The provided document is an Operation Manual for the ABB Turbocharger A100-L series, specifically referencing the A165-L34 model with serial number XAC24182. The manual details the turbocharger's function, technical specifications, usage, and maintenance procedures.
Function Description
The turbocharger is a turbomachine designed for charging internal combustion engines, specifically 2-stroke engines that can operate with liquid and gaseous fuels. Its primary function is to supply the engine with the necessary air volume and associated charging pressure for operation. The turbocharger consists of a turbine and a compressor, both installed on a common shaft, forming the rotor.
Exhaust gases from the internal combustion engine flow through the gas inlet casing and the nozzle ring onto the turbine wheel. The turbine wheel harnesses the energy from the exhaust gas to drive the rotor and, consequently, the compressor wheel. The exhaust gases then exit to the atmosphere via the exhaust gas pipe connected to the gas outlet casing.
The compressor wheel draws in fresh air, which passes through a filter silencer, and then compresses it before it exits the turbocharger through the compressor casing. An optional air outlet silencer can be installed to reduce noise generated at the compressor outlet.
The rotor operates on two radial plain bearings located in the bearing casing between the compressor and turbine. An axial thrust bearing is situated at the compressor end. These plain bearings are connected to a central lubricating oil duct, typically supplied by the engine's lubricating oil circuit. The bearing casing integrates an oil tank that provides oil to the rotor bearings until standstill in case of an emergency engine shutdown due to a lubrication oil system malfunction. The turbocharger is intended to be operated with a clockwise direction of rotation when viewed from the turbine end.
Important Technical Specifications
General Specifications (A165-L34 / XAC24182):
- Document Number: HZTL4034
- Revision: T
- Language: English (Original Operation Manual)
- Serial Number: XAC24182
- Customer Part Number: AV65MK00252
- Delivery Date: 2021-05-07
- Weight: 2300 kg
Operating Limits (according to rating plate):
- Speed limit in test rig operation only (nMmax): 382 1/s
- Speed limit during operation (nBmax): 361 1/s
- Gas inlet temperature limit in test rig operation only (tMmax): 550 °C
- Gas inlet temperature limit during operation (tBmax): 520 °C
Lubricating Oil Pressure (before turbocharger):
- Admissible for normal operation (30-65°C inlet temp): 0.8 – 2.5 bar
- Admissible for normal operation (65-80°C inlet temp): 1.0 – 2.0 bar
- Admissible during engine warm-up (30-65°C inlet temp): 0.8 – 4.0 bar
- Admissible during engine warm-up (65-80°C inlet temp): 1.0 – 4.0 bar
- Temporarily admissible (< 1h) (30-65°C inlet temp): 0.6 – 0.8 bar (alarm)
- Temporarily admissible (< 1h) (65-85°C inlet temp): 0.8 – 1.0 bar (alarm)
- Not admissible (30-65°C inlet temp): < 0.6 bar (emergency stop)
- Not admissible (65-85°C inlet temp): < 0.8 bar (emergency stop)
- Admissible during pre-lubrication and post-lubrication (engine stopped): 0.2 – 0.6 bar
Lubricating Oil Temperature (at the inlet):
- Admissible: 30 – 80 °C
- Temporarily admissible (< 1h): > 80 °C (alarm)
- Not admissible: > 85 °C (stop engine)
Lubricating Oil Temperature (at the outlet):
- Admissible (45°C inlet temp): ≤ 110 °C
- Admissible (80°C inlet temp): ≤ 125 °C
- Temporarily admissible (45°C inlet temp): > 110 °C (alarm)
- Temporarily admissible (80°C inlet temp): > 125 °C (alarm)
- Not admissible (45°C inlet temp): > 120 °C (stop engine)
- Not admissible (80°C inlet temp): > 135 °C (stop engine)
Admissible Air Inlet Temperature: -40°C to +45°C.
Axial Clearance A (prior to disassembly):
Weights of Assemblies (A165-L):
- Filter silencer: 240 kg
- Wall insert: 240 kg
- Diffuser: 40 kg
- Compressor casing: 320 kg
- Cover ring: 30 kg
- Nozzle ring: 10 kg
- Gas inlet casing: 180 kg
- Total wall insert (wall insert + diffuser): 280 kg
Tightening Torques (A165-L):
- Foot screws (M22): 440 Nm (torque-controlled) or 120 Nm (pre-tightening) + 30° (tightening angle) + 3.7°/10mm (additional angle)
- Speed sensor (86505, M18x1.5): 150 Nm
- Filter plug (81125, G1/2"): 45 Nm
- Nozzle ring (56014, M10): 35 Nm
- Gas inlet casing (51087, M16): 30 Nm (pre-tightening) / 140 Nm
- Diffuser (77015, M5): 6 Nm
- Wall insert (72011, M18): 370 Nm
- Filter silencer (72004, M14): 130 Nm
- Cover ring (57005, M12): 50 Nm
- Insulation (M8): 28 Nm
Amount of Granulate for Dry Cleaning (A165-L): 1.0 dm³
Usage Features
- CE Conformity: ABB turbochargers comply with the Machinery Directive 2006/42/EC and are partly completed machinery.
- Intended Use: Designed for 2-stroke internal combustion engines, operating with liquid and gaseous fuels. Operation must be within specified limits and in an engine room classified as "not at risk of explosion."
- Speed Monitoring: The turbocharger speed must be continuously monitored. Differences in speed between multiple turbochargers on an engine should not exceed 3% relative to nBmax.
- Pre- and Post-Lubrication: Pre-lubrication is required for at least 5 minutes before starting the engine to prevent damage. Post-lubrication for at least 10 minutes is needed after stopping, unless the engine has run for 5-10 minutes in idle mode.
- Flexible Turbocharger Cut-out: For engines with multiple turbochargers, one can be switched off at low loads. During cut-out, the air outlet flap and gas inlet flap must be completely closed. Manual switching of flaps requires careful adherence to procedures to avoid high turbocharger speeds. Automatic switching should only occur below charging pressures of 0.3 bar, with the compressor outlet flap closing just before the gas inlet flap.
- Contamination with Closed Flaps: To minimize deposits, flaps should be opened at least every 500 hours of operation.
- Emergency Operation: In case of turbocharger damage, the unit must be taken out of operation. Procedures are provided for engines with one or multiple turbochargers, including locking the rotor and blanking off inlets/outlets.
Maintenance Features
- Periodic Maintenance: Includes regular visual controls and cleaning to ensure trouble-free operation. Key areas for maintenance are the filter silencer, compressor, turbine, and nozzle ring.
- Service Intervals:
- Every 25-50 hours: Visual check for leaks (air, exhaust gas, water, oil), record operating data.
- 100 hours after commissioning: Clean or replace the oil filter in the supply pipe.
- Every 18,000 hours: Recommended service work by an ABB Turbocharging Service Station, including cleaning and checking the filter silencer, wall insert, axial clearance A, compressor wheel, diffuser, compressor casing, nozzle ring, turbine diffuser, and turbine blades. Damaged/worn parts must be replaced with original ABB parts.
- Every 36,000 hours: Service work on the rotor and bearing parts by an ABB Turbocharging Service Station, including dismantling, inspection, and balancing of the rotor, and replacement of plain bearings.
- Every 5 years (after last service): Recommended inspection by an ABB Turbocharging Service Station to prevent machine damage from aging.
- Compressor Cleaning (Wet Cleaning): Performed during operation with pure water at an engine load of 25-85%. Water is injected upstream of the compressor wheel to remove deposits. Cleaning interval is typically every 50 hours. Not recommended for air inlet temperatures below 0°C due to ice formation risk.
- Turbine Cleaning (Dry Cleaning): Performed during operation using granulate at an engine load of 5-85%. Granulate removes dirt coating by mechanical action. Cleaning interval is typically every 50 hours (for HFO applications) or up to 150 hours (for mixed gas/HFO under specific conditions).
- Draining Gas Outlet Casing: Procedures for draining the gas outlet casing if water ingress occurs, including using a drain cock and air from the compressor casing.
- Troubleshooting: The manual provides detailed tables for identifying and remedying malfunctions related to delayed start-up, vibrations, rubbing of rotating parts, low lubricating oil pressure, drop in speed, high exhaust gas temperature, low charge air pressure, high charge air pressure, surging, runout noises, shortened runout time, and speed measurement system malfunctions.
- Mothballing: Instructions for taking the engine out of operation for up to 12 months or more than 12 months, including oil condition checks, use of preservative oil, dismantling, cleaning, and coating parts with anticorrosive oil. Storage in dry rooms with controlled humidity is specified.
- Spare Parts: Detailed lists of spare parts with part numbers and designations are provided, categorized by assembly (bearing casing, oil tank, cartridge, compressor casing, filter silencer, gas inlet casing, rotor and bearing parts, sealing air supply, speed measurement, U-tube manometer, turbine dry cleaning).
- Tools: A list of required customer tool sets with designations and quantities is provided.
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