ABB A140-M Series - User Manual

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Overview

Function Description
Important Technical Specifications
Usage Features
Maintenance Features

This document is an operation manual for the ABB A140-M55 turbocharger, with serial number HT608519. It provides comprehensive information on the turbocharger's function, technical specifications, usage, and maintenance.

Function Description

The turbocharger is a turbomachine designed for charging internal combustion engines. It consists of a turbine and a compressor, both installed on a common shaft, forming the rotor.

Turbine: Exhaust gases from the engine flow through the turbine casing and nozzle ring onto the turbine, driving the rotor. The exhaust gases then exit to the atmosphere via the gas outlet flange.
Compressor: The compressor wheel draws fresh air through the air suction branch or filter silencer. This air is compressed in the compressor wheel, further compressed by flowing through the diffuser and compressor casing, and then directed to the engine cylinders.
Bearings: The rotor operates on two radial plain bearings located in the bearing casing between the compressor and turbine. An axial thrust bearing is situated between the two radial plain bearings. These plain bearings are connected to a central lubricating oil duct, typically supplied by the engine's lubricating oil circuit. The oil outlet is at the deepest point of the bearing casing.
Compressor Wheel Cooling (optional): For some applications (indicated by turbocharger type M6.. on the rating plate), the turbocharger is equipped with compressor wheel cooling. Cooled compressor air, after passing through the charge air cooler, is supplied to the turbocharger via a lateral connection in the bearing casing (X) to cool the compressor wheel. This cooling is mandatory for reliability and to ensure specified replacement intervals under relevant operating conditions.

Important Technical Specifications

The rating plate provides specific operating limits and recommended inspection/replacement intervals.

Model: A140-M55
Serial Number: HT608519
Weight: 500 kg
Speed Limits:
- Speed limit in test rig operation only (n_Mmax): 725 1/s
- Speed limit during operation (n_Bmax): 706 1/s
Gas Inlet Temperature Limits:
- Gas inlet temperature limit in test rig operation only (t_Mmax): 630 °C
- Gas inlet temperature limit during operation (t_Bmax): 600 °C
Operating Limits Explanation:
- n_Mmax and t_Mmax typically apply to overload operation (110%) during engine test bed trials, or for special applications. Operation above these values is not permitted.
- Operation above n_Bmax and t_Bmax can significantly shorten recommended replacement intervals.
Recommended Inspection and Replacement Intervals (in 1000 h):
- Plain bearings: 03
- Compressor: 04
- Turbine: 05
Threaded Rods for Installation:
- A140: Diameter Ø 24 / M24, Material 10.9 / 12.9, Thread length L1 ≥ 70 mm, Oil-cooled L2 350-360 mm, Water-cooled L2 410-420 mm.
Tightening Torques for Standard Nuts (A140): M24, 960 Nm.
Tightening Torques for Clamping Nuts (A140): M12 fixing screw, 75 Nm.
Permissible Clearances (A140-M):
- Clearance A: 0.12 ... 0.21 mm
- Clearance B: 0.70 ... 1.37 mm
Nozzle Ring Compression PD (A140-M): -0.16 ... 0.16 mm
Radial Clearances N and R (A140-M):
- N: 0.45 ... 0.90 mm
- R: 0.64 ... 1.00 mm

Usage Features

Intended Use: ABB turbochargers are designed for charging internal combustion engines. For gas engines, they must be operated in an engine room classified as "not at risk of explosion." Appropriate safety measures (e.g., flame barriers) must be implemented by the engine builder for pre-mix gas engines to prevent transient pressure increases exceeding 12 bar before the turbocharger.
Direction of Rotation: The turbocharger is designed for clockwise rotation as viewed from the turbine end.
Operating Limits: Operation must always be within the limits specified on the rating plate.
Safety: The turbocharger must be in technically flawless condition and operated according to its intended use. Modifications require ABB approval. Burst protection and insulation must always be fitted.
Commissioning: Includes visual checks, monitoring, and measuring work. Pre-lubrication of the lubricating system with warm oil is crucial. Special running-in filters should be used. Oil pressure and temperature at the inlet must be within admissible values.
Monitoring Operation: Constant monitoring of lubricating oil pressure, oil temperature, exhaust gas temperature before the turbine, and turbocharger speed is essential. Deviations from normal values indicate potential malfunctions.
Speed Measurement System: Enables constant monitoring of turbocharger speed. Cables should not be strained. Speed differences between multiple turbochargers on an engine should not exceed 3% of n_Bmax.

Maintenance Features

Service Work: Includes regular visual controls, monitoring, measuring, and functional checks to ensure operability and detect changes.
Service Intervals:
- Every 25-50 hours (Engine load 50-85%): Cleaning the compressor during operation.
- Every 50-200 hours (Engine load 20-40%): Cleaning the turbine during operation.
- According to rating plate (usually 8000-16000 operating hours): Mechanical cleaning of components, rotor and bearing parts inspection by an ABB Turbocharging Service Station.
- Every 100 hours after commissioning: Clean or replace the oil filter in the supply pipe.
- Every 50000 hours: Replace the protective grid in the gas outlet casing (if installed by ABB).
- Every 5 years after last service: Recommended inspection by an ABB Turbocharging Service Station to prevent machine damage from aging and downtime.
Cleaning Procedures:
- Wet Cleaning (Compressor/Turbine): Uses pure water, not salt water or cooling water treatment substances. Water volume, temperature, and injection period parameters must be strictly observed to prevent damage.
- Mechanical Cleaning: Use only soft tools (rags, brushes, wire brushes). Avoid needle descalers or other striking tools. Heavily contaminated parts may require soaking in diesel oil or water with household cleaning agent. Components must be dried completely and sprayed with penetrating oil (except outer surfaces of turbocharger).
- Filter Silencer Cleaning: Remove and clean the filter ring every 500 hours or as required. Absorption segments should be cleaned lightly with compressed air, a soft brush, or a moist cloth.
Mothballing: For storage up to 6 months, new turbochargers can remain in closed packages in dry rooms (40-70% humidity). For longer storage, VCI corrosion protection emitters need replacement every 6 months. Turbochargers prepared for long-term storage include a hygrometer to monitor humidity.
Troubleshooting: The manual provides tables for identifying possible causes and remedies for malfunctions such as delayed start-up, vibrations, rubbing of rotating parts, low/high lubricating oil pressure, reduced/increased speed, high exhaust gas temperature, low/high charge air pressure, and surging.
Spare Parts: A customer spare part set (97070) is required for maintenance. All spare parts must be kept intact and ready for use. Ordering requires turbocharger type, serial number, designation, and part number.
Tools: A customer tool set (90000) is required for maintenance. Tools must be inspected for damage before and after use.
Disposal: Turbocharger components must be disposed of in an environmentally compatible and professional manner, adhering to local regulations. Metals for recycling, non-metallic materials as waste, lubricants as waste oil, electronic components as electronic waste, and thermal insulation as hazardous waste.