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ABB A130-H Series - User Manual

ABB A130-H Series
124 pages
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Turbocharging
Operation Manual / A140-H56
HT606870
Document identification
Document number HZTL4030
Revision G
Language English
Original Operation Manual
Product identification
Serial number HT606870
Customer part number 12284756
Delivery date (yyyy-mm-dd) 2021-11-01
Weight 460 kg
Operating limits according to rating plate
Speed limit in test rig operation only
n
Mmax
693 1/s
Speed limit during operation
n
Bmax
652 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

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ABB A130-H Series Specifications

General IconGeneral
BrandABB
ModelA130-H Series
CategoryIndustrial Equipment
LanguageEnglish

Summary

1 Introduction

1.1 Purpose of the manual

Explains the manual's scope, target audience, and availability requirements.

1.2 Contact information

Provides contact details for ABB Turbocharging Service Stations.

1.3 Essential information

Discusses document validity for design variants and illustration accuracy.

1.4 Registered trademarks

Notes the use of third-party trademarks within the document.

1.5 Layout and function of the turbocharger

Details the turbocharger's main components and operational principles.

1.6 Symbols, definitions

Explains document symbols, notes, cautions, and warning definitions.

1.7 Storage of new turbochargers and spare parts

Provides guidelines for storing new turbochargers and spare parts.

2 Safety

2.1 Introduction

Introduces safety aspects and potential residual risks during operation.

2.3 Definition of mandatory signs

Explains mandatory signs for personal protective equipment.

2.4 Definition of safety instructions

Defines WARNING and CAUTION instructions and their implications.

2.2 CE conformity

Confirms compliance with Machinery Directive 2006/42/EC.

2.5 Intended use

Specifies approved applications and non-intended uses of the turbocharger.

2.6 Deflagration on gas engines

Addresses deflagration tolerance and post-event inspection requirements.

2.7 Periodic check of the pressure vessels

Outlines requirements for periodic checks of pressure vessels.

2.8 Warning plates on the turbocharger

Details locations and procedures for managing warning plates.

2.9 Turbocharger rating plate

Explains the information presented on the turbocharger's rating plate.

2.10 Lifting of loads

Provides safety guidelines for lifting turbocharger components.

2.11 Prerequisites for operation and maintenance

Lists requirements for personnel and modifications.

2.12 Hazards during operation and maintenance

Covers noise hazards and risks from hot surfaces.

2.13 Safe operation

Details safe practices during commissioning and operation.

2.14 Safe maintenance

Outlines occupational safety rules for maintenance activities.

3 Removing and Installing

3.1 Weight and transportation of the turbocharger

Specifies turbocharger weights and lifting gear requirements.

3.2 Removing the turbocharger

Provides step-by-step instructions for removing the turbocharger.

3.3 Installing the turbocharger

Details procedures for installing the turbocharger onto the engine.

4 Commissioning

4.1 Oil supply

Covers oil supply, filtering, and pressure requirements for operation.

4.2 Inspection procedures

Outlines essential checks before and after commissioning.

4.3 Commissioning after taking out of operation

Describes steps to recommission after periods of inactivity.

5 Monitoring operation

5.1 Oil pressure, oil temperature

Specifies admissible oil pressure and temperature values for operation.

5.2 Exhaust gas temperature before turbine

Discusses factors influencing component replacement intervals.

5.3 Turbocharger speed

Explains speed monitoring and potential malfunctions.

6 Operation and service

6.1 Noise emission

Addresses noise hazards and required insulation measures.

6.2 Service work

Details general service procedures and interval recommendations.

6.3 Expected replacement intervals

Provides guidelines for component replacement based on operating hours.

6.4 Stopping the engine

Outlines procedures for safely stopping the engine.

7 Periodic maintenance work

7.1 Foreword to maintenance

Introduces routine visual controls and cleaning operations.

7.2 Cleaning components mechanically

Guides on cleaning various turbocharger parts and filter silencer.

8 Eliminating malfunctions

8.1 Malfunctions when starting

Lists causes and remedies for turbocharger starting issues.

8.2 Malfunctions during operation

Covers issues like low oil pressure, speed reduction, and temperature.

8.3 Turbocharger is surging

Explains turbocharger surging causes and recommended remedies.

8.4 Malfunctions when stopping

Addresses runout noises and short runout times during shutdown.

8.5 Speed measurement system

Troubleshoots issues with the speed sensor signal.

9 Dismantling and fitting

9.1 Introduction

General safety and preparation for dismantling and fitting procedures.

9.2 Weights of individual parts

Lists the weights of various turbocharger assemblies.

9.3 Removing the air inlets

Step-by-step instructions for removing the air inlets.

9.4 Removing the gas outlet casing

Instructions for safely removing the gas outlet casing.

9.5 Removing the gas outlet flange

Details the procedure for removing the gas outlet flange.

9.6 Removing the compressor casing

Guide to removing the compressor casing.

9.7 Pressing off the casing

Method for pressing off casings using specialized tools.

9.8 Removing the cartridge group

Procedure for removing the cartridge group.

9.9 Removing the nozzle ring

Steps required to remove the nozzle ring.

9.10 Installing the cartridge group on the service support

Instructions for fitting the cartridge group to the service support.

9.11 Measuring clearance A and B

How to measure critical internal clearances.

9.12 Nozzle ring compression PD

Explains measuring nozzle ring compression (PD).

9.13 Installing the nozzle ring

Guide to installing the nozzle ring correctly.

9.14 Installing the cartridge group

Procedure for installing the cartridge group.

9.15 Installing the compressor casing

Steps for installing the compressor casing.

9.16 Measuring radial clearances N and R

How to measure radial clearances (N and R).

9.17 Installing the air inlets

Guide to installing the air inlets.

9.18 Installing the gas outlet flange

Instructions for installing the gas outlet flange.

9.19 Installing the gas outlet casing

Steps for installing the gas outlet casing.

9.20 Table of tightening torques

Compiles screw fitting tightening torques for various components.

10 Taking out of operation at short notice

10.1 Possible emergency repairs

Outlines emergency repair options for quick engine restart.

10.2 Installing the replacement turbocharger

Steps to install a replacement turbocharger after damage.

10.3 Installing the replacement cartridge group

Guide for installing a replacement cartridge group.

11 Mothballing the turbocharger

11.1 Taking the engine out of operation for up to 12 months

Procedures for short-term engine shutdown and turbocharger protection.

11.2 Taking the engine out of operation for more than 12 months

Procedures for long-term engine shutdown and turbocharger storage.

12 Material and Disposal

12.1 REACH and RoHS Compliance Declaration For Products

Declares product compliance with chemical and hazardous substance regulations.

12.2 Disposing of turbocharger components

Guidelines for environmentally sound disposal of turbocharger parts.

13 Spare parts

13.1 Ordering spare parts

Information and data required for ordering spare parts.

13.2 Required customer spare part set (97070)

Lists essential spare parts included in customer set 97070.

13.3 Spare part - Illustrations

Visual guide identifying various spare parts with part numbers.

14 Tools

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