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ABB HT613686 manual available for free PDF download: Operation Manual
ABB HT613686 Operation Manual (184 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 31.04 MB
Table of Contents
Operation Manual / A150-M58/68
3
Table of Contents
3
Fig. 1: Serial Number (01) on the Rating Plate
6
Introduction
6
Purpose of the Manual
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
Definition of Mandatory Signs
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Definition of Safety Instructions
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
Lifting of Loads
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Fig. 10: Attachment Angle
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
Table 4: Weight of Complete Turbocharger Unit
31
Turbocharger Weight and Transportation
31
Fig. 11: Suspension of Complete Turbocharger Unit
31
Removing and Installing
31
Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Fig. 13: Removing the Turbocharger
33
Fig. 14: Loosening the Clamping Nut
34
Fig. 15: Turbocharger Centre of Gravity
35
Fig. 16: Inserting the Gasket
36
Installing the Turbocharger
36
Fig. 17: Inserting the Threaded Rods
37
Fig. 18: Placing the Turbocharger on the Bracket
37
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
38
Fig. 20: Tightening Pressure Screws
39
Table 5: 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
Oil Supply
41
Commissioning
41
Fig. 24: Oil Orifice
42
Inspection Procedures
43
Commissioning after Taking out of Operation
45
Monitoring Operation
46
Oil Pressure, Oil Temperature
46
Table 6: Lubricating Oil Pressure at Oil Inlet before Turbocharger
46
Table 7: Lubricating Oil Temperature at the Inlet
47
Table 8: 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 9: Tightening Torque (86505)
51
Operation and Service
52
Noise Emission
52
Fig. 27: Noise Insulation, Bellows
53
Service Work
54
Table 10: Expected Replacement Intervals
57
Expected Replacement Intervals
57
Stopping the Engine
59
Periodic Maintenance Work
60
Foreword to Maintenance
60
Table 11: Maintenance Table
60
Cleaning the Compressor During Operation
61
Fig. 28: Carrying out Wet Cleaning of Compressor
63
Table 12: Parameters for Wet Cleaning of Compressor
63
Cleaning the Turbine During Operation
64
Table 13: Turbine Wet Cleaning, Recommended Operating State
66
Fig. 29: Turbine Cleaning Devices
66
Fig. 30: Carrying out Wet Cleaning of Turbine
67
Table 14: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
67
Cleaning Components Mechanically
68
Table 15: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
68
Fig. 31: Cleaning the Filter Silencer
69
Fig. 32: Compressor Casing
71
Fig. 33: Diffuser
72
Fig. 34: Turbine End, Non-Rotating Parts
73
Table 16: Value Table for Soaking
76
Fig. 35: Soaking the Turbine End
76
Malfunctions When Starting
79
Table 17: Malfunctions When Starting - Delayed Start-Up
79
Table 18: Malfunctions When Starting - Vibrations
79
Table 19: Malfunctions When Starting - Rubbing of Rotating Parts
79
Eliminating Malfunctions
79
Table 21: Malfunctions During Operation - Speed Reduces
80
Table 22: Malfunctions During Operation - Speed Increases
80
Table 20: Malfunctions During Operation - Lubricating Oil Pressure too Low
80
Malfunctions During Operation
80
Table 23: Malfunctions During Operation - Exhaust Gas Temperature too High
81
Table 24: Malfunctions During Operation - Charge Air Pressure too Low
81
Table 25: Malfunctions During Operation - Charge Air Pressure too High
82
Table 26: Malfunctions During Operation - Engine Performance Losses
82
Turbocharger Is Surging
83
Table 27: Malfunction - Turbocharger Surging
83
Table 28: Malfunction - Sporadic Surge Blows
83
Table 30: Malfunctions When Stopping - Runout Time too Short
84
Malfunctions When Stopping
84
Table 29: Malfunctions When Stopping - Runout Noises
84
Table 33: Malfunction of the Speed Measurement System - Measured Speed too Low
85
Speed Measurement System
85
Table 32: Malfunction of the Speed Measurement System - Measured Speed too High
85
Table 31: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
85
Dismantling and Fitting, General
86
Introduction
86
Material Required
87
Fig. 36: Swivel Lifting Eye (Example)
87
Table 34: Swivel Lifting Eyes
87
Fig. 37: Press-Off Screws
88
Fig. 38: Dismantling Screw
88
Table 35: Press-Off Screws
88
Table 36: Dismantling Screw
88
Disassembly and Assembly Concepts
90
Fig. 39: Removing the Cartridge Group with Compressor and Turbine Casing
90
Fig. 40: Cartridge Concept
91
Fig. 41: Optional Spanner Holder
92
Table 37: Weights of Assemblies
93
Weights of Individual Parts
93
Fig. 42: Weights of Assemblies
93
Table of Tightening Torques
94
Fig. 43 Overview of Tightening Torques
94
Table 38: Tightening Torques
94
Fig. 44: Tightening Torques for Insulation
95
Table 39: Tightening Torques for Insulation
95
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
96
Removing Air Inlets
96
Fig. 45: Removing the Air Inlets
96
Removing the Gas Outlet Casing
97
Fig. 46: Remove Gas Outlet Casing Without Support
97
Fig. 47: Removing Gas Outlet Casing with Support 1
98
Fig. 48: Removing Gas Outlet Casing with Support 1
99
Removing the Gas Outlet Flange
100
Fig. 49: Removing the Gas Outlet Flange
100
Table 40: Press-Off Screws - Gas Outlet Flange
100
Fig. 51: Remove Insulation
101
Fig. 50: Turbine Cleaning Nozzle
101
Removing the Cartridge Group with Compressor and Turbine Casing
101
Fig. 52: Removing the Cartridge Group with Compressor and Turbine Casing
102
Fig. 53: Setting down the Cartridge Group with the Compressor and Turbine Casing
102
Removing the Compressor Casing
103
Fig. 54: Removing the Compressor Casing
103
Removing the Cartridge Group
104
Fig. 55: Removing Cartridge Group 1
104
Table 41: Tightening Torque (90012-01)
104
Fig. 56: Removing Cartridge Group 2
105
Fig. 57: Removing Cartridge Group 3
106
Installing the Cartridge Group on the Service Support
107
Fig. 58: Installing the Cartridge Group on the Service Support
107
Removing the Nozzle Ring
108
Fig. 59: Removing the Nozzle Ring
108
Measuring Clearance a and B
109
Fig. 60: Measuring Clearance a and B
109
Table 42: Permissible Clearances a and B
109
Table 43: Nozzle Ring Compression PD
110
Nozzle Ring Compression PD
110
Fig. 61: Nozzle Ring Compression PD
110
Installing Nozzle Ring
111
Fig. 62: Installing the Nozzle Ring
111
Installing the Cartridge Group
112
Fig. 63: Lifting the Cartridge Group and Rotating It
112
Fig. 64: Turning the Cartridge Group
113
Table 44: Tightening Torque (90012-01)
113
Fig. 65: Installing the Cartridge Group
114
Table 45: Tightening Torque (51007)
114
Table 46: Tightening Torque (79041)
115
Installing the Compressor Casing
115
Fig. 67: Installing the Compressor Casing
115
Fig. 66: Fitting the Diffuser
115
Table 47: Tightening Torque (72011)
116
Turning the Cartridge Group with Compressor and Turbine Casing
117
Fig. 68: Turning the Cartridge Group with Compressor and Turbine Casing
117
Installing the Gas Outlet Flange
118
Fig. 69: Installing the Gas Outlet Flange
118
Table 48: Permissible Clearances N and R
119
Radial Clearances N and R
119
Fig. 70: Measuring Clearances N and R
119
Fitting the Insulation
120
Fig. 71: Fitting the Insulation
120
Installing the Cartridge Group with Compressor and Turbine Casing
121
Fig. 72: Installing the Cartridge Group with Compressor and Turbine Casing
121
Fig. 73: Installing the Cartridge Group with Compressor and Turbine Casing
121
Installing the Gas Outlet Casing
122
Fig. 74: Fitting Gas Outlet Casing Without Support
122
Table 49: Tightening Torque (51009)
122
Fig. 75: Installing Gas Outlet Casing with Support 1
123
Table 50: Tightening Torque (51009)
123
Fig. 76: Installing Gas Outlet Casing with Support 2
124
Installing Air Inlets
125
Fig. 77: Installing the Air Inlets
125
Table 51: Tightening Torque (72051)
125
Dismantling and Fitting, Cartridge Concept
126
Removing Air Inlets
126
Fig. 78: Removing the Air Inlets
126
Removing the Compressor Casing
127
Fig. 79: Removing the Compressor Casing
127
Fig. 80: Pressing off Compressor Casing
128
Fig. 81: Remove the Diffuser
128
Removing the Cartridge Group
129
Fig. 82: Removing Insulation Sheets
129
Fig. 83: Removing Cartridge Group 1
129
Fig. 84: Removing Cartridge Group 2
130
Fig. 85: Removing Cartridge Group 3
131
Fig. 86: S_05180
132
Fig. 87: Measuring Clearance a and B
133
Table 52: Permissible Clearances a and B
133
Fig. 88: Nozzle Ring Compression PD
134
Table 53: Nozzle Ring Compression PD
134
Fig. 89: Installing the Nozzle Ring
135
Fig. 90: Installing the Cartridge Group
136
Fig. 91: Installing the Cartridge Group 2
137
Table 54: Tightening Torque (51007)
137
Table 55: Tightening Torque (51007) with Spanner Holder
137
Fig. 92: Fitting the Diffuser
138
Table 56: Tightening Torque (79041)
138
Fig. 93: Installing the Compressor Casing
139
Table 57: Tightening Torque (72011)
139
Fig. 94: Measuring Clearances N and R
140
Table 58: Permissible Clearances N and R
140
Fig. 95: Fitting the Insulation
141
Fig. 96: Installing the Air Inlets
142
Table 59: Tightening Torque (72051)
142
Table 60: Customer Tool
143
Fig. 97: Customer Tool
143
Dismantling and Fitting, Special Tools for Fastening Strips
143
Fig. 98: Positioning the Collection Tub
144
Fig. 99: Removing the Fastening Strips
144
Application, Special Tools
144
Fig. 100: Fitting the Upper Fastening Strips
145
Fig. 101: Fitting the Bottom Fastening Strip
145
Table 61: Tightening Torque (51007)
145
Fig. 102: Fitting the Bottom Fastening Strip
146
Table 62: Tightening Torque (51007) with Spanner Holder
146
Fig. 104: Disassembly of the Elbows
147
Removing and Installing 6-Nozzle Turbine Cleaning Component (Optional)
147
Fig. 103: Initial Situation
147
Disassembly
147
Fig. 105: Disassembly of the Elbows
148
Fig. 106: Pipe Disassembly
148
Fig. 107: Disassembly of the Connecting Pieces
149
Fig. 108: Disassembly of the Cleaning Nozzle
149
Table 63: Dismantling Screw
149
Table 64: Dismantling Screw
150
Fig. 109: Assembly of the Cleaning Nozzle
150
Fig. 110: Assembly of the Connecting Pieces
150
Assembly
150
Fig. 111: Pipe Assembly
151
Fig. 112: Elbow 1 Assembly
151
Fig. 113: Elbow 2 Assembly
152
Table 65: Tightening Torque (51314 / 51316)
152
Fitting the Cleaning Nozzles with Multi-Inlet Turbine Casings
153
Fig. 114: Fit the Cleaning Nozzles
153
Taking out of Operation at Short Notice
154
Possible Emergency Repairs
154
Installing the Replacement Cartridge Group
155
Installing the Replacement Turbocharger
155
Fitting the Cover Plate
156
Fig. 115: Fitting the Cover Plate
156
Cover Plate Drawing
157
Fig. 116: Cover Plate Drawing
157
Table 66: Cover Plate Dimensions [MM]
157
Fig. 117: Dimensions for Cover Plate
158
Table 67: Cover Plate Dimensions [MM]
158
Mothballing the Turbocharger
159
Taking the Engine out of Operation for more than 12 Months
160
Material and Disposal
161
REACH and Rohs Compliance Declaration for Products
161
Disposing of Turbocharger Components
162
Required Customer Spare Part Set (97070)
163
Table 68: Customer Spare Part Set 97070
163
Ordering Spare Parts
163
Spare Parts
163
Spare Part - Illustrations
164
Table 69: Spare Parts - Cartridge, Oil Cooled
165
Table 70: Spare Parts - Bearing, Casing Oil Cooled
166
Table 71: Spare Parts - Rotor and Bearing Parts
167
Table 72: Spare Parts - Turbine Casing, 1 Inlet
168
Table 73: Spare Parts - Turbine Casing, 2 Inlets
169
Table 74: Spare Parts - Turbine Casing, 3 Inlets
170
Table 75: Spare Parts - Cleaning Device
171
Table 76: Spare Parts - Gas Outlet Casing, Radial
172
Table 77: Spare Parts - Compressor Casing
173
Table 78: Spare Parts - Filter Silencer
175
Table 79: Spare Parts - Air Suction Branch Axial
175
Table 80: Spare Parts - Air Suction Branch Radial
176
Table 81: Spare Parts - Speed Measurement System
177
Tools
178
Fig. 118: Special Tool
178
Table 82: Customer Tool Set 90000
178
Table 83: Special Tool (90160)
178
Figures
180
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