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ABB A170-M66 manuals available for free PDF download: Operation Manual
ABB A170-M66 Operation Manual (150 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 23.53 MB
Table of Contents
Operation Manual / A170-M - A175-M
3
Table of Contents
3
Operation Manual / A170-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
Registered Trademarks
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function
8
Fig. 3: Connection of the Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Storage of New Turbochargers and Spare Parts
12
Fig. 5: Package with Hygrometer
13
Safety
14
Introduction
14
CE Conformity
14
Definition of Mandatory Signs
15
Definition of Safety Instructions
15
Table 2: Personal Protective Equipment to be Worn at All Times
15
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
15
Intended Use
16
Deflagration on Gas Engines
17
Periodic Check of the Pressure Vessels
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plates on the Turbocharger
18
Fig. 7: Rating Plate
19
Turbocharger Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Lifting of Loads
21
Fig. 9: Attachment of Loads on the Crane Hook
21
Fig. 10: Attachment Angle
21
Prerequisites for Operation and Maintenance
22
Hazards During Operation and Maintenance
23
Safe Operation
25
Safe Maintenance
26
Removal and Installation
30
Turbocharger Weight
30
Fig. 11: Turbocharger Suspension Points
30
Table 4: Weight of Complete Turbocharger Unit
30
Fig. 12: Turbocharger Suspension Points
31
Removing the Turbocharger
31
Fig. 13: Removing the Foot Mounting
32
Fig. 14: Loosening the Clamping Nut
33
Installing the Turbocharger
34
Fig. 15: Turbocharger Suspension Points
34
Fig. 16: Removing Auxiliary Screw
35
Fig. 17: Compressor-End Foot
35
Fig. 18: Turbine-End Foot
36
Table 5: Foot Screws, Dimension and Strength Class
36
Table 6: Foot Screws, Dimension CE
36
Table 7: Foot Screws, Dimension te
36
Table 8: Foot Screws, Number of Cup Springs
36
Fig. 19: CE Foot Contact Surface
37
Fig. 20: te Foot: Handling of Cup Spring Contact Surface / Foot Contact Surface
37
Fig. 21: Tightening the Foot Screws (1)
38
Fig. 22: Tightening Procedure
39
Table 9: Torque-Controlled Tightening of the Pressure Screws
39
Commissioning
40
Oil Supply
40
Inspection Procedures
41
Commissioning after Taking out of Operation
42
Monitoring During Operation
43
Oil Pressure, Oil Temperature
43
Fig. 23: Lubricating Oil Pressure Measuring Point
43
Table 10: Oil Pressure Range
43
Table 11: Oil Temperature at the Inlet
44
Table 12: Oil Temperature at the Outlet
44
Turbocharger Speed
45
Fig. 24: Speed Measurement
45
Noise Emission
48
Operation and Service
48
Fig. 25: Noise Insulation, Bellows
49
Service Work
50
Expected Replacement Intervals
53
Stopping the Engine
54
Table 13: Expected Replacement Intervals
54
Table 14: Recommended Replacement Intervals
54
Periodic Maintenance
55
Foreword to Maintenance
55
Cleaning the Filter Silencer
56
Fig. 26: Cleaning the Filter Silencer
56
Fig. 27: Cleaning the Filter Silencer (2)
58
Table 15: Tightening Torque (81272)
58
Table 16: Tightening Torque (81273)
58
Cleaning the Slotted Diffuser
59
Fig. 28: Cleaning the Slotted Diffuser
59
Cleaning the Compressor During Operation
60
Table 17: Compressor Cleaning Parameters
62
Fig. 29: Operation of Water Pressure Vessel
64
Table 18: Compressor Cleaning Parameters
65
Cleaning Turbine and Nozzle Ring
66
Fig. 30: Turbine and Nozzle Ring Cleaning Cycle
68
Fig. 31: Cleaning Cycle of Turbine and Nozzle Ring with Load Ramp
69
Fig. 32: Procedure Wet Cleaning of Turbine and Nozzle Ring
70
Table 19: Cleaning Parameters Wet Cleaning of Turbine and Nozzle Ring
71
Table 21: Malfunctions When Starting - Vibrations
72
Table 22: Malfunctions When Starting - Rubbing of Rotating Parts
72
Table 20: Malfunctions When Starting - Delayed Start-Up
72
Malfunctions When Starting
72
Troubleshooting
72
Malfunctions During Operation
73
Table 23: Malfunctions During Operation - Lubricating Oil Pressure too Low
73
Table 24: Malfunctions During Operation - Drop in Speed
73
Table 25: Malfunctions During Operation - Speed Increases
73
Table 26: Malfunctions During Operation - Exhaust Gas Temperature too High
74
Table 27: Malfunctions During Operation - Charge Air Pressure too Low
74
Surging of the Turbocharger
75
Table 28: Malfunctions During Operation - Charge Air Pressure too High
75
Table 29: Surging of the Turbocharger
75
Malfunctions When Stopping
76
Table 30: Malfunctions When Stopping - Runout Noises
76
Table 31: Malfunctions When Stopping - Shortened Runout Time
76
Table 34: Malfunction, Measured Speed too Low
77
Table 33: Malfunction, Measured Speed too High
77
Table 32: Malfunction, no Speed Measurement Signal or Poor Signal Amplitude
77
Speed Measurement System
77
Disassembly and Assembly
78
Introduction
78
Weight of Assemblies
80
Fig. 33: Weight of Assemblies
80
Table 35: Assembly Weights
80
Removing the Air Inlets
81
Fig. 34: Removing the Filter Silencer
81
Fig. 35: Removing the Air Suction Branch
82
Axial Clearance a Prior to Disassembly
83
Fig. 36: Axial Clearance
83
Table 36: Axial Clearance a
83
Fig. 37: Removing Wall Insert
84
Removing the Compressor Casing
84
Fig. 38: Transporting and Turning Wall Insert
85
Fig. 39: Removing the Diffuser
86
Fig. 40: Removing the Compressor Casing
87
Removing the Cartridge Group
88
Fig. 41: Safety-Relevant Screws
88
Fig. 42: Removing Cartridge Group 1
89
Fig. 43: Removing Cartridge Group 2
90
Removing the Nozzle Ring
91
Fig. 44: Removing Turbine Diffuser 1
91
Fig. 45: Removing Turbine Diffuser 2
92
Fig. 46: Removing Cover Ring 1
93
Fig. 47: Removing Cover Ring 2
94
Fig. 48: Removing Nozzle Ring 1
94
Fig. 49: Removing Nozzle Ring 2
95
Installing the Nozzle Ring
96
Fig. 50: Installing Nozzle Ring 1
96
Fig. 51: Installing Nozzle Ring 2
97
Table 37: Tightening Torque (56014)
97
Fig. 52: Installing Cover Ring
98
Table 38: Tightening Torque (57005)
98
Fig. 53: Installing Turbine Diffuser 1
99
Fig. 54: Installing Turbine Diffuser 2
100
Table 39: Tightening Torque (61069)
100
Installing the Cartridge Group
101
Fig. 55: Installing the Cartridge Group 1
101
Fig. 56: Installing the Cartridge Group 2
102
Fig. 57: Installing the Cartridge Group 3
102
Table 40: Tightening Torque (61059 / 42128)
102
Table 41: Tightening Torque (86505)
103
Fitting the Spinner Nose Cone
104
Fig. 58: Preparing the Threaded Stud (25008)
104
Table 42: Inner Thread Size (25008)
104
Fig. 59: Fitting the Spinner Nose Cone (25012)
105
Table 43: Tightening Torque (25013)
105
Installing the Compressor Casing
106
Fig. 60: Installing the Compressor Casing
106
Table 44: Tightening Torque (61037)
106
Table 45: Tightening Torque, Nuts that Are Difficult
106
Table 46: Tightening Torque (61090)
106
Fig. 61: Installing Diffuser
107
Table 47: Tightening Torque (77015)
107
Fig. 62: Turning and Moving in Wall Insert
108
Table 48: Tightening Torque (72011)
109
Fig. 63: Fitting Wall Insert
109
Axial Clearance a after Assembly
110
Fig. 64: Axial Clearance
110
Table 49: Axial Clearance a
110
Installing the Air Inlets
111
Fig. 65: Installing the Air Suction Branch
111
Table 50: Tightening Torque (72027)
111
Fig. 66: Installing the Filter Silencer
112
Table 51: Tightening Torque (72027)
112
Removing and Installing Turbine-End Nozzle Ring
114
Fig. 67: Removing the Nozzle Ring at the Turbine End (Radial Gas Inlet Casing)
115
Fig. 68: Removing the Nozzle Ring at the Turbine End (Axial Gas Inlet Casing)
115
Fig. 69: Installing the Nozzle Ring at the Turbine End (Radial Gas Inlet Casing)
116
Fig. 70: Installing the Nozzle Ring at the Turbine End (Axial Gas Inlet Casing)
116
Table 52: Tightening Torque (56014)
117
Table 53: Tightening Torque (61009)
117
Table of Tightening Torques
118
Fig. 71: Tightening Torques 1
118
Fig. 72: Tightening Torques 2
118
Table 54: Tightening Torques
119
Fig. 73: Flange Tightening Sequence
120
Table 55: Tightening Torques 61009
120
Taking a Turbocharger out of Operation
121
Possible Emergency Repairs
121
Locking the Rotor
122
Fig. 74: Fitting the Locking Device
123
Table 56: Locking Device Tightening Torque
123
Table 59: Cover Plate Dimensions 3
125
Table 58: Cover Plate Dimensions 2
125
Fig. 76: Fitting the Cover Plate
125
Table 57: Cover Plate Dimensions 1
125
Fig. 75: Cover Plate (01) / Spacer Sleeves (02) Dimensions
125
Fitting the Cover Plate
125
Blanking off the Inlets and Outlets
127
Engines with Bypass Around the Turbocharger
127
Mothballing the Turbocharger
128
Taking the Engine out of Operation for up to 12 Months
128
Taking the Engine out of Operation for more than 12 Months
129
Material and Disposal
130
REACH and Rohs Compliance Declaration for Products
130
Disposing of Turbocharger Components
131
Spare Parts
132
Ordering Spare Parts
132
Table 60: Customer Spare Part Set (97070)
133
Spare Part - Illustrations
134
Table 61: Spare Parts - Cartridge
134
Table 62: Spare Parts - Bearing Casing
135
Table 63: Spare Parts - Rotor and Bearing Parts
136
Table 64: Spare Parts - Water Vessel
137
Table 65: Spare Parts - Gas Inlet Casing Axial
138
Table 66: Spare Parts - Gas Inlet Casing Radial
139
Table 67: Spare Parts - Cleaning Device for Gas Inlet Casing
140
Table 68: Spare Parts - Compressor Casing
141
Table 69: Spare Parts - Filter Silencer
142
Table 70: Spare Parts - Air Suction Branch Radial
143
Tools
144
Table 71: Customer Tool Set 90009
144
Figures
146
Tables
148
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ABB A170-M66 Operation Manual (144 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 26.07 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
24
Product Description
31
Essential Information
33
Introduction
33
Registered Trademarks
33
Related Documents
33
Table 1: Related Documents
33
Fig. 1: Layout and Function
34
Layout and Function of the Turbocharger
34
Fig. 2: Connection of the Compressor Wheel Cooling
35
Fig. 3: Warning Plates on the Turbocharger
36
Warning Plates on the Turbocharger
36
Fig. 4: Locations of the Rating Plates
37
Locations of the Rating Plates
37
Fig. 5: Turbocharger Suspension Points
38
Removal and Installation
38
Table 2: Weight of Complete Turbocharger Unit
38
Turbocharger Weight
38
Fig. 6: Turbocharger Suspension Points
39
Removing the Turbocharger
39
Fig. 7: Removing the Foot Mounting
40
Fig. 8: Loosening the Clamping Nut
41
Fig. 9: Turbocharger Suspension Points
42
Installing the Turbocharger
42
Fig. 10: Removing Auxiliary Screw
43
Fig. 11: Compressor-End Foot
43
Fig. 12: Turbine-End Foot
44
Table 3: Foot Screws, Dimension and Strength Class
44
Table 4: Foot Screws, Dimension CE
44
Table 5: Foot Screws, Dimension te
44
Table 6: Foot Screws, Number of Cup Springs
44
Fig. 13: CE Foot Contact Surface
45
Fig. 14: te Foot: Handling of Cup Spring Contact Surface / Foot Contact Surface
45
Fig. 15: Tightening the Foot Screws (1)
46
Fig. 16: Tightening Procedure
47
Table 7: Torque-Controlled Tightening of the Pressure Screws
47
Commissioning
48
Oil Supply
48
Inspection Procedures
49
Commissioning after Taking out of Operation
50
Fig. 17: Lubricating Oil Pressure Measuring Point
51
Monitoring During Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Oil Pressure Range
51
Table 10: Oil Temperature at the Outlet
52
Table 9: Oil Temperature at the Inlet
52
Fig. 18: Speed Measurement
53
Turbocharger Speed
53
Noise Emission
56
Operation and Service
56
Fig. 19: Noise Insulation, Bellows
57
Service Work
58
Expected Replacement Intervals
61
Stopping the Engine
62
Table 11: Expected Replacement Intervals
62
Table 12: Recommended Replacement Intervals
62
Foreword to Maintenance
63
Periodic Maintenance
63
Cleaning the Filter Silencer
64
Fig. 20: Cleaning the Filter Silencer
64
Fig. 21: Cleaning the Filter Silencer (2)
66
Table 13: Tightening Torque (81272)
66
Table 14: Tightening Torque (81273)
66
Cleaning the Slotted Diffuser
67
Fig. 22: Cleaning the Slotted Diffuser
67
Cleaning the Compressor During Operation
68
Table 15: Compressor Cleaning Parameters
70
Fig. 23: Operation of Water Pressure Vessel
72
Table 16: Compressor Cleaning Parameters
73
Cleaning Turbine and Nozzle Ring
74
Fig. 24: Turbine and Nozzle Ring Cleaning Cycle
76
Fig. 25: Cleaning Cycle of Turbine and Nozzle Ring with Load Ramp
77
Fig. 26: Procedure Wet Cleaning of Turbine and Nozzle Ring
78
Table 17: Cleaning Parameters Wet Cleaning of Turbine and Nozzle Ring
79
Malfunctions When Starting
80
Table 18: Malfunctions When Starting - Delayed Start-Up
80
Table 19: Malfunctions When Starting - Vibrations
80
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
80
Troubleshooting
80
Malfunctions During Operation
81
Table 21: Malfunctions During Operation - Lubricating Oil Pressure too Low
81
Table 22: Malfunctions During Operation - Drop in Speed
81
Table 23: Malfunctions During Operation - Speed Increases
81
Table 24: Malfunctions During Operation - Exhaust Gas Temperature too High
82
Table 25: Malfunctions During Operation - Charge Air Pressure too Low
82
Surging of the Turbocharger
83
Table 26: Malfunctions During Operation - Charge Air Pressure too High
83
Table 27: Surging of the Turbocharger
83
Malfunctions When Stopping
84
Table 28: Malfunctions When Stopping - Runout Noises
84
Table 29: Malfunctions When Stopping - Shortened Runout Time
84
Speed Measurement System
85
Table 30: Malfunction, no Speed Measurement Signal or Poor Signal Amplitude
85
Table 31: Malfunction, Measured Speed too High
85
Table 32: Malfunction, Measured Speed too Low
85
Disassembly and Assembly
86
Introduction
86
Fig. 27: Weight of Assemblies
88
Table 33: Assembly Weights
88
Weight of Assemblies
88
Fig. 28: Removing the Filter Silencer
89
Removing the Air Inlets
89
Fig. 29: Removing the Air Suction Branch
90
Axial Clearance a Prior to Disassembly
91
Fig. 30: Axial Clearance
91
Table 34: Axial Clearance a
91
Fig. 31: Removing Wall Insert
92
Removing the Compressor Casing
92
Fig. 32: Transporting and Turning Wall Insert
93
Fig. 33: Removing the Diffuser
93
Fig. 34: Removing the Compressor Casing
94
Fig. 35: Safety-Relevant Screws
95
Removing the Cartridge Group
95
Fig. 36: Removing Cartridge Group 1
96
Fig. 37: Removing Cartridge Group 2
97
Fig. 38: Removing Turbine Diffuser 1
98
Fig. 39: Removing Turbine Diffuser 2
98
Removing the Nozzle Ring
98
Fig. 40: Removing Cover Ring 1
99
Fig. 41: Removing Cover Ring 2
100
Fig. 42: Removing Nozzle Ring 1
100
Fig. 43: Removing Nozzle Ring 2
101
Fig. 44: Installing Nozzle Ring 1
102
Installing the Nozzle Ring
102
Fig. 45: Installing Nozzle Ring 2
103
Table 35: Tightening Torque (56014)
103
Fig. 46: Installing Cover Ring
104
Table 36: Tightening Torque (57005)
104
Fig. 47: Installing Turbine Diffuser 1
105
Fig. 48: Installing Turbine Diffuser 2
106
Table 37: Tightening Torque (61069)
106
Fig. 49: Installing the Cartridge Group 1
107
Installing the Cartridge Group
107
Fig. 50: Installing the Cartridge Group 2
108
Table 38: Tightening Torque (61059 / 42128)
108
Fig. 51: Installing the Cartridge Group 3
109
Table 39: Tightening Torque (86505)
109
Fig. 52: Preparing the Threaded Stud (25008)
110
Fitting the Spinner Nose Cone
110
Table 40: Inner Thread Size (25008)
110
Fig. 53: Fitting the Spinner Nose Cone (25012)
111
Table 41: Tightening Torque (25013)
111
Fig. 54: Installing the Compressor Casing
112
Installing the Compressor Casing
112
Table 42: Tightening Torque (61037)
112
Table 43: Tightening Torque, Nuts that Are Difficult
112
Table 44: Tightening Torque (61090)
112
Fig. 55: Installing Diffuser
113
Table 45: Tightening Torque (77015)
113
Fig. 56: Turning and Moving in Wall Insert
114
Fig. 57: Fitting Wall Insert
115
Table 46: Tightening Torque (72011)
115
Axial Clearance a after Assembly
116
Fig. 58: Axial Clearance
116
Table 47: Axial Clearance a
116
Fig. 59: Installing the Air Suction Branch
117
Installing the Air Inlets
117
Table 48: Tightening Torque (72027)
117
Fig. 60: Installing the Filter Silencer
118
Table 49: Tightening Torque (72027)
118
Removing and Installing Turbine-End Nozzle Ring
119
Fig. 61: Removing the Nozzle Ring at the Turbine End (Radial Gas Inlet Casing)
120
Fig. 62: Removing the Nozzle Ring at the Turbine End (Axial Gas Inlet Casing)
120
Fig. 63: Installing the Nozzle Ring at the Turbine End (Radial Gas Inlet Casing)
121
Fig. 64: Installing the Nozzle Ring at the Turbine End (Axial Gas Inlet Casing)
121
Table 50: Tightening Torque (56014)
122
Table 51: Tightening Torque (61009)
122
Fig. 65: Tightening Torques 1
123
Fig. 66: Tightening Torques 2
123
Table of Tightening Torques
123
Table 52: Tightening Torques
124
Fig. 67: Flange Tightening Sequence
125
Table 53: Tightening Torques 61009
125
Possible Emergency Repairs
126
Taking a Turbocharger out of Operation
126
Locking the Rotor
127
Fig. 68: Fitting the Locking Device
128
Table 54: Locking Device Tightening Torque
128
Fig. 69: Cover Plate (01) / Spacer Sleeves (02) Dimensions
130
Fig. 70: Fitting the Cover Plate
130
Fitting the Cover Plate
130
Table 55: Cover Plate Dimensions 1
130
Table 56: Cover Plate Dimensions 2
130
Table 57: Cover Plate Dimensions 3
130
Blanking off the Inlets and Outlets
132
Engines with Bypass Around the Turbocharger
132
Mothballing the Turbocharger
133
Taking the Engine out of Operation for up to 12 Months
133
Taking the Engine out of Operation for more than 12 Months
134
Disposing of Turbocharger Components
135
Ordering Spare Parts
136
Spare Parts
136
Fig. 71: Turbocharger with Part Numbers
137
Table 58: Customer Spare Part Set (97070)
137
View of Turbocharger with Part Numbers
137
Tools
139
Figures
140
ABB A170-M66 Operation Manual (144 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 26.08 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
24
Product Description
31
Essential Information
33
Introduction
33
Registered Trademarks
33
Related Documents
33
Table 1: Related Documents
33
Fig. 1: Layout and Function
34
Layout and Function of the Turbocharger
34
Fig. 2: Connection of the Compressor Wheel Cooling
35
Fig. 3: Warning Plates on the Turbocharger
36
Warning Plates on the Turbocharger
36
Fig. 4: Locations of the Rating Plates
37
Locations of the Rating Plates
37
Fig. 5: Turbocharger Suspension Points
38
Removal and Installation
38
Table 2: Weight of Complete Turbocharger Unit
38
Turbocharger Weight
38
Fig. 6: Turbocharger Suspension Points
39
Removing the Turbocharger
39
Fig. 7: Removing the Foot Mounting
40
Fig. 8: Loosening the Clamping Nut
41
Fig. 9: Turbocharger Suspension Points
42
Installing the Turbocharger
42
Fig. 10: Removing Auxiliary Screw
43
Fig. 11: Compressor-End Foot
43
Fig. 12: Turbine-End Foot
44
Table 3: Foot Screws, Dimension and Strength Class
44
Table 4: Foot Screws, Dimension CE
44
Table 5: Foot Screws, Dimension te
44
Table 6: Foot Screws, Number of Cup Springs
44
Fig. 13: CE Foot Contact Surface
45
Fig. 14: te Foot: Handling of Cup Spring Contact Surface / Foot Contact Surface
45
Fig. 15: Tightening the Foot Screws (1)
46
Fig. 16: Tightening Procedure
47
Table 7: Torque-Controlled Tightening of the Pressure Screws
47
Commissioning
48
Oil Supply
48
Inspection Procedures
49
Commissioning after Taking out of Operation
50
Fig. 17: Lubricating Oil Pressure Measuring Point
51
Monitoring During Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Oil Pressure Range
51
Table 10: Oil Temperature at the Outlet
52
Table 9: Oil Temperature at the Inlet
52
Fig. 18: Speed Measurement
53
Turbocharger Speed
53
Noise Emission
56
Operation and Service
56
Fig. 19: Noise Insulation, Bellows
57
Service Work
58
Expected Replacement Intervals
61
Stopping the Engine
62
Table 11: Expected Replacement Intervals
62
Table 12: Recommended Replacement Intervals
62
Foreword to Maintenance
63
Periodic Maintenance
63
Cleaning the Filter Silencer
64
Fig. 20: Cleaning the Filter Silencer
64
Fig. 21: Cleaning the Filter Silencer (2)
66
Table 13: Tightening Torque (81272)
66
Table 14: Tightening Torque (81273)
66
Cleaning the Slotted Diffuser
67
Fig. 22: Cleaning the Slotted Diffuser
67
Cleaning the Compressor During Operation
68
Table 15: Compressor Cleaning Parameters
70
Fig. 23: Operation of Water Pressure Vessel
72
Table 16: Compressor Cleaning Parameters
73
Cleaning Turbine and Nozzle Ring
74
Fig. 24: Turbine and Nozzle Ring Cleaning Cycle
76
Fig. 25: Cleaning Cycle of Turbine and Nozzle Ring with Load Ramp
77
Fig. 26: Procedure Wet Cleaning of Turbine and Nozzle Ring
78
Table 17: Cleaning Parameters Wet Cleaning of Turbine and Nozzle Ring
79
Malfunctions When Starting
80
Table 18: Malfunctions When Starting - Delayed Start-Up
80
Table 19: Malfunctions When Starting - Vibrations
80
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
80
Troubleshooting
80
Malfunctions During Operation
81
Table 21: Malfunctions During Operation - Lubricating Oil Pressure too Low
81
Table 22: Malfunctions During Operation - Drop in Speed
81
Table 23: Malfunctions During Operation - Speed Increases
81
Table 24: Malfunctions During Operation - Exhaust Gas Temperature too High
82
Table 25: Malfunctions During Operation - Charge Air Pressure too Low
82
Surging of the Turbocharger
83
Table 26: Malfunctions During Operation - Charge Air Pressure too High
83
Table 27: Surging of the Turbocharger
83
Malfunctions When Stopping
84
Table 28: Malfunctions When Stopping - Runout Noises
84
Table 29: Malfunctions When Stopping - Shortened Runout Time
84
Speed Measurement System
85
Table 30: Malfunction, no Speed Measurement Signal or Poor Signal Amplitude
85
Table 31: Malfunction, Measured Speed too High
85
Table 32: Malfunction, Measured Speed too Low
85
Disassembly and Assembly
86
Introduction
86
Fig. 27: Weight of Assemblies
88
Table 33: Assembly Weights
88
Weight of Assemblies
88
Fig. 28: Removing the Filter Silencer
89
Removing the Air Inlets
89
Fig. 29: Removing the Air Suction Branch
90
Axial Clearance a Prior to Disassembly
91
Fig. 30: Axial Clearance
91
Table 34: Axial Clearance a
91
Fig. 31: Removing Wall Insert
92
Removing the Compressor Casing
92
Fig. 32: Transporting and Turning Wall Insert
93
Fig. 33: Removing the Diffuser
93
Fig. 34: Removing the Compressor Casing
94
Fig. 35: Safety-Relevant Screws
95
Removing the Cartridge Group
95
Fig. 36: Removing Cartridge Group 1
96
Fig. 37: Removing Cartridge Group 2
97
Fig. 38: Removing Turbine Diffuser 1
98
Fig. 39: Removing Turbine Diffuser 2
98
Removing the Nozzle Ring
98
Fig. 40: Removing Cover Ring 1
99
Fig. 41: Removing Cover Ring 2
100
Fig. 42: Removing Nozzle Ring 1
100
Fig. 43: Removing Nozzle Ring 2
101
Fig. 44: Installing Nozzle Ring 1
102
Installing the Nozzle Ring
102
Fig. 45: Installing Nozzle Ring 2
103
Table 35: Tightening Torque (56014)
103
Fig. 46: Installing Cover Ring
104
Table 36: Tightening Torque (57005)
104
Fig. 47: Installing Turbine Diffuser 1
105
Fig. 48: Installing Turbine Diffuser 2
106
Table 37: Tightening Torque (61069)
106
Fig. 49: Installing the Cartridge Group 1
107
Installing the Cartridge Group
107
Fig. 50: Installing the Cartridge Group 2
108
Table 38: Tightening Torque (61059 / 42128)
108
Fig. 51: Installing the Cartridge Group 3
109
Table 39: Tightening Torque (86505)
109
Fig. 52: Preparing the Threaded Stud (25008)
110
Fitting the Spinner Nose Cone
110
Table 40: Inner Thread Size (25008)
110
Fig. 53: Fitting the Spinner Nose Cone (25012)
111
Table 41: Tightening Torque (25013)
111
Fig. 54: Installing the Compressor Casing
112
Installing the Compressor Casing
112
Table 42: Tightening Torque (61037)
112
Table 43: Tightening Torque, Nuts that Are Difficult
112
Table 44: Tightening Torque (61090)
112
Fig. 55: Installing Diffuser
113
Table 45: Tightening Torque (77015)
113
Fig. 56: Turning and Moving in Wall Insert
114
Fig. 57: Fitting Wall Insert
115
Table 46: Tightening Torque (72011)
115
Axial Clearance a after Assembly
116
Fig. 58: Axial Clearance
116
Table 47: Axial Clearance a
116
Fig. 59: Installing the Air Suction Branch
117
Installing the Air Inlets
117
Table 48: Tightening Torque (72027)
117
Fig. 60: Installing the Filter Silencer
118
Table 49: Tightening Torque (72027)
118
Removing and Installing Turbine-End Nozzle Ring
119
Fig. 61: Removing the Nozzle Ring at the Turbine End (Radial Gas Inlet Casing)
120
Fig. 62: Removing the Nozzle Ring at the Turbine End (Axial Gas Inlet Casing)
120
Fig. 63: Installing the Nozzle Ring at the Turbine End (Radial Gas Inlet Casing)
121
Fig. 64: Installing the Nozzle Ring at the Turbine End (Axial Gas Inlet Casing)
121
Table 50: Tightening Torque (56014)
122
Table 51: Tightening Torque (61009)
122
Fig. 65: Tightening Torques 1
123
Fig. 66: Tightening Torques 2
123
Table of Tightening Torques
123
Table 52: Tightening Torques
124
Fig. 67: Flange Tightening Sequence
125
Table 53: Tightening Torques 61009
125
Possible Emergency Repairs
126
Taking a Turbocharger out of Operation
126
Locking the Rotor
127
Fig. 68: Fitting the Locking Device
128
Table 54: Locking Device Tightening Torque
128
Fig. 69: Cover Plate (01) / Spacer Sleeves (02) Dimensions
130
Fig. 70: Fitting the Cover Plate
130
Fitting the Cover Plate
130
Table 55: Cover Plate Dimensions 1
130
Table 56: Cover Plate Dimensions 2
130
Table 57: Cover Plate Dimensions 3
130
Blanking off the Inlets and Outlets
132
Engines with Bypass Around the Turbocharger
132
Mothballing the Turbocharger
133
Taking the Engine out of Operation for up to 12 Months
133
Taking the Engine out of Operation for more than 12 Months
134
Disposing of Turbocharger Components
135
Ordering Spare Parts
136
Spare Parts
136
Fig. 71: Turbocharger with Part Numbers
137
Table 58: Customer Spare Part Set (97070)
137
View of Turbocharger with Part Numbers
137
Tools
139
Figures
140
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ABB A170-M66 Operation Manual (144 pages)
Brand:
ABB
| Category:
Engine
| Size: 19.78 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
25
Product Description
31
Table 14 Malfunctions When Starting
31
Table 20 Malfunctions During Operation
32
Table 23 Surging of the Turbocharger
32
Table 24 Malfunctions When Stopping
32
Table 32 Axial Clearance
32
1 Introduction
33
Essential Information
33
Registered Trademarks
33
Related Documents
33
Table 1 Related Documents
33
Layout and Function of the Turbocharger
34
Warning Plates on the Turbocharger
36
Locations of the Rating Plates
37
2 Removal and Installation
39
Turbocharger Weight
39
Table 2 Weight of the Turbocharger
39
Removing the Turbocharger
40
Installing the Turbocharger
43
Table 3 Foot Bolt Dimensions
45
Table 4 Clamping Screw Tightening Torques
48
3 Commissioning
49
Oil Supply
49
Inspection Procedures
50
Commissioning after Taking out of Operation
51
4 Monitoring During Operation
53
Oil Pressure, Oil Temperature
53
Table 5 Oil Pressure Range
53
Table 6 Oil Temperature at the Inlet
54
Table 7 Oil Temperature at the Outlet
54
Turbocharger Speed
55
5 Operation and Service
59
Noise Emission
59
Service Work
61
Expected Replacement Intervals
64
Stopping the Engine
65
Table 8: Expected Replacement Intervals
65
Table 9 Recommended Replacement Intervals
65
6 Periodic Maintenance
67
Foreword to Maintenance
67
Cleaning the Filter Silencer
68
Cleaning the Slotted Diffuser
71
Cleaning the Compressor During Operation
72
Table 12: Compressor Cleaning Parameters
74
Cleaning Turbine and Nozzle Ring
76
Table 13 Cleaning Parameters Wet
79
7 Troubleshooting
81
Malfunctions When Starting
81
Table 15 Malfunctions When Starting
81
Table 16 Malfunctions When Starting - Rubbing of Rotating Parts
81
Malfunctions During Operation
82
Table 17 Malfunctions During Operation - Lubricating Oil Pressure too Low
82
Table 18 Malfunctions During Operation - Speed Reductions
82
Table 19 Malfunctions During Operation - Speed Increases
82
Table 21 Malfunctions During Operation - Charge Air Pressure too Low
83
Surging of the Turbocharger
84
Table 22 Malfunctions During Operation
84
Malfunctions When Stopping
85
Table 25 Malfunctions When Stopping
85
Speed Measurement System
86
Table 26 Malfunction, no Speed Meas
86
Table 27 Malfunction, Measured Speed too High
86
Table 28 Malfunction, Measured Speed too Low
86
8 Disassembly and Assembly
87
Introduction
87
Weights of Assemblies
89
Table 29 Assembly Weights
89
Removing / Installing Air-Inlets
90
Table 30 Tightening Torque (27027)
90
Table 31 Tightening Torque (27027)
91
Axial Clearance a Prior to Disassembly
92
Removing the Compressor Casing
93
Removing the Cartridge Group
97
Removing Nozzle Ring
100
Installing Nozzle Ring
103
Table 33 Tightening Torque (56014)
104
Table 34 Tightening Torque (57005)
105
Table 35 Tightening Torque (61069)
106
Installing the Cartridge Group
107
Table 36 Tightening Torque (61059 / 42128 / 86505 / 25013)
108
Installing the Compressor Casing
110
Table 37 Tightening Torque
110
Table 38 Tightening Torque (77015)
111
Table 39 Tightening Torque (72011)
113
Axial Clearance a after Assembly
114
Table 40 Axial Clearance
114
Removing and Installing Turbine-End Nozzle Ring
115
Table 41 Tightening Torque
117
Table of Tightening Torques
120
Table 42 Tightening Torques
121
Table 43 Tightening Torques 61009
122
9 Taking a Turbocharger out of Operation
123
Possible Emergency Repairs
123
Locking the Rotor
124
Table 44 Locking Device Tightening
125
Fitting the Cover Plate
127
Table 45 Cover Plate Dimensions 1
127
Table 46 Cover Plate Dimensions 2
127
Table 47 Cover Plate Dimensions 3
127
Blanking off the Inlets and Outlets
129
Engines with Bypass Around the Turbocharger
129
10 Mothballing the Turbocharger
131
Taking the Engine out of Operation for up to 12 Months
131
Taking the Engine out of Operation for more than 12 Months
132
11 Disposing of Turbocharger Components
133
12 Spare Parts
135
Ordering Spare Parts
135
Table 48 Customer Spare Part Set
136
View of Turbocharger with Part Numbers
138
Table 49 Turbocharger with Part Num
139
Figures
141
Tables/Table 10 Tightening Torque (81272)
143
Table 10 Tightening Torque (81272)
143
Table 11 Tightening Torque (81273)
143
Tables
143
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