ABB HT608709 Operation Manual

HT608709 Document identification Document number HZTL4030 Revision G Language English Original Operation Manual Product identification Serial number HT608709 Customer part number X00074672 Delivery date (yyyy-mm-dd) 2022-02-04 Weight 270 kg Operating limits according to rating plate Speed limit in test rig operation only n Mmax 908 1/s Speed limit during operation n Bmax 888 1/s Gas inlet temperature limit in test rig operation only t Mmax 680 °C Gas inlet temperature limit during operation t Bmax 650 °C ...

Table of contents © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 Operation Manual / A130-H.. - A140-H.. 1 Introduction............................................................................................................ 4 1.1 Purpose of the manual................................................................................................. 4 1.2 Contact information...................................................................................................... 5 1.3 Essential information........................................................................................ ...

Table of contents © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 6.2 Service work................................................................................................................. 53 6.3 Expected replacement intervals ............................................................................... 57 6.4 Stopping the engine................................................................................................... 59 7 Periodic maintenance work ................................................................................ 60 7.1 Foreword to maintenance............. ...

Table of contents © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 12 Material and Disposal........................................................................................ 108 12.1 REACH and RoHS Compliance Declaration For Products ................................. 108 12.2 Disposing of turbocharger components ............................................................. 109 13 Spare parts ......................................................................................................... 110 13.1 Ordering spare parts........................................................... ...

1 Introduction / 1.1 Purpose of the manual © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 1 Introduction 1.1 Purpose of the manual Fig. 1: Serial number (01) on the rating plate This Operation Manual belongs to the turbocharger with the identical serial number (01), see the Operation Manual title page 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 ...

1 Introduction / 1.2 Contact information © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 1.2 Contact information Contact information for the ABB Turbocharging Service Stations is available online. u Scan the QR code to access our website. ABB Switzerland Ltd, Turbocharging Bruggerstrasse 71a CH-5401 Baden Switzerland www.abb.com/turbocharging 1.3 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 Turbo ...

1 Introduction / 1.5 Layout and function of the turbocharger © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 1.5 Layout and function of the turbocharger Fig. 2: Layout and function of the turbocharger 01 Air suction branch 08 Turbine 02 Compressor casing 09 Gas outlet flange 03 Diffuser 10 Nozzle ring 04 Bearing casing 11 Turbine casing 05 Axial thrust bearing 12 Turbine-end bearing flange 06 Radial plain bearing 13 Compressor-end bearing flange 07 Gas outlet casing 14 Compressor wheel Page 6 / 122 ...

1 Introduction / 1.5 Layout and function of the turbocharger © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 Mode of operation The turbocharger is a turbomachine and consists of the following main components: ¡ Turbine ¡ Compressor. The exhaust gases of the internal combustion engine flow through the turbine casing (11) and the nozzle ring (10) onto the turbine (08). The turbine (08) uses the energy contained in the exhaust gas to drive the rotor and thus the compressor wheel (14). The exhaust gases then reach the atmosphere through the exhaust gas pipe connected to the gas outlet ca ...

1 Introduction / 1.6 Symbols, definitions © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 1.6 Symbols, definitions Symbols The following symbols are used in this document: u 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 des ...

1 Introduction / 1.6 Symbols, definitions © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 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 Tighten with specified torque Tighten over specified tightening angle Hand-tight, tighten without tools Oil Apply screw locking paste (e.g. Loctite) Apply high-temperature grease Apply other paste in accordance with specifications Oil free, grease free and dry Affix Measure Note Visually inspect Please note t ...

1 Introduction / 1.7 Storage of new turbochargers and spare parts © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 1.7 Storage of new turbochargers and spare parts Storage of new turbochargers and spare parts 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. Only dry rooms in which the relative humidity is between 40…70 % and no condensation can form are suitable for storage. Storage of new turbochargers and spare parts for more than 6 months As the contents of the packag ...

1 Introduction / 1.7 Storage of new turbochargers and spare parts © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 Long-term storage of turbochargers The turbochargers will be prepared for long-term storage if requested in the purchase order. The package is equipped with a hygrometer (see illustration). Fig. 5: Package with hygrometer Every 6 months, the following measures are required: u Check the hygrometer (02) in the sight-glass. There is an opening (01) in the wooden crate which allows this check to be carried out. When the display field has changed colour at the 70% level, the maxi ...

2 Safety / 2.1 Introduction © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 2 Safety 2.1 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. ¡ ...

2 Safety / 2.3 Definition of mandatory signs © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 2.3 Definition of mandatory signs To be worn at all times Protective clothing Safety footwear to protect against mechanical hazard and risk of falling Table 2: Personal protective equipment to be worn at all times To be worn specific to the respective task Safety glasses Safety goggles Safety gloves to protect against - Mechanical hazard - Chemical hazard - Thermal hazard - Electrical hazard Respiratory mask to protect against - Dusts - Gases Safety helmet Ear protection Table 3: Personal protecti ...

2 Safety / 2.5 Intended use © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 2.5 Intended use Use on internal combustion engines in general ABB turbochargers are intended for charging 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 im ...

2 Safety / 2.6 Deflagration on gas engines © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 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. 2.6 Deflagration on gas engines ABB turbochargers can tolerate a deflagration with a transient pressure increase of 12 bar. After a deflagration event ABB recommends verifying the following points on the turbochar- ger: ¡ Posit ...

2 Safety / 2.8 Warning plates on the turbocharger © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 2.8 Warning plates on the turbocharger Warning plates are affixed at the following locations: Fig. 6: Warning plate locations If warning plates are not present in the designated locations or not readable, proceed as fol- lows: u Order new warning plates from ABB Turbocharging Service Stations. u Remove any warning plates that have become unreadable. u Clean and degrease the areas designated for the warning plates. u Fit new warning plates and remove protective sheets. Turbochargers supplied to ...

2 Safety / 2.9 Turbocharger rating plate © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 2.9 Turbocharger rating plate Fig. 7: 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 p ...

2 Safety / 2.9 Turbocharger rating plate © Copyright 2021 ABB. All rights reserved. HZTL4030_EN Rev.G July 2021 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 cases, we recommend contacting the nearest ABB Turbochar- ging Service Station. nMmax, tMmax normally apply only when running at overload (110 %) during trials on th ...