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Turbocharging

Operation Manual / A135-H66

HT846309

Document identification

Document number HZTL4030

Revision G

Language English

Original Operation Manual

Product identification

Serial number HT846309

Customer part number 1238114

Delivery date (yyyy-mm-dd) 2021-07-28

Weight 270 kg

Operating limits according to rating plate

Speed limit in test rig operation only

Mmax

864 1/s

Speed limit during operation

Bmax

846 1/s

Gas inlet temperature limit in test rig operation only

Mmax

680 °C

Gas inlet temperature limit during operation

Bmax

650 °C

Table of Contents3
Operation Manual / A130-H6
Introduction6
Purpose of the Manual6
Fig. 1: Serial Number (01) on the Rating Plate6
Contact Information7
Essential Information7
Registered Trademarks7
Layout and Function of the Turbocharger8
Fig. 2: Layout and Function of the Turbocharger8
Fig. 3: Compressor Wheel Cooling9
Symbols, Definitions10
Table 1: Definition of Pictograms11
Storage of New Turbochargers and Spare Parts12
Fig. 4: Volatile Corrosion Inhibitor (VCI)12
Fig. 5: Package with Hygrometer13
Safety14
Introduction14
CE Conformity14
Definition of Mandatory Signs15
Definition of Safety Instructions15
Table 2: Personal Protective Equipment to be Worn at All Times15
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task15
Intended Use16
Deflagration on Gas Engines17
Periodic Check of the Pressure Vessels17
Warning Plates on the Turbocharger18
Fig. 6: Warning Plate Locations18
Turbocharger Rating Plate19
Fig. 7: Rating Plate19
Fig. 8: Locations of the Rating Plates20
Lifting of Loads21
Fig. 9: Attachment of Loads on the Crane Hook21
Fig. 10: Attachment Angle21
Prerequisites for Operation and Maintenance22
Hazards During Operation and Maintenance23
Safe Operation25
Safe Maintenance26
Removing and Installing30
Weight and Transportation of the Turbocharger30
Fig. 11: Transportation of the Turbocharger30
Table 4: Weight of Complete Turbocharger Unit30
Removing the Turbocharger31
Fig. 12: Removing the Turbocharger31
Fig. 13: Loosening the Clamping Nut33
Fig. 14: Putting down the Turbocharger34
Installing the Turbocharger35
Fig. 15: Inserting Gaskets into the Bracket35
Fig. 16: Fitting Threaded Rods Onto the Bracket36
Fig. 17: Requirements for Threaded Rods36
Table 5: Requirements for Threaded Rods36
Fig. 18: Placing the Turbocharger on the Bracket37
Table 6: Tightening Torque for Standard Nuts38
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure39
Fig. 20: Tightening Pressure Screws40
Table 7: Torque-Controlled Tightening of the Pressure Screws40
Fig. 21: Connecting the Compressor Cooling Air Intake41
Fig. 22: Attaching the Support41
Commissioning42
Oil Supply42
Fig. 23: Oil Orifice43
Inspection Procedures44
Commissioning after Taking out of Operation46
Monitoring Operation47
Oil Pressure, Oil Temperature47
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger47
Table 9: Lubricating Oil Temperature at the Inlet48
Table 10: Lubricating Oil Temperature at the Outlet48
Exhaust Gas Temperature before Turbine49
Turbocharger Speed49
Fig. 24: Layout and Overview of Speed Measurement System50
Fig. 25: Replacing the Speed Sensor52
Table 11: Tightening Torque (86505)52
Operation and Service53
Noise Emission53
Fig. 26: Noise Insulation, Bellows54
Service Work55
Fig. 27: Replacing the Protective Grid57
Expected Replacement Intervals59
Table 12: Expected Replacement Intervals60
Stopping the Engine61
Periodic Maintenance Work62
Foreword to Maintenance62
Table 13: Maintenance Table62
Cleaning Components Mechanically63
Fig. 28: Cleaning the Filter Silencer64
Fig. 29: Compressor-End, Non-Rotating Parts66
Fig. 30: Turbine End, Non-Rotating Parts67
Fig. 31: Soaking the Turbine End70
Table 14: Value Table for Soaking70
Eliminating Malfunctions73
Malfunctions When Starting73
Table 15: Malfunctions When Starting - Delayed Start-Up73
Table 16: Malfunctions When Starting - Vibrations73
Table 17: Malfunctions When Starting - Rubbing of Rotating Parts73
Malfunctions During Operation74
Table 18: Malfunctions During Operation - Lubricating Oil Pressure too Low74
Table 19: Malfunctions During Operation - Speed Reduces74
Table 20: Malfunctions During Operation - Speed Increases74
Table 21: Malfunctions During Operation - Exhaust Gas Temperature too High75
Table 22: Malfunctions During Operation - Charge Air Pressure too Low75
Table 23: Malfunctions During Operation - Charge Air Pressure too High76
Table 24: Malfunctions During Operation - Engine Performance Losses76
Turbocharger Is Surging77
Table 25: Malfunction - Turbocharger Pumping77
Table 26: Malfunction - Sporadic Surge Blows77
Malfunctions When Stopping78
Table 27: Malfunctions When Stopping - Runout Noises78
Table 28: Malfunctions When Stopping - Runout Time too Short78
Speed Measurement System79
Table 29: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude79
Table 30: Malfunction of the Speed Measurement System - Measured Speed too High79
Table 31: Malfunction of the Speed Measurement System - Measured Speed too Low79
Dismantling and Fitting80
Introduction80
Weights of Individual Parts82
Fig. 32: Swivel Lifting Eyes82
Fig. 33: Starpoint Ring Nut VRM82
Table 32: Swivel Lifting Eyes82
Fig. 34: Weights of Assemblies83
Table 33: Weights of Assemblies83
Removing the Air Inlets84
Fig. 35: Removing the Air Inlets84
Removing the Gas Outlet Casing85
Removing the Gas Outlet Flange85
Fig. 36: Removing the Gas Outlet Casing85
A130 A135 A14086
Fig. 37: Dismantling the Gas Outlet Flange86
Table 34: 3 Press-Off Screws86
Fig. 38: Removing the Gas Outlet Flange87
Table 35: 6 Press-Off Screws87
Removing the Compressor Casing88
Compressor Casing88
Fig. 39: Removing the Compressor Casing88
Wall Insert89
Fig. 40: Dismantling the Wall Insert89
Pressing off the Casing90
Fig. 41: Press off the Casing90
Removing the Cartridge Group91
Fig. 42: Oil Orifice91
Fig. 43: Removing Cartridge Group 191
Fig. 44: Removing Cartridge Group 292
Removing the Nozzle Ring93
Fig. 45: Removing the Nozzle Ring93
Installing the Cartridge Group on the Service Support94
Fig. 46: Installing the Cartridge Group on the Service Support94
Measuring Clearance a and B95
Fig. 47: Measuring Clearance a and B95
Table 36: Permissible Clearances a and B95
Nozzle Ring Compression PD96
Fig. 48: Nozzle Ring Compression PD96
Table 37: Nozzle Ring Compression PD96
Installing the Nozzle Ring97
Fig. 49: Installing the Nozzle Ring97
Installing the Cartridge Group98
Fig. 50: Measuring the End Position of the Nozzle Ring98
Fig. 51: Lifting the Cartridge Group and Rotating It by 9098
Table 38: End Position of the Nozzle Ring, Control Dimension H98
Fig. 52: Installing the Cartridge Group99
Table 39: Tightening Torque (51007)99
Installing the Compressor Casing100
Fig. 53: Fitting the Wall Insert and the Diffuser100
Table 40: Tightening Torque (79041)100
Fig. 54: Installing the Compressor Casing101
Table 41: Tightening Torque (72011)101
Measuring Radial Clearances N and R102
Fig. 55: Measuring Clearances N and R102
Table 42: Permissible Clearances N and R102
Installing the Air Inlets103
Fig. 56: Installing the Air Inlets103
Table 43: Tightening Torque (72020)103
Installing the Gas Outlet Flange104
Installing the Gas Outlet Casing104
Fig. 57: Installing the Gas Outlet Flange104
Fig. 58: Installing the Gas Outlet Casing104
Table 44: Tightening Torque (51009)104
Table of Tightening Torques105
Fig. 59: Tightening Torques105
Table 45: Tightening Torques of the Screw Fittings105
Taking out of Operation at Short Notice106
Possible Emergency Repairs106
Installing the Replacement Turbocharger107
Installing the Replacement Cartridge Group107
Mothballing the Turbocharger108
Taking the Engine out of Operation for up to 12 Months108
Taking the Engine out of Operation for more than 12 Months109
Material and Disposal110
REACH and Rohs Compliance Declaration for Products110
Disposing of Turbocharger Components111
Spare Parts112
Ordering Spare Parts112
Required Customer Spare Part Set (97070)112
Table 46: Customer Spare Part Set 97070112
Spare Part - Illustrations113
Table 47113
Nozzle Ring 2 2114
Turbine Casing * 45 65114
Gas Outlet Flange114
Gas Outlet Casing115
Table 48115
Table 49115
Table 50116
Table 51117
Fig. 60: SPI Air Suction Branch Radial118
Table 52: Spare Parts - Air Suction Branch Radial118
Table 53119
Table 54120
Tools121
Figures122
Tables123

Brand	ABB
Model	A135-H66
Category	Industrial Equipment
Language	English

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