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HT580635
User Manuals: ABB HT580635 Industrial Equipment
Manuals and User Guides for ABB HT580635 Industrial Equipment. We have
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ABB HT580635 Industrial Equipment manual available for free PDF download: Operation Manual
ABB HT580635 Operation Manual (192 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 30 MB
Table of Contents
Introduction
3
Table of Contents
3
Purpose of the Manual
4
Symbols, Definitions
5
Storage of New Turbochargers and Spare Parts
7
Contact Information
9
Safety
11
CE Conformity
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
Introduction
32
Essential Information
34
Introduction
34
Registered Trademarks
34
Related Documents
35
Table 1: Related Documents
35
Fig. 1: Layout and Function of the Turbocharger
36
Layout and Function of the Turbocharger
36
Fig. 2: Compressor Wheel Cooling
37
Fig. 3: Warning Plate Locations
38
Warning Plates on the Turbocharger
38
Fig. 4: Locations of the Rating Plates
39
Locations of the Rating Plates
39
Fig. 5: Suspension of Complete Turbocharger Unit
40
Removing and Installing
40
Table 2: Weights of Turbocharger A150-M
40
Turbocharger Weight and Transportation
40
Fig. 6: Turbine Cleaning Nozzle
41
Fig. 7: Removing the Turbocharger
41
Removing the Turbocharger
41
Fig. 8: Loosening the Clamping Nut
42
Fig. 9: Turbocharger Centre of Gravity
43
Fig. 10: Inserting the Gasket
44
Installing the Turbocharger
44
Fig. 11: Fitting the Turbocharger 1
45
Fig. 12: Fitting the Turbocharger 2
46
Table 3: Fitting the Turbocharger, Dimensions X, L
46
Fig. 13: Preparing the Clamping Nut for the Tightening Procedure
47
Fig. 14: Tightening Pressure Screws
48
Table 4: Pressure Screw Tightening Torques
48
Fig. 15: Connecting the Speed Sensor
49
Fig. 16: Connecting the Compressor Cooling Air Intake
49
Fig. 17: Attaching the Support
49
Commissioning
50
Oil Supply
50
Fig. 18: Oil Orifice
51
Inspection Procedures
52
Commissioning after Taking out of Operation
54
Monitoring Operation
55
Oil Pressure, Oil Temperature
55
Table 5: Lubricating Oil Pressure at Oil Inlet before Turbocharger
55
Table 6: Lubricating Oil Temperature at the Inlet
56
Exhaust Gas Temperature before Turbine
57
Table 7: Maximum Lubricating Oil Temperature at the Outlet
57
Fig. 19: Layout and Overview of Speed Measurement System
58
Turbocharger Speed
58
Fig. 20: Replacing the Speed Sensor
60
Table 8: Tightening Torque (86505)
60
Noise Emission
61
Operation and Service
61
Fig. 21: Noise Insulation, Bellows
62
Service Work
63
Expected Replacement Intervals
66
Table 9: Expected Replacement Intervals
66
Stopping the Engine
68
Foreword to Maintenance
69
Periodic Maintenance Work
69
Table 10: Maintenance Table
69
Cleaning the Compressor During Operation
70
Fig. 22: Carrying out Wet Cleaning of Compressor
72
Table 11: Parameters for Wet Cleaning of Compressor
72
Cleaning the Turbine During Operation
73
Fig. 23: Turbine Cleaning Devices
75
Table 12: Turbine Wet Cleaning, Recommended Operating State
75
Fig. 24: Carrying out Wet Cleaning of Turbines
76
Table 13: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
76
Cleaning Components Mechanically
77
Table 14: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
77
Fig. 25: Cleaning the Filter Silencer
78
Fig. 26: Compressor-End, Non-Rotating Parts
80
Fig. 27: Turbine End, Non-Rotating Parts
82
Fig. 28: Soaking the Turbine End
84
Table 15: Value Table for Soaking
84
Eliminating Malfunctions
87
Malfunctions When Starting
87
Table 16: Malfunctions When Starting - Delayed Start-Up
87
Table 17: Malfunctions When Starting - Vibrations
87
Table 18: Malfunctions When Starting - Rubbing of Rotating Parts
87
Malfunctions During Operation
88
Table 19: Malfunctions During Operation - Lubricating Oil Pressure too Low
88
Table 20: Malfunctions During Operation - Speed Reduces
88
Table 21: Malfunctions During Operation - Speed Increases
88
Table 22: Malfunctions During Operation - Exhaust Gas Temperature too High
89
Table 23: Malfunctions During Operation - Charge Air Pressure too Low
89
Table 24: Malfunctions During Operation - Charge Air Pressure too High
90
Table 25: Malfunctions During Operation - Engine Performance Losses
90
Table 26: Malfunction - Turbocharger Pumping
91
Table 27: Malfunction - Sporadic Surge Blows
91
Turbocharger Is Surging
91
Malfunctions When Stopping
92
Table 28: Malfunctions When Stopping - Runout Noises
92
Table 29: Malfunctions When Stopping - Runout Time too Short
92
Speed Measurement System
93
Table 30: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
93
Table 31: Malfunction of the Speed Measurement System - Measured Speed too High
93
Table 32: Malfunction of the Speed Measurement System - Measured Speed too Low
93
Dismantling and Fitting, General
94
Introduction
94
Table 33: Swivel Lifting Eyes
96
Table 34: Press-Off Screws
97
Table 35: Dismantling Screw
97
Disassembly and Assembly Concepts
98
Fig. 29: Removing the Cartridge Group with Compressor and Turbine Casing
98
Fig. 30: Cartridge Concept
99
Fig. 31: Optional Spanner Holder
100
Fig. 32: Weights of Assemblies
101
Table 36: Weights of Assemblies
101
Weights of Individual Parts
101
Fig. 33: Overview of Tightening Torques
102
Table 37: Tightening Torques
102
Table of Tightening Torques
102
Fig. 34: Tightening Torques for Insulation
103
Table 38: Tightening Torques for Insulation
103
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
104
Fig. 35: Removing the Air Inlets
104
Removing Air Inlets
104
Fig. 36: Remove Gas Outlet Casing Without Support
105
Removing the Gas Outlet Casing
105
Fig. 37: Removing Gas Outlet Casing with Support 1
106
Fig. 38: Removing Gas Outlet Casing with Support 1
107
Removing the Gas Outlet Flange
108
Fig. 39: Dismantling the Gas Outlet Flange
109
Table 39: 3 Press-Off Screws
109
Fig. 40: Removing the Gas Outlet Flange
110
Table 40: Press-Off Screws - Gas Outlet Flange
110
Fig. 41: Turbine Cleaning Nozzle
111
Fig. 42: Remove Insulation
111
Removing the Cartridge Group with Compressor and Turbine Casing
111
Fig. 43: Removing the Cartridge Group with Compressor and Turbine Casing
112
Fig. 44: Set down the Cartridge Group with the Compressor and Turbine Casing
112
Fig. 45: Removing the Compressor Casing
113
Removing the Compressor Casing
113
Fig. 46: Dismantling the Diffuser and the Wall Insert
114
Fig. 47: Removing Cartridge Group 1
115
Removing the Cartridge Group
115
Table 41: Tightening Torque (90012-01)
115
Fig. 48: Removing Cartridge Group 2
116
Fig. 49: Remove Cartridge Group 3
117
Fig. 50: Installing the Cartridge Group on the Service Support
118
Installing the Cartridge Group on the Service Support
118
Fig. 51: Removing the Nozzle Ring
119
Removing the Nozzle Ring
119
Axial Clearance a and Radial Clearance B
120
Fig. 52: Measuring Clearance a and B
120
Table 42: Permissible Clearances a and B
120
Fig. 53: Nozzle Ring Compression PD
121
Nozzle Ring Compression PD
121
Table 43: Permitted Nozzle Ring Compression PD
121
Fig. 54: Installing the Nozzle Ring
122
Installing Nozzle Ring
122
Fig. 55: Lifting the Cartridge Group and Rotating It
123
Fig. 57: Installing the Cartridge Group
123
Installing the Cartridge Group
123
Fig. 56: Turning the Cartridge Group
124
Table 44: Tightening Torque (90012-01)
124
Table 45: Tightening Torque (51007)
125
Fig. 58: Fitting the Wall Insert and the Diffuser
126
Installing the Compressor Casing
126
Table 46: Tightening Torque (79041)
126
Fig. 59: Installing the Compressor Casing
127
Table 47: Tightening Torque (72011)
127
Fig. 60: Turning the Cartridge Group with Compressor and Turbine Casing
128
Turning the Cartridge Group with Compressor and Turbine Casing
128
Fig. 61: Installing the Gas Outlet Flange
129
Installing the Gas Outlet Flange
129
Fig. 62: Measuring Clearances N and R
130
Radial Clearances N and R
130
Table 48: Permissible Clearances N and R
130
Fig. 63: Fitting the Insulation
131
Fitting the Insulation
131
Fig. 64: Installing the Cartridge Group with Compressor and Turbine Casing
132
Fig. 65: Installing the Cartridge Group with Compressor and Turbine Casing
132
Installing the Cartridge Group with Compressor and Turbine Casing
132
Fig. 66: Fit Gas Outlet Casing Without Support
133
Installing the Gas Outlet Casing
133
Table 49: Tightening Torque (51009)
133
Fig. 67: Fitting Gas Outlet Casing with Support 1
134
Table 50: Tightening Torque (51009)
134
Fig. 68: Fitting Gas Outlet Casing with Support 2
135
Fig. 69: Installing the Air Inlets
136
Installing Air Inlets
136
Table 51: Tightening Torque (72051)
136
Dismantling and Fitting, Cartridge Concept
137
Fig. 70: Removing the Air Inlets
137
Removing Air Inlets
137
Fig. 71: Removing the Compressor Casing
138
Removing the Compressor Casing
138
Fig. 72: Pressing off Compressor Casing
139
Fig. 73: Remove the Diffuser
139
Fig. 74: Dismantling the Diffuser and the Wall Insert
140
Fig. 75: Removing Insulation Sheets
141
Removing the Cartridge Group
141
Fig. 76: Removing Cartridge Group 1
142
Table 52: Threaded Rod, Dimension X
142
Fig. 77: Removing Cartridge Group 2
143
Fig. 78: Removing Cartridge Group 2
144
Fig. 79: S_05180
145
Removing the Nozzle Ring
145
Axial Clearance a and Radial Clearance B
146
Fig. 80: Measuring Clearance a and B
146
Table 53: Permissible Clearances a and B
146
Fig. 81: Nozzle Ring Compression PD
147
Nozzle Ring Compression PD
147
Table 54: Permitted Nozzle Ring Compression PD
147
Fig. 82: Installing the Nozzle Ring
148
Installing Nozzle Ring
148
Fig. 83: Installing the Cartridge Group 1
149
Installing the Cartridge Group
149
Fig. 84: Installing the Cartridge Group 2
150
Table 55: Fitting the Turbocharger, Dimensions X,L
150
Table 56: Tightening Torque (51007)
150
Fig. 85: Fitting the Wall Insert and the Diffuser
151
Installing the Compressor Casing
151
Table 57: Tightening Torque (79041)
151
Fig. 86: Installing the Compressor Casing
152
Table 58: Tightening Torque (72011)
152
Fig. 87: Measuring Clearances N and R
153
Radial Clearances N and R
153
Table 59: Permissible Clearances N and R
153
Fig. 88: Fitting the Insulation
154
Fitting the Insulation
154
Fig. 89: Installing the Air Inlets
155
Installing Air Inlets
155
Table 60: Tightening Torque (72051)
155
Dismantling and Fitting, Special Tools for Fastening Strips
156
Application, Special Tools
157
Fig. 90: Special Tools
157
Fig. 91: Client Tool
157
Table 61: Special Tools (90160)
157
Table 62: Client Tool
157
Fig. 92: Special Tools
158
Fig. 93: Client Tool
158
Table 63: Special Tools (90160)
158
Table 64: Client Tool
158
Fig. 94: Positioning the Collection Tub
159
Fig. 95: Removing the Fastening Strips
159
Fig. 96: Fitting the Upper Fastening Strips
160
Fig. 97: Fitting the Bottom Fastening Strip
160
Table 65: Tightening Torque (51007)
160
Fig. 98: Fitting the Bottom Fastening Strip
161
Table 66: Tightening Torque (51007) with Spanner Holder
161
Fig. 99: Fitting the Cartridge Group
162
Table 67: Tightening Torque (51007)
162
Fig. 100: Positioning the Fastening Strip
163
Fig. 101: Clamping Device
164
Fig. 102: Attach Nut
165
Table 68: Tightening Torque (51007) with Spanner Holder
165
Disassembly
166
Fig. 103: Initial Situation
166
Fig. 104: Disassembly of the Elbows
166
Removing and Installing 6-Nozzle Turbine Cleaning Component (Optional)
166
Fig. 105: Disassembly of the Elbows
167
Fig. 106: Pipe Disassembly
167
Fig. 107: Disassembly of the Connecting Pieces
168
Fig. 108: Disassembly of the Cleaning Nozzle
168
Table 69: Dismantling Screw
168
Assembly
169
Fig. 109: Assembly of the Cleaning Nozzle
169
Fig. 110: Assembly of the Connecting Pieces
169
Table 70: Dismantling Screw
169
Fig. 111: Pipe Assembly
170
Fig. 112: Assembly of Elbows 1
170
Fig. 113: Assembly of Elbows 2
171
Table 71: Tightening Torque (51314, 51316)
171
Fig. 114: Fit the Cleaning Nozzles
172
Fitting the Cleaning Nozzles with Multi-Inlet Turbine Casings
172
Possible Emergency Repairs
173
Taking out of Operation at Short Notice
173
Fitting the Cover Plate
174
Installing the Replacement Cartridge Group
174
Installing the Replacement Turbocharger
174
Fig. 115: Fitting the Cover Plate
175
Cover Plate Drawing
176
Fig. 116: Cover Plate Drawing
176
Table 72: Cover Plate Dimensions [MM]
176
Fig. 117: Dimensions for Cover Plate
177
Table 73: Cover Plate Dimensions [MM]
177
Mothballing the Turbocharger
178
Taking the Engine out of Operation for up to 12 Months
178
Taking the Engine out of Operation for more than 12 Months
179
Disposing of Turbocharger Components
180
Ordering Spare Parts
181
Required Customer Spare Part Set (97070)
181
Spare Parts
181
Table 74: Customer Spare Part Set 97070
181
Required Customer Spare Part Set (97151) for 6-Nozzle Turbine Cleaning
182
Table 75: Customer Spare Part Set (97151) for the Optional 6-Nozzle Turbine Cleaning Component
182
Fig. 118: Overview of Part Numbers
184
View of Turbocharger with Part Numbers
184
Table 76: Spare Parts List
185
Fig. 119: Overview of Part Numbers
186
Table 77: Spare Parts List
186
View of Turbine Cleaning Device
186
Fig. 120: Overview of Part Numbers
187
Table 78: Spare Parts List
187
Figures
188
Tables
190
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