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ABB A145-M56 Battery Charger Manuals
Manuals and User Guides for ABB A145-M56 Battery Charger. We have
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ABB A145-M56 Battery Charger manuals available for free PDF download: Operation Manual
ABB A145-M56 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.1 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Operation Manual / A130-M
6
Introduction
6
Purpose of the Manual
6
Fig. 1: Serial Number (01) on the Rating Plate
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
Safety
15
Introduction
15
CE Conformity
15
Definition of Mandatory Signs
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Intended Use
17
Deflagration on Gas Engines
18
Warning Plates on the Turbocharger
19
Fig. 6: Warning Plate Locations
19
Turbocharger Rating Plate
20
Fig. 7: Rating Plate
20
Fig. 8: Locations of the Rating Plates
21
Periodic Check of the Pressure Vessels
22
Lifting of Loads
23
Fig. 9: Attachment of Loads on the Crane Hook
23
Fig. 10: Attachment Angle
23
Prerequisites for Operation and Maintenance
24
Hazards During Operation and Maintenance
25
Safe Operation
27
Fig. 11
27
Safe Maintenance
28
Removing and Installing
32
Turbocharger Weight and Transportation
32
Fig. 12: Suspension of Complete Turbocharger Unit
32
Table 4: Weight of Complete Turbocharger Unit
32
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
33
Fig. 14: Removing the Turbocharger
34
Fig. 15: Loosening the Clamping Nut
36
Fig. 16: Turbocharger Centre of Gravity
37
Installing the Turbocharger
38
Fig. 17: Inserting Gaskets into the Bracket
38
Fig. 18: Fitting Threaded Rods Onto the Bracket
39
Fig. 19: Requirements for Threaded Rods
39
Table 5: Requirements for Threaded Rods
39
Fig. 20: Placing the Turbocharger on the Bracket
40
Table 6: Tightening Torque for Standard Nuts
41
Fig. 21: Preparing the Clamping Nut for the Tightening Procedure
42
Fig. 22: Tightening Pressure Screws
43
Table 7: Torque-Controlled Tightening of the Pressure Screws
43
Fig. 23: Connecting the Speed Sensor
44
Fig. 24: Connecting the Compressor Cooling Air Intake
44
Fig. 25: Attaching the Support
45
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
46
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Fig. 27: Layout and Overview of Speed Measurement System
54
Turbocharger Speed
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
66
Table 13: Maintenance Table
66
Cleaning the Compressor During Operation
67
Fig. 31: Carrying out Wet Cleaning of Compressor
69
Table 14: Parameters for Wet Cleaning of Compressor
69
Cleaning the Turbine During Operation
70
Table 15: Turbine Wet Cleaning, Recommended Operating State
72
Fig. 32: Carrying out Wet Cleaning of Turbine
73
Table 16: Wet Cleaning of Turbine, Parameters
73
Cleaning Components Mechanically
74
Fig. 33: Cleaning the Filter Silencer
75
Fig. 34: Compressor-End, Non-Rotating Parts
77
Fig. 35: Turbine End, Non-Rotating Parts
78
Fig. 36: Soaking the Turbine End
81
Table 17: Value Table for Soaking
81
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
84
Malfunctions During Operation
85
Table 21: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 22: Malfunctions During Operation - Speed Reduces
85
Table 23: Malfunctions During Operation - Speed Increases
85
Table 24: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 25: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 26: Malfunctions During Operation - Charge Air Pressure too High
87
Table 27: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Surging
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Malfunctions When Stopping
89
Speed Measurement System
90
Table 32: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 33: Malfunction of the Speed Measurement System - Measured Speed too High
90
Table 34: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eye (Example)
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
Advertisement
ABB A145-M56 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.1 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Operation Manual / A130-M
6
Introduction
6
Purpose of the Manual
6
Fig. 1: Serial Number (01) on the Rating Plate
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
Safety
15
Introduction
15
CE Conformity
15
Definition of Mandatory Signs
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Intended Use
17
Deflagration on Gas Engines
18
Warning Plates on the Turbocharger
19
Fig. 6: Warning Plate Locations
19
Turbocharger Rating Plate
20
Fig. 7: Rating Plate
20
Fig. 8: Locations of the Rating Plates
21
Periodic Check of the Pressure Vessels
22
Lifting of Loads
23
Fig. 9: Attachment of Loads on the Crane Hook
23
Fig. 10: Attachment Angle
23
Prerequisites for Operation and Maintenance
24
Hazards During Operation and Maintenance
25
Safe Operation
27
Fig. 11
27
Safe Maintenance
28
Removing and Installing
32
Turbocharger Weight and Transportation
32
Fig. 12: Suspension of Complete Turbocharger Unit
32
Table 4: Weight of Complete Turbocharger Unit
32
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
33
Fig. 14: Removing the Turbocharger
34
Fig. 15: Loosening the Clamping Nut
36
Fig. 16: Turbocharger Centre of Gravity
37
Installing the Turbocharger
38
Fig. 17: Inserting Gaskets into the Bracket
38
Fig. 18: Fitting Threaded Rods Onto the Bracket
39
Fig. 19: Requirements for Threaded Rods
39
Table 5: Requirements for Threaded Rods
39
Fig. 20: Placing the Turbocharger on the Bracket
40
Table 6: Tightening Torque for Standard Nuts
41
Fig. 21: Preparing the Clamping Nut for the Tightening Procedure
42
Fig. 22: Tightening Pressure Screws
43
Table 7: Torque-Controlled Tightening of the Pressure Screws
43
Fig. 23: Connecting the Speed Sensor
44
Fig. 24: Connecting the Compressor Cooling Air Intake
44
Fig. 25: Attaching the Support
45
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
46
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Fig. 27: Layout and Overview of Speed Measurement System
54
Turbocharger Speed
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
66
Table 13: Maintenance Table
66
Cleaning the Compressor During Operation
67
Fig. 31: Carrying out Wet Cleaning of Compressor
69
Table 14: Parameters for Wet Cleaning of Compressor
69
Cleaning the Turbine During Operation
70
Table 15: Turbine Wet Cleaning, Recommended Operating State
72
Fig. 32: Carrying out Wet Cleaning of Turbine
73
Table 16: Wet Cleaning of Turbine, Parameters
73
Cleaning Components Mechanically
74
Fig. 33: Cleaning the Filter Silencer
75
Fig. 34: Compressor-End, Non-Rotating Parts
77
Fig. 35: Turbine End, Non-Rotating Parts
78
Fig. 36: Soaking the Turbine End
81
Table 17: Value Table for Soaking
81
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
84
Malfunctions During Operation
85
Table 21: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 22: Malfunctions During Operation - Speed Reduces
85
Table 23: Malfunctions During Operation - Speed Increases
85
Table 24: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 25: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 26: Malfunctions During Operation - Charge Air Pressure too High
87
Table 27: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Surging
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Malfunctions When Stopping
89
Speed Measurement System
90
Table 32: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 33: Malfunction of the Speed Measurement System - Measured Speed too High
90
Table 34: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eye (Example)
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
ABB A145-M56 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.21 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Fig. 1: Serial Number (01) on the Rating Plate
6
Operation Manual / A130-M
6
Purpose of the Manual
6
Introduction
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
CE Conformity
15
Safety
15
Introduction
15
Definition of Mandatory Signs
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Intended Use
17
Deflagration on Gas Engines
18
Warning Plates on the Turbocharger
19
Fig. 6: Warning Plate Locations
19
Turbocharger Rating Plate
20
Fig. 7: Rating Plate
20
Fig. 8: Locations of the Rating Plates
21
Periodic Check of the Pressure Vessels
22
Lifting of Loads
23
Fig. 9: Attachment of Loads on the Crane Hook
23
Fig. 10: Attachment Angle
23
Prerequisites for Operation and Maintenance
24
Hazards During Operation and Maintenance
25
Safe Operation
27
Fig. 11
27
Safe Maintenance
28
Removing and Installing
32
Turbocharger Weight and Transportation
32
Fig. 12: Suspension of Complete Turbocharger Unit
32
Table 4: Weight of Complete Turbocharger Unit
32
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
33
Fig. 14: Removing the Turbocharger
34
Fig. 15: Loosening the Clamping Nut
36
Fig. 16: Turbocharger Centre of Gravity
37
Installing the Turbocharger
38
Fig. 17: Inserting Gaskets into the Bracket
38
Fig. 18: Inserting the Threaded Rods
39
Fig. 19: Requirements for Threaded Rods
39
Table 5: Requirements for Threaded Rods
39
Fig. 20: Placing the Turbocharger on the Bracket
40
Table 6: Tightening Torque for Standard Nuts
41
Fig. 21: Preparing the Clamping Nut for the Tightening Procedure
42
Fig. 22: Tightening Pressure Screws
43
Table 7: Torque-Controlled Tightening of the Pressure Screws
43
Fig. 23: Connecting the Speed Sensor
44
Fig. 24: Connecting the Compressor Cooling Air Intake
44
Fig. 25: Attaching the Support
45
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
47
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Turbocharger Speed
54
Fig. 27: Layout and Overview of Speed Measurement System
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
66
Table 13: Maintenance Table
66
Cleaning the Compressor During Operation
67
Table 14: Parameters for Wet Cleaning of Compressor
69
Fig. 31: Carrying out Wet Cleaning of Compressor
69
Cleaning the Turbine During Operation
70
Table 15: Turbine Wet Cleaning, Recommended Operating State
72
Fig. 32: Carrying out Wet Cleaning of Turbine
73
Table 16: Wet Cleaning of Turbine, Parameters
73
Cleaning Components Mechanically
74
Fig. 33: Cleaning the Filter Silencer
75
Fig. 34: Compressor-End, Non-Rotating Parts
77
Fig. 35: Turbine End, Non-Rotating Parts
78
Fig. 36: Soaking the Turbine End
81
Table 17: Value Table for Soaking
81
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
84
Malfunctions During Operation
85
Table 21: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 22: Malfunctions During Operation - Speed Reduces
85
Table 23: Malfunctions During Operation - Speed Increases
85
Table 24: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 25: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 26: Malfunctions During Operation - Charge Air Pressure too High
87
Table 27: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Pumping
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Malfunctions When Stopping
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Speed Measurement System
90
Table 32: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 33: Malfunction of the Speed Measurement System - Measured Speed too High
90
Table 34: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eyes
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
Advertisement
ABB A145-M56 Operation Manual (146 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 17.45 MB
Table of Contents
Introduction
3
Table of Contents
3
Introduction
4
Purpose of the Manual
4
Symbols, Definitions
5
Storage of New Turbochargers and Spare Parts
7
Contact Information
9
Safety
11
CE Conformity
12
Introduction
12
Safety
12
Definition of Mandatory Signs
13
Definition of Safety Instructions
13
Intended Use
14
Deflagration on Gas Engines
15
Warning Plates on the Turbocharger
16
Turbocharger Rating Plate
17
Periodic Check of the Pressure Vessels
18
Lifting of Loads
19
Prerequisites for Operation and Maintenance
20
Hazards During Operation and Maintenance
21
Safe Operation
23
Safe Maintenance
25
Product Description
31
1 Introduction
34
Essential Information
34
Registered Trademarks
34
Related Documents
34
Table 1: Related Documents
34
Layout and Function of the Turbocharger
35
Fig. 1: Layout and Function of the Turbocharger
35
Fig. 2: Compressor Wheel Cooling
36
Warning Plates on the Turbocharger
37
Fig. 3: Warning Plate Locations
37
Locations of the Rating Plates
38
Fig. 4: Locations of the Rating Plates
38
2 Removing and Installing
39
Turbocharger Weight and Transportation
39
Fig. 5: Suspension of Complete Turbocharger Unit
39
Table 2: Weight of Complete Turbocharger Unit
39
Removing the Turbocharger
40
Fig. 6: Turbine Cleaning Nozzle
40
Fig. 7: Removing the Turbocharger
41
Fig. 8: Loosening the Clamping Nut
43
Fig. 9: Turbocharger Centre of Gravity
44
Installing the Turbocharger
45
Fig. 10: Inserting Gaskets into the Bracket
45
Fig. 11: Inserting the Threaded Rods
46
Fig. 12: Requirements for Threaded Rods
46
Table 3: Requirements for Threaded Rods
46
Fig. 13: Placing the Turbocharger on the Bracket
47
Table 4: Tightening Torque for Standard Nuts
48
Fig. 14: Preparing the Clamping Nut for the Tightening Procedure
49
Fig. 15: Tightening Pressure Screws
50
Table 5: Torque-Controlled Tightening of the Pressure Screws
50
Fig. 16: Connecting the Speed Sensor
51
Fig. 17: Connecting the Compressor Cooling Air Intake
51
Fig. 18: Attaching the Support
52
3 Commissioning
53
Oil Supply
53
Fig. 19: Oil Orifice
54
Inspection Procedures
55
Commissioning after Taking out of Operation
57
4 Monitoring Operation
58
Oil Pressure, Oil Temperature
58
Table 6: Lubricating Oil Pressure at Oil Inlet before Turbocharger
58
Table 7: Lubricating Oil Temperature at the Inlet
59
Table 8: Lubricating Oil Temperature at the Outlet
59
Exhaust Gas Temperature before Turbine
60
Turbocharger Speed
61
Fig. 20: Layout and Overview of Speed Measurement System
61
Fig. 21: Replacing the Speed Sensor
63
Table 9: Tightening Torque (86505)
63
5 Operation and Service
64
Noise Emission
64
Fig. 22: Noise Insulation, Bellows
65
Service Work
66
Fig. 23: Replacing the Protective Grid
68
Expected Replacement Intervals
70
Table 10: Expected Replacement Intervals
70
Stopping the Engine
72
6 Periodic Maintenance Work
73
Foreword to Maintenance
73
Table 11: Maintenance Table
73
Cleaning the Compressor During Operation
74
Fig. 24: Carrying out Wet Cleaning of Compressor
76
Table 12: Parameters for Wet Cleaning of Compressor
76
Cleaning the Turbine During Operation
77
Table 13: Turbine Wet Cleaning, Recommended Operating State
79
Fig. 25: Carrying out Wet Cleaning of Turbine
80
Table 14: Wet Cleaning of Turbine, Parameters
80
Cleaning Components Mechanically
81
Fig. 26: Cleaning the Filter Silencer
82
Fig. 27: Compressor-End, Non-Rotating Parts
84
Fig. 28: Turbine End, Non-Rotating Parts
86
Fig. 29: Soaking the Turbine End
88
Table 15: Value Table for Soaking
88
7 Eliminating Malfunctions
91
Malfunctions When Starting
91
Table 16: Malfunctions When Starting - Delayed Start-Up
91
Table 17: Malfunctions When Starting - Vibrations
91
Table 18: Malfunctions When Starting - Rubbing of Rotating Parts
91
Malfunctions During Operation
92
Table 19: Malfunctions During Operation - Lubricating Oil Pressure too Low
92
Table 20: Malfunctions During Operation - Speed Reduces
92
Table 21: Malfunctions During Operation - Speed Increases
92
Table 22: Malfunctions During Operation - Exhaust Gas Temperature too High
93
Table 23: Malfunctions During Operation - Charge Air Pressure too Low
93
Table 24: Malfunctions During Operation - Charge Air Pressure too High
94
Table 25: Malfunctions During Operation - Engine Performance Losses
94
Turbocharger Is Surging
95
Table 26: Malfunction - Turbocharger Pumping
95
Table 27: Malfunction - Sporadic Surge Blows
95
Malfunctions When Stopping
96
Table 28: Malfunctions When Stopping - Runout Noises
96
Table 29: Malfunctions When Stopping - Runout Time too Short
96
Speed Measurement System
97
Table 30: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
97
Table 31: Malfunction of the Speed Measurement System - Measured Speed too High
97
Table 32: Malfunction of the Speed Measurement System - Measured Speed too Low
97
8 Dismantling and Fitting
98
Introduction
98
Material Required
99
Fig. 30: Swivel Lifting Eyes
99
Table 33: Swivel Lifting Eyes
99
Weights of Individual Parts
100
Fig. 31: Starpoint Ring Nut VRM
100
Fig. 32: Weights of Assemblies
101
Table 34: Weights of Assemblies
101
Removing the Air Inlets
102
Fig. 33: Removing the Air Inlets
102
Removing the Gas Outlet Casing
103
Fig. 34: Removing the Insulation
103
Removing the Gas Outlet Flange
104
Fig. 35: Removing the Gas Outlet Casing
104
Fig. 36: Dismantling the Gas Outlet Flange
105
Table 35: 3 Press-Off Screws
105
Fig. 37: Removing the Gas Outlet Flange
106
Table 36: 6 Press-Off Screws
106
Removing the Compressor Casing
107
Fig. 38: Removing the Compressor Casing
107
Fig. 39: Dismantling the Wall Insert
108
Pressing off the Casing
109
Fig. 40: Press off the Casing
109
Removing the Cartridge Group
110
Fig. 41: Removing Insulation Sheets
110
Fig. 42: Oil Orifice
110
Fig. 43: Removing Cartridge Group 1
111
Fig. 44: Removing Cartridge Group 2
111
Removing the Nozzle Ring
112
Fig. 45: Removing the Nozzle Ring
112
Installing the Cartridge Group on the Service Support
113
Fig. 46: Installing the Cartridge Group on the Service Support
113
Measuring Clearance a and B
114
Fig. 47: Measuring Clearance a and B
114
Table 37: Permissible Clearances a and B
114
Nozzle Ring Compression PD
115
Fig. 48: Nozzle Ring Compression PD
115
Table 38: Nozzle Ring Compression PD
115
Installing the Nozzle Ring
116
Fig. 49: Installing the Nozzle Ring
116
Installing the Cartridge Group
117
Fig. 50: Lifting the Cartridge Group and Rotating It
117
Fig. 51: Installing the Cartridge Group
117
Table 39: Tightening Torque (51007)
118
Fig. 52: Turbine Casing Insulation / Burst Protection
119
Installing the Compressor Casing
120
Table 40: Tightening Torque (79041)
120
Fig. 53: Installing the Compressor Casing
121
Table 41: Tightening Torque (72011)
121
Measuring Radial Clearances N and R
122
Fig. 54: Measuring Clearances N and R
122
Table 42: Permissible Clearances N and R
122
Installing the Air Inlets
123
Fig. 55: Installing the Air Inlets
123
Table 43: Tightening Torque (72020)
123
Installing the Gas Outlet Flange
124
Fig. 56: Installing the Gas Outlet Flange
124
Fitting the Insulation of the Turbine Casing
125
Fig. 57: Fitting the Insulation
125
Installing the Gas Outlet Casing
126
Fig. 58: Installing the Gas Outlet Casing
126
Table 44: Tightening Torque (51009)
126
Fig. 59: Fitting the Insulation
127
Table of Tightening Torques
128
Fig. 60: Tightening Torques
128
Table 45: Tightening Torques
128
Fig. 61: Tightening Torques for Insulation
129
Table 46: Tightening Torques for Insulation
129
9 Taking out of Operation at Short Notice
130
Possible Emergency Repairs
130
Installing the Replacement Turbocharger
131
Installing the Replacement Cartridge Group
131
Fitting the Cover Plate
132
Fig. 62: Fitting the Cover Plate
132
Cover Plate Drawing
133
Fig. 63: Cover Plate Drawing
133
Table 47: Cover Plate Dimensions [MM]
133
10 Mothballing the Turbocharger
134
Taking the Engine out of Operation for up to 12 Months
134
Taking the Engine out of Operation for more than 12 Months
135
11 Disposing of Turbocharger Components
136
12 Spare Parts
137
Ordering Spare Parts
137
Required Customer Spare Part Set (97070)
137
Table 48: Customer Spare Part Set 97070
137
View of Turbocharger with Part Numbers
139
Fig. 64: Overview of Part Numbers
139
Table 49: Spare Parts List
140
View of Turbine Cleaning Device
141
Table 50: Spare Parts List
141
13 Tools
142
Table 51: Customer Tool Set 90000
142
ABB A145-M56 Operation Manual (142 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 18.93 MB
Table of Contents
Introduction
3
Table of Contents
3
Introduction
4
Purpose of the Manual
4
Symbols, Definitions
5
Storage of New Turbochargers and Spare Parts
7
Contact Information
9
Safety
11
CE Conformity
12
Introduction
12
Safety
12
Definition of Mandatory Signs
13
Definition of Safety Instructions
13
Intended Use
14
Deflagration on Gas Engines
15
Warning Plates on the Turbocharger
16
Turbocharger Rating Plate
17
Periodic Check of the Pressure Vessels
18
Lifting of Loads
19
Prerequisites for Operation and Maintenance
20
Hazards During Operation and Maintenance
21
Safe Operation
23
Safe Maintenance
25
Product Description
31
Essential Information
33
Introduction
33
Registered Trademarks
33
Related Documents
33
Table 1: Related Documents
33
Fig. 1: Layout and Function of the Turbocharger
34
Layout and Function of the Turbocharger
34
Fig. 2: Compressor Wheel Cooling
35
Fig. 3: Warning Plate Locations
36
Warning Plates on the Turbocharger
36
Fig. 4: Locations of the Rating Plates
37
Locations of the Rating Plates
37
Fig. 5: Suspension of Complete Turbocharger Unit
38
Removing and Installing
38
Table 2: Weights of Turbochargers A130-M
38
Turbocharger Weight and Transportation
38
Fig. 6: Removing the Turbocharger
39
Removing the Turbocharger
39
Fig. 7: Loosening the Clamping Nut
41
Fig. 8: Turbocharger Centre of Gravity
42
Fig. 9: Inserting Gaskets into the Bracket
43
Installing the Turbocharger
43
Fig. 10: Inserting the Threaded Rods
44
Fig. 11: Requirements for Threaded Rods
44
Table 3: Requirements for Threaded Rods
44
Fig. 12: Placing the Turbocharger on the Bracket
45
Table 4: Tightening Torques for Standard Nuts
46
Fig. 13: Preparing the Clamping Nut for the Tightening Procedure
47
Fig. 14: Tightening Pressure Screws
48
Table 5: Pressure Screw Tightening Torques
48
Fig. 15: Connecting the Compressor Cooling Air Intake
49
Fig. 16: Attaching the Support
49
Commissioning
50
Oil Supply
50
Fig. 17: Oil Orifice
51
Inspection Procedures
52
Commissioning after Taking out of Operation
54
Monitoring Operation
55
Oil Pressure, Oil Temperature
55
Table 6: Lubricating Oil Pressure, Oil Inlet
55
Table 7: Lubricating Oil Temperature at the Inlet
56
Table 8: Lubricating Oil Temperature at the Outlet
56
Exhaust Gas Temperature before Turbine
57
Fig. 18: Layout and Overview of Speed Measurement System
58
Turbocharger Speed
58
Fig. 19: Replacing the Speed Sensor
60
Table 9: Tightening Torque (86505)
60
Fig. 20: Noise Insulation, Bellows
61
Noise Emission
61
Operation and Service
61
Service Work
63
Fig. 21: Replacing the Protective Grid
65
Expected Replacement Intervals
67
Table 10: Expected Replacement Intervals
67
Stopping the Engine
69
Foreword to Maintenance
70
Periodic Maintenance Work
70
Table 11: Maintenance Table
70
Cleaning the Compressor During Operation
71
Fig. 22: Carrying out Wet Cleaning of Compressor
74
Table 12: Parameters for Wet Cleaning of Compressor
74
Cleaning the Turbine During Operation
75
Table 13: Turbine Wet Cleaning, Recommended Operating State
77
Fig. 23: Carrying out Wet Cleaning of Turbines
78
Table 14: Wet Cleaning of Turbines, Parameters
78
Cleaning Components Mechanically
79
Fig. 24: Cleaning the Filter Silencer
80
Fig. 25: Compressor-End, Non-Rotating Parts
82
Fig. 26: Turbine End, Non-Rotating Parts
83
Fig. 27: Soaking the Turbine End
86
Table 15: Value Table for Soaking
86
Eliminating Malfunctions
89
Malfunctions When Starting
89
Table 16: Malfunctions When Starting - Delayed Start-Up
89
Table 17: Malfunctions When Starting - Vibrations
89
Table 18: Malfunctions When Starting - Rubbing of Rotating Parts
89
Malfunctions During Operation
90
Table 19: Malfunctions During Operation - Lubricating Oil Pressure too Low
90
Table 20: Malfunctions During Operation - Speed Reduces
90
Table 21: Malfunctions During Operation - Speed Increases
90
Table 22: Malfunctions During Operation - Exhaust Gas Temperature too High
91
Table 23: Malfunctions During Operation - Charge Air Pressure too Low
91
Table 24: Malfunctions During Operation - Charge Air Pressure too High
92
Table 25: Malfunctions During Operation - Engine Performance Losses
92
Table 26: Malfunction - Turbocharger Pumping
93
Table 27: Malfunction - Sporadic Surge Blows
93
Turbocharger Is Surging
93
Malfunctions When Stopping
94
Table 28: Malfunctions When Stopping - Runout Noises
94
Table 29: Malfunctions When Stopping - Runout Time too Short
94
Speed Measurement System
95
Table 30: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
95
Table 31: Malfunction of the Speed Measurement System - Measured Speed too High
95
Table 32: Malfunction of the Speed Measurement System - Measured Speed too Low
95
Dismantling and Fitting
96
Introduction
96
Table 33: Swivel Lifting Eyes
98
Table 34: Ring Nuts to be Used
99
Fig. 28: Weights of Assemblies
100
Table 35: Weights of Assemblies
100
Weights of Individual Parts
100
Fig. 29: Removing Air Inlets
101
Removing Air Inlets
101
Fig. 30: Removing the Insulation
102
Removing the Gas Outlet Casing
102
Fig. 31: Removing the Gas Outlet Casing
103
Removing the Gas Outlet Flange
104
Fig. 32: Dismantling the Gas Outlet Flange
105
Table 36: 3 Press-Off Screws
105
Fig. 33: Removing the Gas Outlet Flange
106
Table 37: 6 Press-Off Screws
106
Fig. 34: Removing the Compressor Casing
107
Removing the Compressor Casing
107
Fig. 35: Dismantling the Wall Insert
108
Fig. 36: Press off the Casing
109
Pressing off the Casing
109
Fig. 37: Removing Insulation Sheets
110
Fig. 38: Oil Orifice
110
Removing the Cartridge Group
110
Fig. 39: Removing Cartridge Group 1
111
Fig. 40: Removing Cartridge Group 2
111
Fig. 41: Removing the Nozzle Ring
112
Removing the Nozzle Ring
112
Fig. 42: Installing the Cartridge Group on the Service Support
113
Installing the Cartridge Group on the Service Support
113
Axial Clearance a and Radial Clearance B
114
Fig. 43: Measuring Clearance a and B
114
Table 38: Permissible Clearances a and B
114
Fig. 44: Nozzle Ring Compression PD
115
Nozzle Ring Compression PD
115
Table 39: Permitted Nozzle Ring Compression PD
115
Fig. 45: Installing the Nozzle Ring
116
Installing Nozzle Ring
116
Fig. 46: Lifting the Cartridge Group and Rotating It
117
Installing the Cartridge Group
117
Fig. 47: Installing the Cartridge Group
118
Table 40: Tightening Torque (51007)
118
Fig. 48: Turbine Casing Insulation / Burst Protection
119
Installing the Compressor Casing
120
Table 41: Tightening Torque (79041)
120
Fig. 49: Installing the Compressor Casing
121
Table 42: Tightening Torque (72011)
121
Fig. 50: Measuring Clearances N and R
122
Radial Clearances N and R
122
Table 43: Permissible Clearances N and R
122
Fig. 51: Installing the Air Inlets
123
Installing Air Inlets
123
Table 44: Tightening Torque (72020)
123
Fig. 52: Installing the Gas Outlet Flange
124
Installing the Gas Outlet Flange
124
Fig. 53: Fitting the Insulation
125
Fig. 54: Installing the Gas Outlet Casing
126
Installing the Gas Outlet Casing
126
Table 45: Tightening Torque (51009)
126
Fig. 55: Fitting the Insulation
127
Fig. 56: Tightening Torques
128
Table 46: Tightening Torques
128
Table of Tightening Torques
128
Fig. 57: Tightening Torques for Insulation
129
Table 47: Tightening Torques for Insulation
129
Possible Emergency Repairs
130
Taking out of Operation at Short Notice
130
Installing a Replacement Cartridge Group
131
Installing a Replacement Turbocharger
131
Fig. 58: Fitting the Cover Plate
132
Fitting the Cover Plate
132
Cover Plate Drawing
133
Fig. 59: Cover Plate Drawing
133
Table 48: Cover Plate Dimensions [MM]
133
Mothballing the Turbocharger
134
Taking the Engine out of Operation for up to 12 Months
134
Taking the Engine out of Operation for more than 12 Months
135
Disposing of Turbocharger Components
136
Ordering Spare Parts
137
Required Customer Spare Part Set (97070)
137
Spare Parts
137
Table 49: Customer Spare Part Set 97070
137
Fig. 60: Overview of Part Numbers
138
View of Turbocharger with Part Numbers
138
Table 50: Spare Parts List
139
ABB A145-M56 Operation Manual (154 pages)
Brand:
ABB
| Category:
charger
| Size: 14.09 MB
Table of Contents
Introduction
3
Table of Contents
3
Introduction
5
Purpose of the Manual
5
Symbols, Definitions
6
Storage of New Turbochargers and Spare Parts
8
Contact Information
10
Safety
11
CE Conformity
13
Introduction
13
Safety
13
Definition of Mandatory Signs
14
Definition of Safety Instructions
14
Intended Use
15
Deflagration on Gas Engines
16
Warning Plates on the Turbocharger
17
Turbocharger Rating Plate
18
Periodic Check of the Pressure Vessels
19
Lifting of Loads
20
Prerequisites for Operation and Maintenance
21
Hazards During Operation and Maintenance
22
Safe Operation
24
Safe Maintenance
26
Product Description
33
Table 10 Expected Replacement Intervals
33
Table 16 Malfunctions When Starting
33
Table 19 Malfunctions During Operation
34
Table 28 Malfunctions When Stopping
34
1 Introduction
37
Essential Information
37
Registered Trademarks
37
Related Documents
37
Table 1 Related Documents
37
Layout and Function of the Turbocharger
38
Warning Plates on the Turbocharger
40
Locations of the Rating Plates
41
2 Removing and Installing
43
Turbocharger Weight and Transportation
43
Table 2 Weights of Turbochargers A130
43
Removing the Turbocharger
44
Installing the Turbocharger
48
Table 3 Requirements for Threaded Rods
49
Table 4 Tightening Torques for Standard
51
Table 5 Pressure Screw Tightening Tor
53
3 Commissioning
55
Oil Supply
55
Inspection Procedures
57
Commissioning after Taking out of Operation
59
4 Monitoring Operation
61
Oil Pressure, Oil Temperature
61
Table 6 Lubricating Oil Pressure, Oil Inlet
61
Table 7 Lubricating Oil Temperature at the Inlet
62
Table 8 Lubricating Oil Temperature at the Outlet
62
Exhaust Gas Temperature before Turbine
63
Turbocharger Speed
64
Table 9 Tightening Torque
66
5 Operation and Service
67
Noise Emission
67
Service Work
69
Expected Replacement Intervals
73
Stopping the Engine
75
6 Periodic Maintenance Work
77
Foreword to Maintenance
77
Table 11 Maintenance Table
77
Cleaning the Compressor During Operation
78
Table 12 Parameters for Wet Cleaning of
81
Cleaning the Turbine During Operation
82
Table 13: Turbine Wet Cleaning, Recommended Operating State
84
Table 14 Wet Cleaning of Turbines, Pa
85
Cleaning Components Mechanically
86
Table 15 Value Table for Soaking
93
7 Eliminating Malfunctions
97
Malfunctions When Starting
97
Table 17 Malfunctions When Starting
97
Table 18 Malfunctions When Starting - Rubbing of Rotating Parts
97
Malfunctions During Operation
98
Table 20 Malfunctions During Operation - Speed Reduces
98
Table 21 Malfunctions During Operation - Speed Increases
98
Table 22 Malfunctions During Operation
99
Table 23 Malfunctions During Operation - Charge Air Pressure too Low
99
Table 24 Malfunctions During Operation - Charge Air Pressure too High
100
Table 25 Malfunctions During Operation - Engine Performance Losses
100
Turbocharger Is Surging
101
Table 26 Malfunction - Turbocharger
101
Table 27 Malfunction - Sporadic Surge Blows
101
Malfunctions When Stopping
102
Table 29 Malfunctions When Stopping - Runout Time too Short
102
Speed Measurement System
103
Table 30 Malfunction of the Speed Meas
103
Table 31 Malfunction of the Speed Meas
103
Table 32 Malfunction of the Speed Meas
103
8 Dismantling and Fitting
105
Introduction
105
Table 33 Swivel Lifting Eyes
107
Table 34 Ring Nuts to be Used
108
Weights of Individual Parts
109
Table 35 Weights of Assemblies
109
Removing Air Inlets
110
Removing the Gas Outlet Casing
111
Removing the Gas Outlet Flange
113
Table 36 3 Press-Off Screws
114
Table 37 6 Press-Off Screws
115
Removing the Compressor Casing
116
Pressing off the Casing
118
Removing the Cartridge Group
119
Removing the Nozzle Ring
121
Installing the Cartridge Group on the Service Support
122
Axial Clearance a and Radial Clearance B
123
Table 38 Permissible Clearances a and B
123
Nozzle Ring Compression PD
124
Table 39: Permitted Nozzle Ring Compression PD
124
Installing Nozzle Ring
125
Installing the Cartridge Group
126
Table 40 Tightening Torque (51007)
127
Installing the Compressor Casing
129
Table 41 Tightening Torque (79041)
129
Table 42 Tightening Torque (72011)
130
Radial Clearances N and R
131
Table 43 Permissible Clearances N and R
131
Installing Air Inlets
132
Table 44 Tightening Torque (72020)
132
Installing the Gas Outlet Flange
133
Installing the Gas Outlet Casing
135
Table 45 Tightening Torque (51009)
135
Table of Tightening Torques
137
Table 46 Tightening Torques
137
Table 47 Tightening Torques for Insulation
138
9 Taking out of Operation at Short Notice
139
Possible Emergency Repairs
139
Installing a Replacement Turbocharger
140
Installing a Replacement Cartridge Group
140
Fitting the Cover Plate
141
Cover Plate Drawing
142
Table 48 Cover Plate Dimensions [MM]
142
10 Mothballing the Turbocharger
143
11 Disposing of Turbocharger Components
145
12 Spare Parts
147
Ordering Spare Parts
147
Required Customer Spare Part Set (97070)
147
Table 49 Customer Spare Part Set 97070
147
View of Turbocharger with Part Numbers
148
Table 50 Spare Parts List
149
Figures
151
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