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ABB A155-M57 Manuals
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ABB A155-M57 manuals available for free PDF download: Operation Manual, Instruction Manual, Manual
ABB A155-M57 Operation Manual (196 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 33.64 MB
Table of Contents
Operation Manual / A150-M - A155-M
3
Table of Contents
3
Operation Manual / A150-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
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Definition of Safety Instructions
16
Definition of Mandatory Signs
16
Intended Use
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 7: Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Periodic Check of the Pressure Vessels
21
Fig. 10: Attachment Angle
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Lifting of Loads
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
Removing and Installing
31
Turbocharger Weight and Transportation
31
Fig. 11: Suspension of Complete Turbocharger Unit
31
Table 4: Weight of Complete Turbocharger Unit
31
Fig. 13: Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Removing the Turbocharger
32
Fig. 14: Loosening the Clamping Nut
33
Fig. 15: Turbocharger Centre of Gravity
34
Installing the Turbocharger
35
Fig. 16: Inserting the Gasket
35
Fig. 17: Fitting the Turbocharger 1
36
Fig. 18: Fitting the Turbocharger 2
37
Table 5: Fitting the Turbocharger, Value X, L
37
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
38
Fig. 20: Tightening Pressure Screws
39
Table 6: Torque-Controlled Tightening of the Pressure Screws
39
Fig. 21: Connecting the Speed Sensor
40
Fig. 22: Connecting the Compressor Cooling Air Intake
40
Fig. 23: Attaching the Support
40
Commissioning
41
Oil Supply
41
Fig. 24: Oil Orifice
42
Inspection Procedures
43
Commissioning after Taking out of Operation
45
Table 7: Lubricating Oil Pressure at Oil Inlet before Turbocharger
46
Oil Pressure, Oil Temperature
46
Monitoring Operation
46
Table 8: Lubricating Oil Temperature at the Inlet
47
Table 9: Maximum Lubricating Oil Temperature at the Outlet
47
Exhaust Gas Temperature before Turbine
48
Turbocharger Speed
49
Fig. 25: Layout and Overview of Speed Measurement System
49
Fig. 26: Replacing the Speed Sensor
51
Table 10: Tightening Torque (86505)
51
Operation and Service
52
Noise Emission
52
Fig. 27: Noise Insulation, Bellows
53
Service Work
54
Expected Replacement Intervals
57
Table 11: Expected Replacement Intervals
57
Stopping the Engine
59
Periodic Maintenance Work
60
Foreword to Maintenance
60
Table 12: Maintenance Table
60
Cleaning the Compressor During Operation
61
Fig. 28: Carrying out Wet Cleaning of Compressor
63
Table 13: Parameters for Wet Cleaning of Compressor
63
Cleaning the Turbine During Operation
64
Fig. 29: Turbine Cleaning Devices
66
Table 14: Turbine Wet Cleaning, Recommended Operating State
66
Fig. 30: Carrying out Wet Cleaning of Turbines
67
Table 15: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
67
Cleaning Components Mechanically
68
Table 16: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
68
Fig. 31: Cleaning the Filter Silencer
69
Fig. 32: Compressor-End, Non-Rotating Parts
71
Fig. 33: Turbine End, Non-Rotating Parts
73
Table 17: Value Table for Soaking
75
Fig. 34: Soaking the Turbine End
75
Fig. 35: Disassembling the Absorption Element
78
Changing the Absorption Element
78
Fig. 36: Installing the Absorption Element
79
Table 18: Tightening Torque (81152 / 81154)
79
Eliminating Malfunctions
80
Malfunctions When Starting
80
Table 19: Malfunctions When Starting - Delayed Start-Up
80
Table 20: Malfunctions When Starting - Vibrations
80
Table 21: Malfunctions When Starting - Rubbing of Rotating Parts
80
Table 24: Malfunctions During Operation - Speed Increases
81
Malfunctions During Operation
81
Table 23: Malfunctions During Operation - Speed Reduces
81
Table 22: Malfunctions During Operation - Lubricating Oil Pressure too Low
81
Table 25: Malfunctions During Operation - Exhaust Gas Temperature too High
82
Table 26: Malfunctions During Operation - Charge Air Pressure too Low
82
Table 27: Malfunctions During Operation - Charge Air Pressure too High
83
Table 28: Malfunctions During Operation - Engine Performance Losses
83
Turbocharger Is Surging
84
Table 29: Malfunction - Turbocharger Pumping
84
Table 30: Malfunction - Sporadic Surge Blows
84
Table 32: Malfunctions When Stopping - Runout Time too Short
85
Malfunctions When Stopping
85
Table 31: Malfunctions When Stopping - Runout Noises
85
Speed Measurement System
86
Table 33: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
86
Table 34: Malfunction of the Speed Measurement System - Measured Speed too High
86
Table 35: Malfunction of the Speed Measurement System - Measured Speed too Low
86
Dismantling and Fitting, General
87
Introduction
87
Table 36: Swivel Lifting Eyes
88
Fig. 37: Swivel Lifting Eyes
88
Material Required
88
Fig. 38: Press-Off Screws
89
Fig. 39: Dismantling Screw
89
Table 37: Press-Off Screws
89
Table 38: Dismantling Screw
89
Disassembly and Assembly Concepts
91
Fig. 40: Removing the Cartridge Group with Compressor and Turbine Casing
91
Fig. 41: Cartridge Concept
92
Fig. 42: Optional Spanner Holder
93
Table 39: Weights of Assemblies
94
Fig. 43: Weights of Assemblies
94
Weights of Individual Parts
94
Table of Tightening Torques
95
Fig. 44: Overview of Tightening Torques
95
Table 40: Tightening Torques
95
Fig. 45: Tightening Torques for Insulation
96
Table 41: Tightening Torques for Insulation
96
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
97
Removing Air Inlets
97
Fig. 46: Removing the Air Inlets
97
Fig. 47: Removing the Uncoupled Filter Silencer
98
Removing the Gas Outlet Casing
99
Fig. 48: Remove Gas Outlet Casing Without Support
99
Fig. 49: Removing Gas Outlet Casing with Support 1
100
Fig. 50: Removing Gas Outlet Casing with Support 1
101
Removing the Gas Outlet Flange
102
Fig. 51: Dismantling the Gas Outlet Flange
103
Table 42: 3 Press-Off Screws
103
Fig. 52: Removing the Gas Outlet Flange
104
Table 43: 6 Press-Off Screws
104
Fig. 54: Remove Insulation
105
Fig. 53: Turbine Cleaning Nozzle
105
Removing the Cartridge Group with Compressor and Turbine Casing
105
Fig. 55: Removing the Cartridge Group with Compressor and Turbine Casing
106
Fig. 56: Set down the Cartridge Group with the Compressor and Turbine Casing
106
Removing the Compressor Casing
107
Fig. 57: Removing the Compressor Casing
107
Fig. 58: Dismantling the Diffuser and the Wall Insert
108
Advertisement
ABB A155-M57 Operation Manual (196 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 33.64 MB
Table of Contents
Operation Manual / A150-M - A155-M
3
Table of Contents
3
Operation Manual / A150-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
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Definition of Safety Instructions
16
Definition of Mandatory Signs
16
Intended Use
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 7: Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Periodic Check of the Pressure Vessels
21
Fig. 10: Attachment Angle
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Lifting of Loads
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
Removing and Installing
31
Turbocharger Weight and Transportation
31
Fig. 11: Suspension of Complete Turbocharger Unit
31
Table 4: Weight of Complete Turbocharger Unit
31
Fig. 13: Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Removing the Turbocharger
32
Fig. 14: Loosening the Clamping Nut
33
Fig. 15: Turbocharger Centre of Gravity
34
Installing the Turbocharger
35
Fig. 16: Inserting the Gasket
35
Fig. 17: Fitting the Turbocharger 1
36
Fig. 18: Fitting the Turbocharger 2
37
Table 5: Fitting the Turbocharger, Value X, L
37
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
38
Fig. 20: Tightening Pressure Screws
39
Table 6: Torque-Controlled Tightening of the Pressure Screws
39
Fig. 21: Connecting the Speed Sensor
40
Fig. 22: Connecting the Compressor Cooling Air Intake
40
Fig. 23: Attaching the Support
40
Commissioning
41
Oil Supply
41
Fig. 24: Oil Orifice
42
Inspection Procedures
43
Commissioning after Taking out of Operation
45
Table 7: Lubricating Oil Pressure at Oil Inlet before Turbocharger
46
Oil Pressure, Oil Temperature
46
Monitoring Operation
46
Table 8: Lubricating Oil Temperature at the Inlet
47
Table 9: Maximum Lubricating Oil Temperature at the Outlet
47
Exhaust Gas Temperature before Turbine
48
Turbocharger Speed
49
Fig. 25: Layout and Overview of Speed Measurement System
49
Fig. 26: Replacing the Speed Sensor
51
Table 10: Tightening Torque (86505)
51
Operation and Service
52
Noise Emission
52
Fig. 27: Noise Insulation, Bellows
53
Service Work
54
Expected Replacement Intervals
57
Table 11: Expected Replacement Intervals
57
Stopping the Engine
59
Periodic Maintenance Work
60
Foreword to Maintenance
60
Table 12: Maintenance Table
60
Cleaning the Compressor During Operation
61
Fig. 28: Carrying out Wet Cleaning of Compressor
63
Table 13: Parameters for Wet Cleaning of Compressor
63
Cleaning the Turbine During Operation
64
Fig. 29: Turbine Cleaning Devices
66
Table 14: Turbine Wet Cleaning, Recommended Operating State
66
Fig. 30: Carrying out Wet Cleaning of Turbines
67
Table 15: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
67
Cleaning Components Mechanically
68
Table 16: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
68
Fig. 31: Cleaning the Filter Silencer
69
Fig. 32: Compressor-End, Non-Rotating Parts
71
Fig. 33: Turbine End, Non-Rotating Parts
73
Table 17: Value Table for Soaking
75
Fig. 34: Soaking the Turbine End
75
Fig. 35: Disassembling the Absorption Element
78
Changing the Absorption Element
78
Fig. 36: Installing the Absorption Element
79
Table 18: Tightening Torque (81152 / 81154)
79
Eliminating Malfunctions
80
Malfunctions When Starting
80
Table 19: Malfunctions When Starting - Delayed Start-Up
80
Table 20: Malfunctions When Starting - Vibrations
80
Table 21: Malfunctions When Starting - Rubbing of Rotating Parts
80
Table 24: Malfunctions During Operation - Speed Increases
81
Malfunctions During Operation
81
Table 23: Malfunctions During Operation - Speed Reduces
81
Table 22: Malfunctions During Operation - Lubricating Oil Pressure too Low
81
Table 25: Malfunctions During Operation - Exhaust Gas Temperature too High
82
Table 26: Malfunctions During Operation - Charge Air Pressure too Low
82
Table 27: Malfunctions During Operation - Charge Air Pressure too High
83
Table 28: Malfunctions During Operation - Engine Performance Losses
83
Turbocharger Is Surging
84
Table 29: Malfunction - Turbocharger Pumping
84
Table 30: Malfunction - Sporadic Surge Blows
84
Table 32: Malfunctions When Stopping - Runout Time too Short
85
Malfunctions When Stopping
85
Table 31: Malfunctions When Stopping - Runout Noises
85
Speed Measurement System
86
Table 33: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
86
Table 34: Malfunction of the Speed Measurement System - Measured Speed too High
86
Table 35: Malfunction of the Speed Measurement System - Measured Speed too Low
86
Dismantling and Fitting, General
87
Introduction
87
Table 36: Swivel Lifting Eyes
88
Fig. 37: Swivel Lifting Eyes
88
Material Required
88
Fig. 38: Press-Off Screws
89
Fig. 39: Dismantling Screw
89
Table 37: Press-Off Screws
89
Table 38: Dismantling Screw
89
Disassembly and Assembly Concepts
91
Fig. 40: Removing the Cartridge Group with Compressor and Turbine Casing
91
Fig. 41: Cartridge Concept
92
Fig. 42: Optional Spanner Holder
93
Table 39: Weights of Assemblies
94
Fig. 43: Weights of Assemblies
94
Weights of Individual Parts
94
Table of Tightening Torques
95
Fig. 44: Overview of Tightening Torques
95
Table 40: Tightening Torques
95
Fig. 45: Tightening Torques for Insulation
96
Table 41: Tightening Torques for Insulation
96
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
97
Removing Air Inlets
97
Fig. 46: Removing the Air Inlets
97
Fig. 47: Removing the Uncoupled Filter Silencer
98
Removing the Gas Outlet Casing
99
Fig. 48: Remove Gas Outlet Casing Without Support
99
Fig. 49: Removing Gas Outlet Casing with Support 1
100
Fig. 50: Removing Gas Outlet Casing with Support 1
101
Removing the Gas Outlet Flange
102
Fig. 51: Dismantling the Gas Outlet Flange
103
Table 42: 3 Press-Off Screws
103
Fig. 52: Removing the Gas Outlet Flange
104
Table 43: 6 Press-Off Screws
104
Fig. 54: Remove Insulation
105
Fig. 53: Turbine Cleaning Nozzle
105
Removing the Cartridge Group with Compressor and Turbine Casing
105
Fig. 55: Removing the Cartridge Group with Compressor and Turbine Casing
106
Fig. 56: Set down the Cartridge Group with the Compressor and Turbine Casing
106
Removing the Compressor Casing
107
Fig. 57: Removing the Compressor Casing
107
Fig. 58: Dismantling the Diffuser and the Wall Insert
108
ABB A155-M57 Operation Manual (196 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 33.64 MB
Table of Contents
Operation Manual / A150-M - A155-M
3
Table of Contents
3
Operation Manual / A150-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
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Definition of Safety Instructions
16
Definition of Mandatory Signs
16
Intended Use
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 7: Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Periodic Check of the Pressure Vessels
21
Fig. 10: Attachment Angle
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Lifting of Loads
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
Removing and Installing
31
Turbocharger Weight and Transportation
31
Fig. 11: Suspension of Complete Turbocharger Unit
31
Table 4: Weight of Complete Turbocharger Unit
31
Fig. 13: Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Removing the Turbocharger
32
Fig. 14: Loosening the Clamping Nut
33
Fig. 15: Turbocharger Centre of Gravity
34
Installing the Turbocharger
35
Fig. 16: Inserting the Gasket
35
Fig. 17: Fitting the Turbocharger 1
36
Fig. 18: Fitting the Turbocharger 2
37
Table 5: Fitting the Turbocharger, Value X, L
37
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
38
Fig. 20: Tightening Pressure Screws
39
Table 6: Torque-Controlled Tightening of the Pressure Screws
39
Fig. 21: Connecting the Speed Sensor
40
Fig. 22: Connecting the Compressor Cooling Air Intake
40
Fig. 23: Attaching the Support
40
Commissioning
41
Oil Supply
41
Fig. 24: Oil Orifice
42
Inspection Procedures
43
Commissioning after Taking out of Operation
45
Table 7: Lubricating Oil Pressure at Oil Inlet before Turbocharger
46
Oil Pressure, Oil Temperature
46
Monitoring Operation
46
Table 8: Lubricating Oil Temperature at the Inlet
47
Table 9: Maximum Lubricating Oil Temperature at the Outlet
47
Exhaust Gas Temperature before Turbine
48
Turbocharger Speed
49
Fig. 25: Layout and Overview of Speed Measurement System
49
Fig. 26: Replacing the Speed Sensor
51
Table 10: Tightening Torque (86505)
51
Operation and Service
52
Noise Emission
52
Fig. 27: Noise Insulation, Bellows
53
Service Work
54
Expected Replacement Intervals
57
Table 11: Expected Replacement Intervals
57
Stopping the Engine
59
Periodic Maintenance Work
60
Foreword to Maintenance
60
Table 12: Maintenance Table
60
Cleaning the Compressor During Operation
61
Fig. 28: Carrying out Wet Cleaning of Compressor
63
Table 13: Parameters for Wet Cleaning of Compressor
63
Cleaning the Turbine During Operation
64
Fig. 29: Turbine Cleaning Devices
66
Table 14: Turbine Wet Cleaning, Recommended Operating State
66
Fig. 30: Carrying out Wet Cleaning of Turbines
67
Table 15: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
67
Cleaning Components Mechanically
68
Table 16: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
68
Fig. 31: Cleaning the Filter Silencer
69
Fig. 32: Compressor-End, Non-Rotating Parts
71
Fig. 33: Turbine End, Non-Rotating Parts
73
Table 17: Value Table for Soaking
75
Fig. 34: Soaking the Turbine End
75
Fig. 35: Disassembling the Absorption Element
78
Changing the Absorption Element
78
Fig. 36: Installing the Absorption Element
79
Table 18: Tightening Torque (81152 / 81154)
79
Eliminating Malfunctions
80
Malfunctions When Starting
80
Table 19: Malfunctions When Starting - Delayed Start-Up
80
Table 20: Malfunctions When Starting - Vibrations
80
Table 21: Malfunctions When Starting - Rubbing of Rotating Parts
80
Table 24: Malfunctions During Operation - Speed Increases
81
Malfunctions During Operation
81
Table 23: Malfunctions During Operation - Speed Reduces
81
Table 22: Malfunctions During Operation - Lubricating Oil Pressure too Low
81
Table 25: Malfunctions During Operation - Exhaust Gas Temperature too High
82
Table 26: Malfunctions During Operation - Charge Air Pressure too Low
82
Table 27: Malfunctions During Operation - Charge Air Pressure too High
83
Table 28: Malfunctions During Operation - Engine Performance Losses
83
Turbocharger Is Surging
84
Table 29: Malfunction - Turbocharger Pumping
84
Table 30: Malfunction - Sporadic Surge Blows
84
Table 32: Malfunctions When Stopping - Runout Time too Short
85
Malfunctions When Stopping
85
Table 31: Malfunctions When Stopping - Runout Noises
85
Speed Measurement System
86
Table 33: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
86
Table 34: Malfunction of the Speed Measurement System - Measured Speed too High
86
Table 35: Malfunction of the Speed Measurement System - Measured Speed too Low
86
Dismantling and Fitting, General
87
Introduction
87
Table 36: Swivel Lifting Eyes
88
Fig. 37: Swivel Lifting Eyes
88
Material Required
88
Fig. 38: Press-Off Screws
89
Fig. 39: Dismantling Screw
89
Table 37: Press-Off Screws
89
Table 38: Dismantling Screw
89
Disassembly and Assembly Concepts
91
Fig. 40: Removing the Cartridge Group with Compressor and Turbine Casing
91
Fig. 41: Cartridge Concept
92
Fig. 42: Optional Spanner Holder
93
Table 39: Weights of Assemblies
94
Fig. 43: Weights of Assemblies
94
Weights of Individual Parts
94
Table of Tightening Torques
95
Fig. 44: Overview of Tightening Torques
95
Table 40: Tightening Torques
95
Fig. 45: Tightening Torques for Insulation
96
Table 41: Tightening Torques for Insulation
96
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
97
Removing Air Inlets
97
Fig. 46: Removing the Air Inlets
97
Fig. 47: Removing the Uncoupled Filter Silencer
98
Removing the Gas Outlet Casing
99
Fig. 48: Remove Gas Outlet Casing Without Support
99
Fig. 49: Removing Gas Outlet Casing with Support 1
100
Fig. 50: Removing Gas Outlet Casing with Support 1
101
Removing the Gas Outlet Flange
102
Fig. 51: Dismantling the Gas Outlet Flange
103
Table 42: 3 Press-Off Screws
103
Fig. 52: Removing the Gas Outlet Flange
104
Table 43: 6 Press-Off Screws
104
Fig. 54: Remove Insulation
105
Fig. 53: Turbine Cleaning Nozzle
105
Removing the Cartridge Group with Compressor and Turbine Casing
105
Fig. 55: Removing the Cartridge Group with Compressor and Turbine Casing
106
Fig. 56: Set down the Cartridge Group with the Compressor and Turbine Casing
106
Removing the Compressor Casing
107
Fig. 57: Removing the Compressor Casing
107
Fig. 58: Dismantling the Diffuser and the Wall Insert
108
Advertisement
ABB A155-M57 Operation Manual (196 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 33.64 MB
Table of Contents
Operation Manual / A150-M - A155-M
3
Table of Contents
3
Operation Manual / A150-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
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Definition of Safety Instructions
16
Definition of Mandatory Signs
16
Intended Use
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 7: Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Periodic Check of the Pressure Vessels
21
Fig. 10: Attachment Angle
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Lifting of Loads
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
Removing and Installing
31
Turbocharger Weight and Transportation
31
Fig. 11: Suspension of Complete Turbocharger Unit
31
Table 4: Weight of Complete Turbocharger Unit
31
Fig. 13: Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Removing the Turbocharger
32
Fig. 14: Loosening the Clamping Nut
33
Fig. 15: Turbocharger Centre of Gravity
34
Installing the Turbocharger
35
Fig. 16: Inserting the Gasket
35
Fig. 17: Fitting the Turbocharger 1
36
Fig. 18: Fitting the Turbocharger 2
37
Table 5: Fitting the Turbocharger, Value X, L
37
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
38
Fig. 20: Tightening Pressure Screws
39
Table 6: Torque-Controlled Tightening of the Pressure Screws
39
Fig. 21: Connecting the Speed Sensor
40
Fig. 22: Connecting the Compressor Cooling Air Intake
40
Fig. 23: Attaching the Support
40
Commissioning
41
Oil Supply
41
Fig. 24: Oil Orifice
42
Inspection Procedures
43
Commissioning after Taking out of Operation
45
Table 7: Lubricating Oil Pressure at Oil Inlet before Turbocharger
46
Oil Pressure, Oil Temperature
46
Monitoring Operation
46
Table 8: Lubricating Oil Temperature at the Inlet
47
Table 9: Maximum Lubricating Oil Temperature at the Outlet
47
Exhaust Gas Temperature before Turbine
48
Turbocharger Speed
49
Fig. 25: Layout and Overview of Speed Measurement System
49
Fig. 26: Replacing the Speed Sensor
51
Table 10: Tightening Torque (86505)
51
Operation and Service
52
Noise Emission
52
Fig. 27: Noise Insulation, Bellows
53
Service Work
54
Expected Replacement Intervals
57
Table 11: Expected Replacement Intervals
57
Stopping the Engine
59
Periodic Maintenance Work
60
Foreword to Maintenance
60
Table 12: Maintenance Table
60
Cleaning the Compressor During Operation
61
Fig. 28: Carrying out Wet Cleaning of Compressor
63
Table 13: Parameters for Wet Cleaning of Compressor
63
Cleaning the Turbine During Operation
64
Fig. 29: Turbine Cleaning Devices
66
Table 14: Turbine Wet Cleaning, Recommended Operating State
66
Fig. 30: Carrying out Wet Cleaning of Turbines
67
Table 15: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
67
Cleaning Components Mechanically
68
Table 16: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
68
Fig. 31: Cleaning the Filter Silencer
69
Fig. 32: Compressor-End, Non-Rotating Parts
71
Fig. 33: Turbine End, Non-Rotating Parts
73
Table 17: Value Table for Soaking
75
Fig. 34: Soaking the Turbine End
75
Fig. 35: Disassembling the Absorption Element
78
Changing the Absorption Element
78
Fig. 36: Installing the Absorption Element
79
Table 18: Tightening Torque (81152 / 81154)
79
Eliminating Malfunctions
80
Malfunctions When Starting
80
Table 19: Malfunctions When Starting - Delayed Start-Up
80
Table 20: Malfunctions When Starting - Vibrations
80
Table 21: Malfunctions When Starting - Rubbing of Rotating Parts
80
Table 24: Malfunctions During Operation - Speed Increases
81
Malfunctions During Operation
81
Table 23: Malfunctions During Operation - Speed Reduces
81
Table 22: Malfunctions During Operation - Lubricating Oil Pressure too Low
81
Table 25: Malfunctions During Operation - Exhaust Gas Temperature too High
82
Table 26: Malfunctions During Operation - Charge Air Pressure too Low
82
Table 27: Malfunctions During Operation - Charge Air Pressure too High
83
Table 28: Malfunctions During Operation - Engine Performance Losses
83
Turbocharger Is Surging
84
Table 29: Malfunction - Turbocharger Pumping
84
Table 30: Malfunction - Sporadic Surge Blows
84
Table 32: Malfunctions When Stopping - Runout Time too Short
85
Malfunctions When Stopping
85
Table 31: Malfunctions When Stopping - Runout Noises
85
Speed Measurement System
86
Table 33: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
86
Table 34: Malfunction of the Speed Measurement System - Measured Speed too High
86
Table 35: Malfunction of the Speed Measurement System - Measured Speed too Low
86
Dismantling and Fitting, General
87
Introduction
87
Table 36: Swivel Lifting Eyes
88
Fig. 37: Swivel Lifting Eyes
88
Material Required
88
Fig. 38: Press-Off Screws
89
Fig. 39: Dismantling Screw
89
Table 37: Press-Off Screws
89
Table 38: Dismantling Screw
89
Disassembly and Assembly Concepts
91
Fig. 40: Removing the Cartridge Group with Compressor and Turbine Casing
91
Fig. 41: Cartridge Concept
92
Fig. 42: Optional Spanner Holder
93
Table 39: Weights of Assemblies
94
Fig. 43: Weights of Assemblies
94
Weights of Individual Parts
94
Table of Tightening Torques
95
Fig. 44: Overview of Tightening Torques
95
Table 40: Tightening Torques
95
Fig. 45: Tightening Torques for Insulation
96
Table 41: Tightening Torques for Insulation
96
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
97
Removing Air Inlets
97
Fig. 46: Removing the Air Inlets
97
Fig. 47: Removing the Uncoupled Filter Silencer
98
Removing the Gas Outlet Casing
99
Fig. 48: Remove Gas Outlet Casing Without Support
99
Fig. 49: Removing Gas Outlet Casing with Support 1
100
Fig. 50: Removing Gas Outlet Casing with Support 1
101
Removing the Gas Outlet Flange
102
Fig. 51: Dismantling the Gas Outlet Flange
103
Table 42: 3 Press-Off Screws
103
Fig. 52: Removing the Gas Outlet Flange
104
Table 43: 6 Press-Off Screws
104
Fig. 54: Remove Insulation
105
Fig. 53: Turbine Cleaning Nozzle
105
Removing the Cartridge Group with Compressor and Turbine Casing
105
Fig. 55: Removing the Cartridge Group with Compressor and Turbine Casing
106
Fig. 56: Set down the Cartridge Group with the Compressor and Turbine Casing
106
Removing the Compressor Casing
107
Fig. 57: Removing the Compressor Casing
107
Fig. 58: Dismantling the Diffuser and the Wall Insert
108
ABB A155-M57 Operation Manual (196 pages)
Turbocharging
Brand:
ABB
| Category:
Industrial Equipment
| Size: 33.64 MB
Table of Contents
Operation Manual / A150-M - A155-M
3
Table of Contents
3
Operation Manual / A150-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
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Definition of Safety Instructions
16
Definition of Mandatory Signs
16
Intended Use
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 7: Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Periodic Check of the Pressure Vessels
21
Fig. 10: Attachment Angle
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Lifting of Loads
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
Removing and Installing
31
Turbocharger Weight and Transportation
31
Fig. 11: Suspension of Complete Turbocharger Unit
31
Table 4: Weight of Complete Turbocharger Unit
31
Fig. 13: Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Removing the Turbocharger
32
Fig. 14: Loosening the Clamping Nut
33
Fig. 15: Turbocharger Centre of Gravity
34
Installing the Turbocharger
35
Fig. 16: Inserting the Gasket
35
Fig. 17: Fitting the Turbocharger 1
36
Fig. 18: Fitting the Turbocharger 2
37
Table 5: Fitting the Turbocharger, Value X, L
37
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
38
Fig. 20: Tightening Pressure Screws
39
Table 6: Torque-Controlled Tightening of the Pressure Screws
39
Fig. 21: Connecting the Speed Sensor
40
Fig. 22: Connecting the Compressor Cooling Air Intake
40
Fig. 23: Attaching the Support
40
Commissioning
41
Oil Supply
41
Fig. 24: Oil Orifice
42
Inspection Procedures
43
Commissioning after Taking out of Operation
45
Table 7: Lubricating Oil Pressure at Oil Inlet before Turbocharger
46
Oil Pressure, Oil Temperature
46
Monitoring Operation
46
Table 8: Lubricating Oil Temperature at the Inlet
47
Table 9: Maximum Lubricating Oil Temperature at the Outlet
47
Exhaust Gas Temperature before Turbine
48
Turbocharger Speed
49
Fig. 25: Layout and Overview of Speed Measurement System
49
Fig. 26: Replacing the Speed Sensor
51
Table 10: Tightening Torque (86505)
51
Operation and Service
52
Noise Emission
52
Fig. 27: Noise Insulation, Bellows
53
Service Work
54
Expected Replacement Intervals
57
Table 11: Expected Replacement Intervals
57
Stopping the Engine
59
Periodic Maintenance Work
60
Foreword to Maintenance
60
Table 12: Maintenance Table
60
Cleaning the Compressor During Operation
61
Fig. 28: Carrying out Wet Cleaning of Compressor
63
Table 13: Parameters for Wet Cleaning of Compressor
63
Cleaning the Turbine During Operation
64
Fig. 29: Turbine Cleaning Devices
66
Table 14: Turbine Wet Cleaning, Recommended Operating State
66
Fig. 30: Carrying out Wet Cleaning of Turbines
67
Table 15: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
67
Cleaning Components Mechanically
68
Table 16: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
68
Fig. 31: Cleaning the Filter Silencer
69
Fig. 32: Compressor-End, Non-Rotating Parts
71
Fig. 33: Turbine End, Non-Rotating Parts
73
Table 17: Value Table for Soaking
75
Fig. 34: Soaking the Turbine End
75
Fig. 35: Disassembling the Absorption Element
78
Changing the Absorption Element
78
Fig. 36: Installing the Absorption Element
79
Table 18: Tightening Torque (81152 / 81154)
79
Eliminating Malfunctions
80
Malfunctions When Starting
80
Table 19: Malfunctions When Starting - Delayed Start-Up
80
Table 20: Malfunctions When Starting - Vibrations
80
Table 21: Malfunctions When Starting - Rubbing of Rotating Parts
80
Table 24: Malfunctions During Operation - Speed Increases
81
Malfunctions During Operation
81
Table 23: Malfunctions During Operation - Speed Reduces
81
Table 22: Malfunctions During Operation - Lubricating Oil Pressure too Low
81
Table 25: Malfunctions During Operation - Exhaust Gas Temperature too High
82
Table 26: Malfunctions During Operation - Charge Air Pressure too Low
82
Table 27: Malfunctions During Operation - Charge Air Pressure too High
83
Table 28: Malfunctions During Operation - Engine Performance Losses
83
Turbocharger Is Surging
84
Table 29: Malfunction - Turbocharger Pumping
84
Table 30: Malfunction - Sporadic Surge Blows
84
Table 32: Malfunctions When Stopping - Runout Time too Short
85
Malfunctions When Stopping
85
Table 31: Malfunctions When Stopping - Runout Noises
85
Speed Measurement System
86
Table 33: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
86
Table 34: Malfunction of the Speed Measurement System - Measured Speed too High
86
Table 35: Malfunction of the Speed Measurement System - Measured Speed too Low
86
Dismantling and Fitting, General
87
Introduction
87
Table 36: Swivel Lifting Eyes
88
Fig. 37: Swivel Lifting Eyes
88
Material Required
88
Fig. 38: Press-Off Screws
89
Fig. 39: Dismantling Screw
89
Table 37: Press-Off Screws
89
Table 38: Dismantling Screw
89
Disassembly and Assembly Concepts
91
Fig. 40: Removing the Cartridge Group with Compressor and Turbine Casing
91
Fig. 41: Cartridge Concept
92
Fig. 42: Optional Spanner Holder
93
Table 39: Weights of Assemblies
94
Fig. 43: Weights of Assemblies
94
Weights of Individual Parts
94
Table of Tightening Torques
95
Fig. 44: Overview of Tightening Torques
95
Table 40: Tightening Torques
95
Fig. 45: Tightening Torques for Insulation
96
Table 41: Tightening Torques for Insulation
96
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
97
Removing Air Inlets
97
Fig. 46: Removing the Air Inlets
97
Fig. 47: Removing the Uncoupled Filter Silencer
98
Removing the Gas Outlet Casing
99
Fig. 48: Remove Gas Outlet Casing Without Support
99
Fig. 49: Removing Gas Outlet Casing with Support 1
100
Fig. 50: Removing Gas Outlet Casing with Support 1
101
Removing the Gas Outlet Flange
102
Fig. 51: Dismantling the Gas Outlet Flange
103
Table 42: 3 Press-Off Screws
103
Fig. 52: Removing the Gas Outlet Flange
104
Table 43: 6 Press-Off Screws
104
Fig. 54: Remove Insulation
105
Fig. 53: Turbine Cleaning Nozzle
105
Removing the Cartridge Group with Compressor and Turbine Casing
105
Fig. 55: Removing the Cartridge Group with Compressor and Turbine Casing
106
Fig. 56: Set down the Cartridge Group with the Compressor and Turbine Casing
106
Removing the Compressor Casing
107
Fig. 57: Removing the Compressor Casing
107
Fig. 58: Dismantling the Diffuser and the Wall Insert
108
ABB A155-M57 Operation Manual (196 pages)
Turbocharging
Brand:
ABB
| Category:
Industrial Equipment
| Size: 33.64 MB
Table of Contents
Operation Manual / A150-M - A155-M
3
Table of Contents
3
Operation Manual / A150-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
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Definition of Safety Instructions
16
Definition of Mandatory Signs
16
Intended Use
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 7: Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Periodic Check of the Pressure Vessels
21
Fig. 10: Attachment Angle
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Lifting of Loads
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
Removing and Installing
31
Turbocharger Weight and Transportation
31
Fig. 11: Suspension of Complete Turbocharger Unit
31
Table 4: Weight of Complete Turbocharger Unit
31
Fig. 13: Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Removing the Turbocharger
32
Fig. 14: Loosening the Clamping Nut
33
Fig. 15: Turbocharger Centre of Gravity
34
Installing the Turbocharger
35
Fig. 16: Inserting the Gasket
35
Fig. 17: Fitting the Turbocharger 1
36
Fig. 18: Fitting the Turbocharger 2
37
Table 5: Fitting the Turbocharger, Value X, L
37
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
38
Fig. 20: Tightening Pressure Screws
39
Table 6: Torque-Controlled Tightening of the Pressure Screws
39
Fig. 21: Connecting the Speed Sensor
40
Fig. 22: Connecting the Compressor Cooling Air Intake
40
Fig. 23: Attaching the Support
40
Commissioning
41
Oil Supply
41
Fig. 24: Oil Orifice
42
Inspection Procedures
43
Commissioning after Taking out of Operation
45
Table 7: Lubricating Oil Pressure at Oil Inlet before Turbocharger
46
Oil Pressure, Oil Temperature
46
Monitoring Operation
46
Table 8: Lubricating Oil Temperature at the Inlet
47
Table 9: Maximum Lubricating Oil Temperature at the Outlet
47
Exhaust Gas Temperature before Turbine
48
Turbocharger Speed
49
Fig. 25: Layout and Overview of Speed Measurement System
49
Fig. 26: Replacing the Speed Sensor
51
Table 10: Tightening Torque (86505)
51
Operation and Service
52
Noise Emission
52
Fig. 27: Noise Insulation, Bellows
53
Service Work
54
Expected Replacement Intervals
57
Table 11: Expected Replacement Intervals
57
Stopping the Engine
59
Periodic Maintenance Work
60
Foreword to Maintenance
60
Table 12: Maintenance Table
60
Cleaning the Compressor During Operation
61
Fig. 28: Carrying out Wet Cleaning of Compressor
63
Table 13: Parameters for Wet Cleaning of Compressor
63
Cleaning the Turbine During Operation
64
Fig. 29: Turbine Cleaning Devices
66
Table 14: Turbine Wet Cleaning, Recommended Operating State
66
Fig. 30: Carrying out Wet Cleaning of Turbines
67
Table 15: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
67
Cleaning Components Mechanically
68
Table 16: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
68
Fig. 31: Cleaning the Filter Silencer
69
Fig. 32: Compressor-End, Non-Rotating Parts
71
Fig. 33: Turbine End, Non-Rotating Parts
73
Table 17: Value Table for Soaking
75
Fig. 34: Soaking the Turbine End
75
Fig. 35: Disassembling the Absorption Element
78
Changing the Absorption Element
78
Fig. 36: Installing the Absorption Element
79
Table 18: Tightening Torque (81152 / 81154)
79
Eliminating Malfunctions
80
Malfunctions When Starting
80
Table 19: Malfunctions When Starting - Delayed Start-Up
80
Table 20: Malfunctions When Starting - Vibrations
80
Table 21: Malfunctions When Starting - Rubbing of Rotating Parts
80
Table 24: Malfunctions During Operation - Speed Increases
81
Malfunctions During Operation
81
Table 23: Malfunctions During Operation - Speed Reduces
81
Table 22: Malfunctions During Operation - Lubricating Oil Pressure too Low
81
Table 25: Malfunctions During Operation - Exhaust Gas Temperature too High
82
Table 26: Malfunctions During Operation - Charge Air Pressure too Low
82
Table 27: Malfunctions During Operation - Charge Air Pressure too High
83
Table 28: Malfunctions During Operation - Engine Performance Losses
83
Turbocharger Is Surging
84
Table 29: Malfunction - Turbocharger Pumping
84
Table 30: Malfunction - Sporadic Surge Blows
84
Table 32: Malfunctions When Stopping - Runout Time too Short
85
Malfunctions When Stopping
85
Table 31: Malfunctions When Stopping - Runout Noises
85
Speed Measurement System
86
Table 33: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
86
Table 34: Malfunction of the Speed Measurement System - Measured Speed too High
86
Table 35: Malfunction of the Speed Measurement System - Measured Speed too Low
86
Dismantling and Fitting, General
87
Introduction
87
Table 36: Swivel Lifting Eyes
88
Fig. 37: Swivel Lifting Eyes
88
Material Required
88
Fig. 38: Press-Off Screws
89
Fig. 39: Dismantling Screw
89
Table 37: Press-Off Screws
89
Table 38: Dismantling Screw
89
Disassembly and Assembly Concepts
91
Fig. 40: Removing the Cartridge Group with Compressor and Turbine Casing
91
Fig. 41: Cartridge Concept
92
Fig. 42: Optional Spanner Holder
93
Table 39: Weights of Assemblies
94
Fig. 43: Weights of Assemblies
94
Weights of Individual Parts
94
Table of Tightening Torques
95
Fig. 44: Overview of Tightening Torques
95
Table 40: Tightening Torques
95
Fig. 45: Tightening Torques for Insulation
96
Table 41: Tightening Torques for Insulation
96
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
97
Removing Air Inlets
97
Fig. 46: Removing the Air Inlets
97
Fig. 47: Removing the Uncoupled Filter Silencer
98
Removing the Gas Outlet Casing
99
Fig. 48: Remove Gas Outlet Casing Without Support
99
Fig. 49: Removing Gas Outlet Casing with Support 1
100
Fig. 50: Removing Gas Outlet Casing with Support 1
101
Removing the Gas Outlet Flange
102
Fig. 51: Dismantling the Gas Outlet Flange
103
Table 42: 3 Press-Off Screws
103
Fig. 52: Removing the Gas Outlet Flange
104
Table 43: 6 Press-Off Screws
104
Fig. 54: Remove Insulation
105
Fig. 53: Turbine Cleaning Nozzle
105
Removing the Cartridge Group with Compressor and Turbine Casing
105
Fig. 55: Removing the Cartridge Group with Compressor and Turbine Casing
106
Fig. 56: Set down the Cartridge Group with the Compressor and Turbine Casing
106
Removing the Compressor Casing
107
Fig. 57: Removing the Compressor Casing
107
Fig. 58: Dismantling the Diffuser and the Wall Insert
108
ABB A155-M57 Operation Manual (196 pages)
Brand:
ABB
| Category:
Engine
| Size: 33.64 MB
Table of Contents
Operation Manual / A150-M - A155-M
3
Table of Contents
3
Operation Manual / A150-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
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Definition of Safety Instructions
16
Definition of Mandatory Signs
16
Intended Use
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 7: Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Periodic Check of the Pressure Vessels
21
Fig. 10: Attachment Angle
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Lifting of Loads
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
Removing and Installing
31
Turbocharger Weight and Transportation
31
Fig. 11: Suspension of Complete Turbocharger Unit
31
Table 4: Weight of Complete Turbocharger Unit
31
Fig. 13: Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Removing the Turbocharger
32
Fig. 14: Loosening the Clamping Nut
33
Fig. 15: Turbocharger Centre of Gravity
34
Installing the Turbocharger
35
Fig. 16: Inserting the Gasket
35
Fig. 17: Fitting the Turbocharger 1
36
Fig. 18: Fitting the Turbocharger 2
37
Table 5: Fitting the Turbocharger, Value X, L
37
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
38
Fig. 20: Tightening Pressure Screws
39
Table 6: Torque-Controlled Tightening of the Pressure Screws
39
Fig. 21: Connecting the Speed Sensor
40
Fig. 22: Connecting the Compressor Cooling Air Intake
40
Fig. 23: Attaching the Support
40
Commissioning
41
Oil Supply
41
Fig. 24: Oil Orifice
42
Inspection Procedures
43
Commissioning after Taking out of Operation
45
Table 7: Lubricating Oil Pressure at Oil Inlet before Turbocharger
46
Oil Pressure, Oil Temperature
46
Monitoring Operation
46
Table 8: Lubricating Oil Temperature at the Inlet
47
Table 9: Maximum Lubricating Oil Temperature at the Outlet
47
Exhaust Gas Temperature before Turbine
48
Turbocharger Speed
49
Fig. 25: Layout and Overview of Speed Measurement System
49
Fig. 26: Replacing the Speed Sensor
51
Table 10: Tightening Torque (86505)
51
Operation and Service
52
Noise Emission
52
Fig. 27: Noise Insulation, Bellows
53
Service Work
54
Expected Replacement Intervals
57
Table 11: Expected Replacement Intervals
57
Stopping the Engine
59
Periodic Maintenance Work
60
Foreword to Maintenance
60
Table 12: Maintenance Table
60
Cleaning the Compressor During Operation
61
Fig. 28: Carrying out Wet Cleaning of Compressor
63
Table 13: Parameters for Wet Cleaning of Compressor
63
Cleaning the Turbine During Operation
64
Fig. 29: Turbine Cleaning Devices
66
Table 14: Turbine Wet Cleaning, Recommended Operating State
66
Fig. 30: Carrying out Wet Cleaning of Turbines
67
Table 15: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
67
Cleaning Components Mechanically
68
Table 16: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
68
Fig. 31: Cleaning the Filter Silencer
69
Fig. 32: Compressor-End, Non-Rotating Parts
71
Fig. 33: Turbine End, Non-Rotating Parts
73
Table 17: Value Table for Soaking
75
Fig. 34: Soaking the Turbine End
75
Fig. 35: Disassembling the Absorption Element
78
Changing the Absorption Element
78
Fig. 36: Installing the Absorption Element
79
Table 18: Tightening Torque (81152 / 81154)
79
Eliminating Malfunctions
80
Malfunctions When Starting
80
Table 19: Malfunctions When Starting - Delayed Start-Up
80
Table 20: Malfunctions When Starting - Vibrations
80
Table 21: Malfunctions When Starting - Rubbing of Rotating Parts
80
Table 24: Malfunctions During Operation - Speed Increases
81
Malfunctions During Operation
81
Table 23: Malfunctions During Operation - Speed Reduces
81
Table 22: Malfunctions During Operation - Lubricating Oil Pressure too Low
81
Table 25: Malfunctions During Operation - Exhaust Gas Temperature too High
82
Table 26: Malfunctions During Operation - Charge Air Pressure too Low
82
Table 27: Malfunctions During Operation - Charge Air Pressure too High
83
Table 28: Malfunctions During Operation - Engine Performance Losses
83
Turbocharger Is Surging
84
Table 29: Malfunction - Turbocharger Pumping
84
Table 30: Malfunction - Sporadic Surge Blows
84
Table 32: Malfunctions When Stopping - Runout Time too Short
85
Malfunctions When Stopping
85
Table 31: Malfunctions When Stopping - Runout Noises
85
Speed Measurement System
86
Table 33: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
86
Table 34: Malfunction of the Speed Measurement System - Measured Speed too High
86
Table 35: Malfunction of the Speed Measurement System - Measured Speed too Low
86
Dismantling and Fitting, General
87
Introduction
87
Table 36: Swivel Lifting Eyes
88
Fig. 37: Swivel Lifting Eyes
88
Material Required
88
Fig. 38: Press-Off Screws
89
Fig. 39: Dismantling Screw
89
Table 37: Press-Off Screws
89
Table 38: Dismantling Screw
89
Disassembly and Assembly Concepts
91
Fig. 40: Removing the Cartridge Group with Compressor and Turbine Casing
91
Fig. 41: Cartridge Concept
92
Fig. 42: Optional Spanner Holder
93
Table 39: Weights of Assemblies
94
Fig. 43: Weights of Assemblies
94
Weights of Individual Parts
94
Table of Tightening Torques
95
Fig. 44: Overview of Tightening Torques
95
Table 40: Tightening Torques
95
Fig. 45: Tightening Torques for Insulation
96
Table 41: Tightening Torques for Insulation
96
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
97
Removing Air Inlets
97
Fig. 46: Removing the Air Inlets
97
Fig. 47: Removing the Uncoupled Filter Silencer
98
Removing the Gas Outlet Casing
99
Fig. 48: Remove Gas Outlet Casing Without Support
99
Fig. 49: Removing Gas Outlet Casing with Support 1
100
Fig. 50: Removing Gas Outlet Casing with Support 1
101
Removing the Gas Outlet Flange
102
Fig. 51: Dismantling the Gas Outlet Flange
103
Table 42: 3 Press-Off Screws
103
Fig. 52: Removing the Gas Outlet Flange
104
Table 43: 6 Press-Off Screws
104
Fig. 54: Remove Insulation
105
Fig. 53: Turbine Cleaning Nozzle
105
Removing the Cartridge Group with Compressor and Turbine Casing
105
Fig. 55: Removing the Cartridge Group with Compressor and Turbine Casing
106
Fig. 56: Set down the Cartridge Group with the Compressor and Turbine Casing
106
Removing the Compressor Casing
107
Fig. 57: Removing the Compressor Casing
107
Fig. 58: Dismantling the Diffuser and the Wall Insert
108
ABB A155-M57 Operation Manual (196 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 33.64 MB
Table of Contents
Operation Manual / A150-M - A155-M
3
Table of Contents
3
Operation Manual / A150-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
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Definition of Safety Instructions
16
Definition of Mandatory Signs
16
Intended Use
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 7: Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Periodic Check of the Pressure Vessels
21
Fig. 10: Attachment Angle
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Lifting of Loads
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
Removing and Installing
31
Turbocharger Weight and Transportation
31
Fig. 11: Suspension of Complete Turbocharger Unit
31
Table 4: Weight of Complete Turbocharger Unit
31
Fig. 13: Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Removing the Turbocharger
32
Fig. 14: Loosening the Clamping Nut
33
Fig. 15: Turbocharger Centre of Gravity
34
Installing the Turbocharger
35
Fig. 16: Inserting the Gasket
35
Fig. 17: Fitting the Turbocharger 1
36
Fig. 18: Fitting the Turbocharger 2
37
Table 5: Fitting the Turbocharger, Value X, L
37
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
38
Fig. 20: Tightening Pressure Screws
39
Table 6: Torque-Controlled Tightening of the Pressure Screws
39
Fig. 21: Connecting the Speed Sensor
40
Fig. 22: Connecting the Compressor Cooling Air Intake
40
Fig. 23: Attaching the Support
40
Commissioning
41
Oil Supply
41
Fig. 24: Oil Orifice
42
Inspection Procedures
43
Commissioning after Taking out of Operation
45
Table 7: Lubricating Oil Pressure at Oil Inlet before Turbocharger
46
Oil Pressure, Oil Temperature
46
Monitoring Operation
46
Table 8: Lubricating Oil Temperature at the Inlet
47
Table 9: Maximum Lubricating Oil Temperature at the Outlet
47
Exhaust Gas Temperature before Turbine
48
Turbocharger Speed
49
Fig. 25: Layout and Overview of Speed Measurement System
49
Fig. 26: Replacing the Speed Sensor
51
Table 10: Tightening Torque (86505)
51
Operation and Service
52
Noise Emission
52
Fig. 27: Noise Insulation, Bellows
53
Service Work
54
Expected Replacement Intervals
57
Table 11: Expected Replacement Intervals
57
Stopping the Engine
59
Periodic Maintenance Work
60
Foreword to Maintenance
60
Table 12: Maintenance Table
60
Cleaning the Compressor During Operation
61
Fig. 28: Carrying out Wet Cleaning of Compressor
63
Table 13: Parameters for Wet Cleaning of Compressor
63
Cleaning the Turbine During Operation
64
Fig. 29: Turbine Cleaning Devices
66
Table 14: Turbine Wet Cleaning, Recommended Operating State
66
Fig. 30: Carrying out Wet Cleaning of Turbines
67
Table 15: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
67
Cleaning Components Mechanically
68
Table 16: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
68
Fig. 31: Cleaning the Filter Silencer
69
Fig. 32: Compressor-End, Non-Rotating Parts
71
Fig. 33: Turbine End, Non-Rotating Parts
73
Table 17: Value Table for Soaking
75
Fig. 34: Soaking the Turbine End
75
Fig. 35: Disassembling the Absorption Element
78
Changing the Absorption Element
78
Fig. 36: Installing the Absorption Element
79
Table 18: Tightening Torque (81152 / 81154)
79
Eliminating Malfunctions
80
Malfunctions When Starting
80
Table 19: Malfunctions When Starting - Delayed Start-Up
80
Table 20: Malfunctions When Starting - Vibrations
80
Table 21: Malfunctions When Starting - Rubbing of Rotating Parts
80
Table 24: Malfunctions During Operation - Speed Increases
81
Malfunctions During Operation
81
Table 23: Malfunctions During Operation - Speed Reduces
81
Table 22: Malfunctions During Operation - Lubricating Oil Pressure too Low
81
Table 25: Malfunctions During Operation - Exhaust Gas Temperature too High
82
Table 26: Malfunctions During Operation - Charge Air Pressure too Low
82
Table 27: Malfunctions During Operation - Charge Air Pressure too High
83
Table 28: Malfunctions During Operation - Engine Performance Losses
83
Turbocharger Is Surging
84
Table 29: Malfunction - Turbocharger Pumping
84
Table 30: Malfunction - Sporadic Surge Blows
84
Table 32: Malfunctions When Stopping - Runout Time too Short
85
Malfunctions When Stopping
85
Table 31: Malfunctions When Stopping - Runout Noises
85
Speed Measurement System
86
Table 33: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
86
Table 34: Malfunction of the Speed Measurement System - Measured Speed too High
86
Table 35: Malfunction of the Speed Measurement System - Measured Speed too Low
86
Dismantling and Fitting, General
87
Introduction
87
Table 36: Swivel Lifting Eyes
88
Fig. 37: Swivel Lifting Eyes
88
Material Required
88
Fig. 38: Press-Off Screws
89
Fig. 39: Dismantling Screw
89
Table 37: Press-Off Screws
89
Table 38: Dismantling Screw
89
Disassembly and Assembly Concepts
91
Fig. 40: Removing the Cartridge Group with Compressor and Turbine Casing
91
Fig. 41: Cartridge Concept
92
Fig. 42: Optional Spanner Holder
93
Table 39: Weights of Assemblies
94
Fig. 43: Weights of Assemblies
94
Weights of Individual Parts
94
Table of Tightening Torques
95
Fig. 44: Overview of Tightening Torques
95
Table 40: Tightening Torques
95
Fig. 45: Tightening Torques for Insulation
96
Table 41: Tightening Torques for Insulation
96
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
97
Removing Air Inlets
97
Fig. 46: Removing the Air Inlets
97
Fig. 47: Removing the Uncoupled Filter Silencer
98
Removing the Gas Outlet Casing
99
Fig. 48: Remove Gas Outlet Casing Without Support
99
Fig. 49: Removing Gas Outlet Casing with Support 1
100
Fig. 50: Removing Gas Outlet Casing with Support 1
101
Removing the Gas Outlet Flange
102
Fig. 51: Dismantling the Gas Outlet Flange
103
Table 42: 3 Press-Off Screws
103
Fig. 52: Removing the Gas Outlet Flange
104
Table 43: 6 Press-Off Screws
104
Fig. 54: Remove Insulation
105
Fig. 53: Turbine Cleaning Nozzle
105
Removing the Cartridge Group with Compressor and Turbine Casing
105
Fig. 55: Removing the Cartridge Group with Compressor and Turbine Casing
106
Fig. 56: Set down the Cartridge Group with the Compressor and Turbine Casing
106
Removing the Compressor Casing
107
Fig. 57: Removing the Compressor Casing
107
Fig. 58: Dismantling the Diffuser and the Wall Insert
108
ABB A155-M57 Operation Manual (196 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 33.64 MB
Table of Contents
Operation Manual / A150-M - A155-M
3
Table of Contents
3
Operation Manual / A150-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