, and conversions of the turbocharger that could compromise safety require the prior approval of ABB Turbo Sys-tems.
Original parts and accessories are especially designed for the turbo-charger supplied by ABB Turbo Systems.
We herewith expressly state that parts and accessories not supplied by us have also not been tested and approved by us.
If components and assemblies not manufactured and tested by ABB Turbo Systems are used, this may have a negative effect on the techni-cal design specifications of the turbocharger. Moreover, the active and/or passive safety of the turbocharger may be compromised by the use of non-original parts. Note that such improper use may endanger personnel and the machine.
ABB Turbo Systems shall not be liable for any damage caused by using non-original parts and accessories.
Qualification of personnel
The turbocharger may be operated and maintained only by trained and authorized personnel.
Work on mechanical components, such as bearings or rotors, may be carried out only by trained fitters from an official service station of ABB Turbo Systems.
This operating manual is valid for various turbocharger design variants.
This means that some sections and component descriptions in this oper-ating manual do not apply to your turbocharger.
Our service stations and agencies will gladly answer your questions relat-ing specifically to your model.
Accuracy of illustrations
The graphics and images shown in this manual are of a general nature and are intended to assist understanding of the work steps and instruc-tions. Differences may exist in certain details.
Storage of new turbochargers
New turbochargers supplied by ABB Turbo Systems can be stored without additional safeguarding measures for a period of 6 months after the deliv-ery date.
Suitable storage locations are dry rooms only where the relative humidity is between 40-70% and no condensation can form.
After 6 months have passed, spray the surfaces and all accessible spaces in the turbocharger with anticorrosive oil.
Repeat the measures listed for the corrosion protection of your turbo-charger every 6 months.
1.5 Symbols and definitions The following symbols are used in the documents:
Prerequisite Work step
Enumeration, first level
- Enumeration, second level
Definition of note / instruction
Note The note provides advice to facilitate working with the product.
Definition of caution / warning
The caution and warning signs are described in the chapter Safety.
ABB Turbo Systems
In this document, ABB Turbo Systems Ltd is abbreviated to ABB Turbo Systems.
Official ABB Turbo Systems service stations
In this document, official service stations are specified as ABB turbo-charger service stations. They are inspected and certified regularly by ABB Turbo Systems.
1 Turbocharger operating limits at engine overload (110 %). In test rig operation only, unless otherwise agreed with the engine manufacturer.
2 Turbocharger operating limits during operation
3 Inspection interval for plain bearings in 1000 h 4 Replacement interval for the compressor in 1000 h 5 Replacement interval for the turbine in 1000 h
6 Customer part number 7 Description for special design 8 Weight of turbocharger in kg 9 CE marking 10 Turbocharger type 11 Serial number 12 Year of turbocharger construction
Operating limits
Recommended inspection / replacement intervals for turbocharger components
The recommended replacement intervals and the corresponding opera-tional limits are jointly defined with the engine manufacturer. This informa-tion is specific to the system.
Operation above the indicated values nBmax, tBmax can considerably shorten the recommended replacement intervals. In such cases, 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 limits can also be permitted during operation for special applications. Operation above nMmax and tMmax is not permitted. Non-observance of the recommended replacement intervals can increase the risk of unpredictable component failures.
Operation Manual / TPS50
Preliminary remarks 1
CE declaration of conformity (form only) 1.7 Page 11
1.7 CE declaration of conformity (form only) Information
ABB turbochargers satisfy the machinery directives 98/37/EC and 2006/42/EC.
ABB Turbo Systems Ltd ABB
ABB
DECLARATION OF CE - CONFORMITY
We,ABB Turbo Systems Ltd.
Bruggerstr. 71a 5401 Baden /Switzerland
hereby declare that the product(s) designated hereafter is (are), with regards to its (their) concept and construction as well as the design offered for sale by us, in conformity with the relevant, fundamental safety and health requirements of the EC - guidelines.
Your order No. (Nos.):
Our order No. (Nos.):
Order Item No. (Nos.):
Serial No. (Nos.):
Type / Description: Turbocharger (type)
Relevant EC– guideline(s): 2006 / 42 / EC
Relevant Standards: EN ISO 12100–1 EN ISO 12100–2 EN 14121-1 EN 1012-1 EN 1679-1
Responsible for documentation: ABB Turbo Systems Ltd., Z-M, S. Höner, Bruggerstr. 71a, 5401 Baden
:erutangiS )etaD( ,nedaB
renöH nafetS M-Z / smetsyS obruT BBA
This Document validates the CE marking on the rating plate of the Turbocharger CE = Communautés Européennes
Turbochargers manufactured by ABB Turbo Systems are state of the art and comply with the pertinent safety and health-protection requirements that applied when the turbocharger was manufactured. Consequently, the turbocharger is safe to operate. Nevertheless, during turbocharger opera-tion and when working on the turbocharger, residual risks can exist which:
emanate from the turbocharger itself and its accessories emanate from the operating and auxiliary materials used are the consequence of insufficient observance of the safety instruc-
tions are the consequence of unsatisfactory and improper execution of main-
tenance and inspection work
The operator is responsible for the organizational measures that regulate the safe handling of the turbocharger by his personnel.
All instructions in this chapter must be observed to ensure safe and trou-ble-free turbocharger operation and during work on the turbocharger.
In the same vein, all other specially marked safety instructions in every chapter of this manual must be observed (see the section entitled Defini-tion of safety instructions).
2.2 Definition of Safety instructions The following symbols and terms used in this manual concern safety or refer to possible hazards:
Definition of warning Serious personal injuries and even accidents with fatal consequences may occur if work and operating instructions marked with this symbol and the word WARNING are either not followed or not followed pre-cisely. Warning signs must be observed at all times.
Definition of caution Serious machine or property damage may occur if work and operating instructions marked with this symbol and the word CAUTION are either not followed or not followed precisely. Caution signs must be observed at all times.
Part number Size [mm] Product 72080 175 x 22 TPS 81080 105 x 74 TPL / TPR
Turbochargers supplied to the enginebuilder without insulation must be fit-ted later with warning plates to be affixed to the insulation. This is the re-sponsibility of the enginebuilder.
Warning plates must be affixed at the designated locations and must be easily visible. For additional information, please contact an ABB Turbo-charger service station.
2.4 Safe operation and maintenance The instructions specified in this section are for the safety of personnel. Together with the instructions in the Hazards during operation and main-tenance section, they allow the user to safely use the turbocharger.
Work safety and work area safety
Risk of falling There is the risk that someone can fall when working on the turbo-charger.
Do not climb on the turbocharger or on parts attached to it or use these as climbing aids.
When working at levels above the head, use climbing aids and work platforms suitable for this purpose.
Observe all general regulations for the prevention of accidents. Do not work on the turbocharger if you are under physical or mental
stress. For each type of work, wear appropriate protective equipment such as:
helmet (hard hat) ear protectors protective glasses protective gloves protective shoes protective clothing hair net (in case of long hair) respiratory mask
Work only with suitable tools as well as equipment and working materi-als that are in perfect condition.
Electric tools must be solidly earthed, and connecting cables may not be damaged.
Keep the workplace clean, clear away loose objects and remove ob-stacles on the floor.
Keep the floor, equipment and the turbocharger clean. Have oil binding materials ready at hand and keep oil catch pans ready
or in position Eliminate leaks. Keep fire-protection materials and fire-extinguishing equipment ready.
If welding work is being carried out above the turbocharger, make sure to cover the filter silencer so that the filter mat is not damaged.
Remove combustible objects and substances out of the range of flying sparks.
Cover all connections on the turbocharger so that no foreign objects can get into the turbocharger.
Safety during start-up / commissioning and operation
Before starting work, carry out a visual inspection of working area. Remove any obstacles and objects lying around. Before start-up / commissioning, check all pipes from and to turbo-
charger for damage and leaks. Refrain from any way of working that could compromise safety when
working on turbocharger. After about every 12 hours of operation or at least once a day, inspect
turbocharger for visible damage and defects. Immediately report any damage or changes in operational performance
to department responsible. If damage is discovered, immediately shut down turbocharger and se-
cure it against inadvertent or unauthorized use. When switching on auxiliary power sources (hydraulics, pneumatics,
electricity, water), keep an eye open for any hazards resulting from supplying these power sources.
Safety during cleaning
It is possible that detergents or solvents will be used for cleaning. In this case, the safety instructions of the Hazard due to operating materials and supplies section in this chapter must always be observed.
Protect the floor against unintentional penetration of detergents or sol-vents before starting cleaning operations.
Wear appropriate protective clothing. Inspect the electric cables for abrasion and damaged areas before and
Safety during disassembly, assembly, maintenance and troubleshooting
Always perform the specified adjustments, servicing as well as inspec-tion work and observe inspection intervals.
Inform operating personnel about all service and repair work before beginning.
Before opening a cover or removing a protective device on a turbo-charger, the engine must be switched off and the turbocharger must have come to a standstill.
Ensure that the supply of oil is interrupted, especially with an external oil supply.
Put the engine into operation only after all parts have been refitted pro-perly.
Mechanical work on the turbocharger Possible damage to or destruction of components on the turbocharger.
Perform only those tasks that are described in this manual. Perform work only for which training has been carried out.
Safety when taking out of operation or mothballing
Secure the rotor so it cannot turn. The rotor can turn on its own from the force of the stack draught.
Clean the turbocharger before mothballing it. Wear appropriate protective clothing.
During normal operation, no mechanical hazards emanate from the turbo-charger if it has been installed properly.
Risk of injury Contact with rotating parts can lead to serious injuries. The turbo-charger must never be operated without a filter silencer or an air suction branch. When the engine is at a standstill, the rotor can turn on its own because of stack draught.
Operate the turbocharger in accordance with instructions. During maintenance work, secure the rotor against unintentional ro-
tation.
Mechanical hazards when working on the turbocharger
During maintenance work, various risks can occur through the improper handling of components, through the non-observance of work instructions, due to inadequate care or as a consequence of insufficient training.
Mechanical hazards Serious personal injuries or accidents with fatal consequences can oc-cur through mechanical influences as a result of risky, improper working methods.
Heed the general rules for work safety and accident prevention. Ensure the safety of the work area. Perform only those tasks that are described in this manual. Perform work only for which training has been carried out.
The development of noise during operation is influenced by the installation and operating conditions. Noise with a level exceeding 85 dB(A) is harm-ful.
Hazards due to noise The noise can cause impaired hearing, damage to health, mental dis-turbances, irritation and diminished attention.
Always wear ear protectors when engine is running. When noise level is above 85 dB(A), always wear ear protectors.
Reference values for the maximal duration of stay in the area of noise emissions (source: Accident Prevention Regulations for Companies En-gaged in Shipping):
240
y
180
120
60
3015
0 5
85 88 91 94 97 120 x
100105
x Noise level [dB(A)] y Maximal duration of stay [min] per workday
During operation, turbocharger surfaces and attached parts as well as op-erating materials (lubricating oil) become hot. The surface temperature is dependent on the effectiveness of the insulation being used. The tem-perature can become high enough so that it falls into ranges where burns are possible.
Risk of burning Touching hot surfaces or contact with hot operating materials can lead to serious burns.
Do not touch hot surfaces and heed the warning plate on the turbo-charger.
Wear heat-resistant protective gloves and protective clothing. Allow the turbocharger to cool down before carrying out any work.
Hot surfaces on uninsulated turbochargers Uninsulated turbochargers can cause serious personal injuries (burns). The turbocharger is supplied by ABB Turbo Systems without insulation depending on the order from the engine builder. In this case, the engine builder is responsible for insulating the turbocharger properly or for pro-viding protection against hot surfaces being touched. The engine builder's instructions and specifications about protection
against hot turbocharger surfaces must be observed in every case.
Hazards due to operating and auxiliary materials
Operating and auxiliary materials are substances used for operation or the execution of maintenance work. Oils, greases, coolants, cleaning agents and solvents, acids, etc. can be regarded as hazardous materials. Operat-ing and auxiliary materials can be combustible and easily ignited.
Risk of poisoning, burning Ingestion or inhalation of vapours of the corresponding operating and auxiliary materials or contact with such can cause damage to health.
Avoid inhalation and contact with the skin. Wear protective clothing and a breathing mask.
Risk of fire, explosion Combustible or easily ignited operating and auxiliary materials can burst into flame, or vapours from them can cause explosions.
Do not allow any exposed flame during cleaning work. Perform cleaning outdoors or ensure for adequate aeration and ven-
tilation.
Risk of environmental damage The escape of operating and auxiliary materials into the atmosphere or contamination of the ground and water due to improper disposal can lead to environmental damage. Handle operating and auxiliary materials carefully.
Heed the instructions for use, safety data sheets and hazard notices on the containers of the operating and auxiliary materials.
Wear appropriate protective clothing. Avoid inhalation and contact with the skin. Ensure that the work space is adequately ventilated. Seal containers tightly immediately after use and put them away. Collect used working and auxiliary materials safely, store them sepa-
rately in suitable containers and dispose of them properly and in an environmentally compatible manner in accordance with statutory regu-lations.
In the event of leaks or after spilling, immediately spread a suitable binding agent and dispose of it properly and in an environmentally compatible manner in accordance with statutory regulations.
Hazards when handling insulating materials
Hazards due to insulating materials Dust and fibres from insulating materials can cause damage to health or irritations. Unsuitable, combustible insulating materials signify a fire hazard. Handle insulating materials cautiously.
Use only suitable, non-combustible insulating materials. Ensure that work area is well ventilated. Wear suitable work clothing (protective glasses, dust mask).
Avoid stirring up dust. Use tools and processes that keep dust to a minimum. Remove packing materials only in work area. Take particular care when removing old insulating materials. Dispose of insulating materials properly and in an environmentally
compatible way in accordance with applicable local regulations.
Hazards due to electrical components
Hazards due to electrical components Electrical components operate with voltages, which can present haz-ards to humans.
All work on or with electrical components may only be performed by trained specialists.
2.6 Use of ABB turbochargers on gas engines ABB turbochargers withstand a deflagration with a transient pressure in-crease of 12 bar. A maximum of 11 bar was measured during deflagration trials on engines with flame traps. Field operating experience of well-known gas engine builders supports this value. In the past, no damage to ABB turbochargers was ascertained after deflagration incidents.
ABB Turbo Systems recommends that the turbocharger is inspected visu-ally after a deflagration incident. During this inspection, the positions of the turbine casing and the compressor casing relative to the bearing cas-ing as well as any shifting of the bearing casing relative to the bracket must be checked. An inspection of the casing for cracks is also recom-mended. The nearest ABB Turbocharger service station should be com-missioned with this inspection and assessment.
Suspended loads Suspending loads in ways that do not comply with regulations can re-sult in serious or fatal injuries.
Carefully fasten assemblies or individual parts weighing more than 25 kg to technically perfect lifting gear with sufficient loading capac-ity.
Make sure load is hung properly on crane hook. Don't let anyone stand beneath a suspended load.
max.45°
In the case of two or more suspension points, the slinging angle must not exceed 45°. This avoids excessive loading due to inclined tensile loading.
Fasten turbocharger assemblies / components as described in respec-tive handling steps.
Before attaching slings, allow turbocharger components to cool down (maximum 80°C).
Use suitable protection at sharp edges. Completely screw in assembly / fitting devices without fail so that they
cannot work loose during use. Use assembly / fitting devices only for applications described. Make sure removed turbocharger components stand safely and se-
A carefully designed and installed oil supply, which functions in all possi-ble operational conditions, is an important prerequisite for trouble-free tur-bocharger operation.
The turbocharger is normally lubricated with oil from the engine oil circuit. If a separate lubricating system is used, then emergency lubrication is al-so to be provided.
Heed the instructions of the engine builder when selecting the lubricat-ing oil and oil-change intervals.
Oil filtration
To avoid hazardous wear of bearing parts and bearing in mind the tur-bine specifications as well as the bearings used, impurities of different size must be filtered out of the lubricating oil.
Oil filtration down to 34 µm is specified as standard for the turbocharger. This means that impurities larger than 0.034 mm must be filtered out of the oil with a separation efficiency > 99%.
Fit an accessory filter if engine oil filter is not efficient enough. Arrange for a bypass to be activated that ensures oil is supplied to tur-
bocharger by circumventing filter when engine is cold started and dirty deposits in accessory filter cause flow resistance to rise above 0.5 bar.
Check that oil filters are clean before every start-up.
Also follow the engine builder's instructions regarding filter mesh size and separation efficiency.
Lubricant
All lubricating oils used for engines are admissible.
The temperature at the oil inlet must not exceed 105°C. Permissible vis-cosities and temperatures at the oil inlet are shown in the following chart.
1) Kinematic viscosity (mm2/s = cSt) 2) Oil inlet temperature (°C) A Permissible range
The temperature is allowed to drop below the bottom limit for a short time during the engine start-up. But then, the oil inlet temperature may not drop below 10°C.
Oil pressure
The oil pressure in front of the bearings must be maintained precisely to ensure trouble-free operation.
The oil pressure (gauge) in front of the turbocharger should be between 2.0 ... 4.5 bar when the engine is under load and at least 0.2 bar when id-ling.
A higher oil pressure up to 8 bar is permissible for a short time during the start-up phase when the oil is cold. The oil pressure must not exceed 1.0 bar during pre- and post-lubrication.
Pre-lubrication
The turbocharger must be supplied with oil from the very first moment the engine is started. Actuate pre-lubrication device before starting engine each time.
3.2 Inspection work Inspection work includes preventive visual checks, monitoring and meas-uring tasks, which ensure that the turbocharger functions correctly. They help to identify anomalies before and during a start-up and consequently to avoid machine damage.
3.2.1 Inspection before commissioning
Check for correct functioning.
Check cleanliness before commissioning.
Check the oil pressure in the oil supply lines.
It is strongly recommended that, before commissioning as well as fol-lowing any servicing work on the lubricating system, you install a by-pass pipe in order to thoroughly flush the entire lubricating system with warm, clean oil. Also, we strongly advise you to use a running-in filter when starting up the engine for the first time as well as following all service work on the lubricating system.
Pre-lubrication
The turbocharger must be supplied with oil from the very first moment the engine is started. Actuate pre-lubrication device before starting engine each time.
The permissible values are listed in the section Oil supply.
Gas, air and oil lines
Check all gas, air and oil lines for leaks after starting the engine. Tighten the V-clamps once to 60 Nm.
Further periodic tightening of the V-clamps is not necessary or recom-mended. Too frequent tightening can lead to wear on the connection.
3.2.3 Check when running up engine
Measure the oil pressure and charging pressure at various engine per-formance levels.
Measure the exhaust gas temperature in front of and behind the tur-bine
Measure the air temperature in front of and behind the compressor.
The measured values must be compared with the values in the accep-tance test report while taking different operating conditions into account.
Lubricants and pastes used during assembly of the turbocharger liquefy or vaporise and might escape as an oily liquid in the first few hours after commissioning. If additional oily liquid continues to escape after this pe-riod, look for the cause of a possible oil leak. The first step is to check for leaks in the oil supply to the turbocharger. If this is not in proper condition, contact an ABB Turbocharger service station.
3.2.4 Inspection after 100 service hours
Clean or replace lubricating oil filters after the first 100 service hours.
Hazards due to noise The noise can cause impaired hearing, damage to health, mental dis-turbances, irritation and diminished attention.
Always wear ear protectors when engine is running. When noise level is above 85 dB(A), always wear ear protectors.
The sound pressure level (A-weighted) of emissions is measured at a dis-tance of 1 metre from the turbocharger.
The highest sound pressure level of emissions1) reaches a maximum of 105 dB(A) near the filter silencer and over the entire speed range.
The following prerequisites must be fulfilled on the turbocharger in order to observe this limit:
A filter silencer is fitted. All standard, noise-reducing measures have been taken2). The bellows at the air outlet have been perfectly insulated acoustically
by the engine builder. He is also responsible for insulating the charge air / scavenging air pipe and the charge air cooler.
1) Directive 2006/42/EC, 1.7.4.2 / u / paragraph 5 + 7 : A-weighted sound pressure level of emissions
2) In the event of divergent insulation designs, the engine builder must ensure that equivalent acoustic insulating measures are ta-ken.
4.2 Servicing work Service work to be carried out during operation involves visual checks, monitoring, measuring, inspection work and functional checks. It is then possible for changes to the turbocharger to be identified and rectified. In this way, it can be ensured that the turbocharger remains in full working order.
Service intervals Service work on the turbocharger that is neglected or carried out too la-te can lead to a heavy dirt build-up and operating failures. Carry out service work at specified time intervals.
4.2.1 Servicing work every 25 to 50 hours
Ckeck visually for air, exhaust gas, water and oil leaks. Record operating data and enter in engine logbook. Clarify cause of variances.
Unknown changes during operation The consequences can range from impairment to operating failure. Have unknown causes clarified by an ABB turbocharger service sta-
tion.
4.2.2 Servicing work according to the engine manufacturer's instructions
Clean or replace oil filter when engine is not running.
4.2.3 Servicing work according to the rating plate
(Normally after 8’000 – 12’000 operating hours)
The rotor and bearing parts must be checked and assessed by an ABB Turbocharger service station.
Remove cartridge group as described in chapter Disassembly and as-sembly.
Measure clearances. Clean turbine and compressor casings and check them for cracks and
erosion / corrosion. Clean bearing casing and blow air through oil ports / holes. Clean nozzle ring and check for cracks and erosion.
4.2.4 Entries in engine logbook
By monitoring the engine, conclusions can be drawn about the turbo-charger performance.
The following operating data and measured values must be entered regu-larly in the engine manufacturer's engine logbook:
Engine performance and speed Air intake temperature Exhaust gas temperature in front of and behind the turbine Pressure of charge air Pressure drop in charge air cooler Lubricating oil pressure and lubricating oil temperature
Air temperature behind compressor and charge air cooler Turbocharger speed Pressure loss in air filter
Before the engine is shut down, it must be allowed to idle for about 5 to 10 minutes so that the circulating lubricating oil can take away heat from the turbocharger bearings.
Maintenance work involves regular visual checks and cleaning tasks, which are intended to ensure trouble-free functioning of the turbocharger.
The external condition and the dirtiness of the cleaning points given in this chapter must be established by visual checks at the specified in-tervals.
The safety instructions must be observed during all maintenance work.
5.2 Cleaning the compressor during operation How dirty the compressor stage (compressor wheel and diffuser) be-comes, depends on how clean the drawn-in air is.
Deposits of dirt can build up in the flow ducts if the following substances are in the intake air:
Oily or salty mist Solid combustion residues Various kinds of dust
Dirty deposits on the compressor stage have a negative influence on the compressor efficiency and the charging pressure.
This results in higher exhaust temperatures and higher fuel consumption by the engine. Dirty deposits on the compressor can also increase rotor unbalance.
Under no circumstances is periodic cleaning of the compressor during op-eration a substitute for the service work carried out when the turbocharger is completely dismantled and the compressor is cleaned mechanically.
If the coating of dirt is very thick and hard, the compressor can only be cleaned manually when disassembled. This cleaning should be carried out by an ABB Turbocharger service station.
The interval between periodic cleaning is very dependent on the operating conditions. In general, cleaning should be carried out every 25 to 100 op-erating hours.
Cleaning intervals Should the specified cleaning intervals prove incompatible with engine operation, please contact ABB Turbo Systems.
Cleaning the compressor while in operation is carried out as wet cleaning. This cleaning method has been tested and approved by ABB Turbo Sys-tems.
To clean the compressor stage while in operation, water is injected in front of the compressor wheel from an injection pipe that is built in the filter si-lencer or suction branch.
The water does not act as a solvent in the process, but the deposit is re-moved by the mechanical impact of the drops. This is a very suitable pro-cess, provided that the build-up of deposits is not too advanced.
Corrosion and deposits when cleaning Damage and impairment of turbocharger parts due to salt water and cooling water additives Always use only clean water for cleaning.
The injection pipe must on no account be connected directly via a cock to a water pipe or a dosing vessel larger than the one supplied. This prevents uncontrolled volumes of water entering the turbocharger and engine, which can lead to serious damage.
In the case of V-engines with several turbochargers on each engine, we recommend parallel cleaning of the compressors. This cleaning process is faster and the risk of turbocharger surging is reduced.
In the case of sequential charging, care must be taken to ensure that tur-bocharger compressors are cleaned regularly, especially after periods of operation in the lower performance range.
5.2.1 Wet cleaning compressor using external water pressure vessel (XC1)
These instructions for wet cleaning apply only when cleaning is carried out with clean water and the engine manufacturer permits the process.
Supplying water from the externally mounted water vessel is suitable only for those applications where a negative pressure exists in front of the compressor wheel (not used for: blowers connected in front of the compressor or high-pressure compressor stages with two-stage charg-ing).
Operating condition prerequisites for compressor cleaning with XC1
In order to carry out a satisfactory cleaning process that has been tested and is recommended by ABB Turbo Systems, the following pre-requisites must be met:
Full engine load if possible High turbocharger speed Start cleaning cycle according to following description in Procedure
X Screw plug D Pressurized air Y Valve activator W Water Z Container
Remove the screw plug (X). Fill the vessel with clean water. Replace the screw plug. Push the valve activator (Y) against the spring and hold it for 10 to 15
seconds until entire volume of water has been injected. After cleaning, wait at least 5 minutes with the engine running to allow
the turbocharger to dry. The cleaning cycle may only be repeated after a stabilisation period of
Whether or not cleaning has been successful can be seen from the charging or flushing pressure and also from the exhaust gas tempera-tures. If the cleaning operation is not satisfactory, it can be repeated up to two times. If the cleaning result is still not satisfactory after three attempts and the engine values are also unsatisfactory, we recommend that the turbo-charger be inspected and cleaned by an official ABB Turbocharger ser-vice station.
Possible causes Remedy Turbocharger fouled Clean Bearing damaged Rotor rubbing
Turbo-charger
Foreign object in the turbo-charger
Contact ABB Turbocharger ser-vice station
Vibrations
Possible causes Remedy Rotor unbalance Turbine or compressor damaged
Turbo-charger
Bearing damaged
Contact ABB Turbocharger ser-vice station
Rubbing of rotating parts
Normal behaviour, not a malfunction Turbo-charger
A minimal and uniform wear at the circumference of the rotor com-ponents, caused by slight local rubbing against adjacent compo-nents is permitted. This causes the compressor or turbine blades to be somewhat shortened. 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 Turbocharger service station. Have a dimensional check carried out by an ABB Turbocharger
Continuous or periodic surging Possible damage to components such as compressor wheel, turbine blades, bearing and filter silencer.
Have the cause clarified and remedied immediately by an ABB Tur-bocharger service station.
Have parts assessed for damage and, if necessary, replaced by an ABB Turbocharger service station.
Sporadic surge blows
Surging of the turbocharger can occur during certain operating conditions such as when reducing the engine performance quickly when manoeu-vring. At the same time, the flow direction in the compressor is momentar-ily reversed. Such sporadic surge blows do not impair the safe operation of the turbocharger.
A surge blow is accompanied by a loud bang and escape of hot air from the filter silencer.
7 Removal and installation 7.1 Turbocharger weights
Turbocharger suspension
Lifting gear with a sufficient load limit must be used for removing and in-stalling the turbocharger. The following weight specification is the heaviest possibility. This guide value can differ from data on the rating plate, de-pending on the specification.
Turbocharger assembly without air suction branch and without exhaust gas pipe
7.2 Remove the turbocharger Disconnect all gas and air lines in accordance with the engine builder’s
instructions.
Secure the lifting gear to the bearing casing. Loosen the fixing screws (C) on the bearing casing. Lift the turbocharger off the engine and put it down to one side. Cover the oil connections.
7.3 Installing the turbocharger Remove the covers from the oil connections. Visually inspect the O-ring gaskets of the oil supply and drain pipe (O-
ring gaskets on the engine side are not included in the scope of deliv-ery from ABB Turbo Systems).
Inspect the lifting gear.
Secure the lifting gear to the bearing casing. Adjust the turbocharger to match the engine. Tighten the fixing screws (C) on the bearing casing in accordance with
engine manufacturer's instructions. Fasten all gas and air lines in accordance with engine builder’s instruc-
The precondition for the work described in the following is a turbocharger removed from the engine (see chapter Removal and installation).
Further work Further tasks, which are not described here, may be carried out only by trained personnel from an ABB turbocharger service station. Only carry out those tasks that are described in this chapter.
Marking casing positions for assembly ABB Turbo Systems recommends that the casing positions be marked before disassemblng the turbocharger.
Identifying assembly devices
Not all assembly devices are marked with a part number. They can be identified using the tool list. This list is enclosed in the toolbox.
Maintaining assembly devices Assembly devices must be checked for damage before and after use.
Visually check for corrosion, cracks, deformation and wear. Don't use damaged assembly devices, but replace them.
Before beginning work, ensure that the required customer spare parts kits are available.
See chapter Reserve and spare parts.
Oil orifice
When disassembling the turbocharger, a fitted oil orifice must not be removed.
Tightening torques for turbocharger components
The specified tightening torques of screw connections for turbocharger components must be observed. (See section Table of tightening torques.)
Tightening torques for assembly devices of ABB Turbo Systems
If nothing else is described, the screws and nuts of the assembly devices must be tightened down firmly.
Definition of terms
Suspension point Defined point of load application on a component or an assembly (blind hole thread, eye / lug, strap / bracket).
Assembly device A device that is mounted on the turbocharger to obtain a suspension point. Assembly devices are specially developed and designed for the defined application. They are not commercially available products. Use assembly / fitting devices only for the applications described.
Lifting gear Equipment for lifting and transporting loads (ropes, chain hoists, cra-nes). Lifting gear is not supplied by ABB Turbo Systems.
Always replace the O-rings (see the section entitled Spare parts).
Fit the O-rings (42005 and 79005). Align the hole in the diffuser (79000) with the positioning pin (42010) in
the bearing flange (42005). Clean the V-clamps (72020/72030) thoroughly before assembly. Lubricate the V-clamp thread and the inside part of the profile with ce-
ramic paste. Install the wall insert (77000/77006) with its O-ring (77005) into the
compressor casing (72000)
Secure the lifting gear to the assembly-disassembly device (90020) and clamp it tightly to the compressor casing (72000) (tightening torque 60 Nm).
Install the compressor casing (72000) with the wall insert (77000/77006).
Attach the V-clamp (72030) and tighten it in accordance with the table of tightening torques.
Fit the filter silencer or the air suction branch and attach all air lines in accordance with the engine builder's instructions.
Disconnect all pipes in accordance with engine manufacturer's instruc-tions. Remove the turbocharger and then the filter silencer as well as the compressor casing (also see the previous chapter).
Treat the screw thread of the V-clamp (52410) with rust remover and allow it to act.
Check the lifting gear and secure it to the bearing casing (10900). Loosen the V-clamp (52410) and remove it. Loosen and remove the fixing screws (C) of the bearing casing
(42001). Remove the cartridge group and set it down to one side.
The V-clamp (52410) is always to be replaced with a new one (see the section entitled Spare parts).
Screw the nozzle ring (56001) off the partition wall. Measure the axial and radial clearances (see the section entitled Axial
Measure the axial and radial clearances (see the section entitled Axial and radial clearances).
Screw the nozzle ring (56001) onto the partition wall. Check the lifting gear and fasten it to the bearing casing (42001). Lubricate the centring seats, the inside part of the V-clamp profile and
the screw thread with ceramic paste. Remove the temporary covers from the oil connections.
Take care not to damage or shift the gasket rings in the mounting sup-port when installing the cartridge group. The gasket rings are on the engine side are not included in the scope of delivery from ABB Turbo Systems.
Fit the V-clamp (52410) and tighten it to the specified tightening torque
These are the theoretical values for the radial clearance between the compressor wheel and the wall insert, or between the turbine wheel and the gas-outlet flange.
The minimum and maximum clearances result from the manufacturing to-lerances of the compressor and turbine wheel or the wall insert and gas-outlet flange.
N1/N2 and R1/R2 are each meas-ured at the same time using two feeler gauges. The feeler gauges may be pushed with some force between the wall insert / compressor wheel or the gas outlet flange / turbine wheel.
10 Mothballing the turbocharger 10.1 Taking out of operation for up to 12 months
Condition of engine lubricating oil
The turbocharger normally remains mounted on the engine. Preservation for storage of a turbocharger depends on the condition of the lubricating oil:
If the total acid number (TAN) is lower than 2 mg KOH/g no measures have to be taken.
If the engine lubricating oil is replaced by storage oil before the shut-down and this is circulated by the prelubrication pump, no measures have to be taken. Any remaining old engine oil will thus be flushed away and bearing sections largely protected against corrosion.
Storage preservation measures
If the total acid number (TAN) is greater than 2 mg KOH/g, the following storage preservation measures are necessary after a shut-down:
Remove turbocharger. Have rotor and bearing parts removed and refitted by an official ABB
Turbo Systems service station. Clean all parts. Oil machined, bright surfaces of steel and cast parts using anticorro-
sive oil. Refit complete turbocharger.
Rotating rotor in stack draught
If the rotor rotates as a result of the stack draught:
Install blind flange between compressor casing outlet flange and char-ge air duct.
Environmentally compatible disposal of turbocharger components
Disposal must be environmentally compatible, professional and in accor-dance with local regulations.
The turbocharger mainly consists of metal (cast-iron materials, steel, ni-ckel-steel alloys, aluminium, bearing brass).
Other components are: Non-metallic materials (filter components made of felt and polyethylene), lubricants (engine oil), electronic components (speed sensor and associated components), thermal insulation.
Dispose of metals as old metal for recycling. Dispose of non-metallic materials as waste. Dispose of lubricant left-overs as used / waste oil. Dispose of electronic components as electrical / electronic scrap.
Handling damaged thermal insulation Damaged thermal insulation can burden the air with dust. The glass fi-bres can cause mechanical irritation of the eyes, skin and respiratory tracts.
Prevent dust from being produced. Remove dust with a suitable vacuum cleaner. Wear respiratory mask as protection against particles (P1 or P2
12 Reserve and spare parts 12.1 Ordering spare parts
When making inquiries or ordering spare parts, the following data must be specified:
Turbocharger type Serial number (HT……) Description and part number
Our service stations and agents take orders for spare parts.
Contact an official ABB Turbocharger service station or an ABB agent if special versions/cases are not addressed in these general instructions.
Spare parts The parts included in the spare parts set are available only as a whole set.
Storaging spare parts All spare parts, ordered with the turbocharger, should be kept complete and ready for use. Parts showing signs of rust should be carefully cleaned and greased.
Dispose of replaced and unusable parts in a professional and environ-mentally compatible way.
The spare parts kit (97070) is required for the work described in this manual. The parts included in the spare parts kit are available only as a complete set.
All spare parts that have been ordered with the turbocharger should be kept complete and serviceable. Parts showing signs of rust should be carefully cleaned and greased.
Dispose of replaced parts that are no longer usable in a professional
Part number Description 51000 Turbine casing 52400 Gas outlet flange 52410 V-clamp 52420 V-clamp 72000 Compressor casing 72020 V-clamp 72030 V-clamp 77000 Wall insert 77005 (in spare parts kit) O-ring 77006 (in spare parts kit) O-ring 79000 Diffuser 79005 (in spare parts kit) O-ring
Part number Description 10900 Cartridge group 21000 Shaft 21002 Piston ring 21003 Lock nut 21004 Cup spring 25000 Compressor wheel 32101 Plain bearing bush 32103 Safety ring 32105 Thrust ring 32106 Thrust bearing 32107 Bearing bush 32108 Piston ring 32221 Bearing cover 32222 (in spare parts kit) O-ring 42001 Bearing casing 42002 Hexagon socket screw 42005 Bearing flange 42011 (in spare parts kit) O-ring 42012 (in spare parts kit) O-ring 42066 Orifice plate 42067 Hexagon socket screw 43001 Partition wall 43003 Hexagon socket screw 43004 Verbusripp washer 56001 Nozzle ring