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ABB HT601672 manual available for free PDF download: Operation Manual
ABB HT601672 Operation Manual (182 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 31.03 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
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
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
Fig. 11: Suspension of Complete Turbocharger Unit
31
Turbocharger Weight and Transportation
31
Removing and Installing
31
Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Fig. 13: Removing the Turbocharger
32
Fig. 14: Loosening the Clamping Nut
33
Fig. 15: Turbocharger Centre of Gravity
34
Fig. 16: Inserting the Gasket
35
Installing the Turbocharger
35
Fig. 17: Inserting the Threaded Rods
36
Fig. 18: Placing the Turbocharger on the Bracket
36
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
37
Fig. 20: Tightening Pressure Screws
38
Table 5: Torque-Controlled Tightening of the Pressure Screws
38
Fig. 21: Connecting the Speed Sensor
39
Fig. 22: Connecting the Compressor Cooling Air Intake
39
Fig. 23: Attaching the Support
39
Oil Supply
40
Commissioning
40
Fig. 24: Oil Orifice
41
Inspection Procedures
42
Commissioning after Taking out of Operation
44
Monitoring Operation
45
Oil Pressure, Oil Temperature
45
Table 6: Lubricating Oil Pressure at Oil Inlet before Turbocharger
45
Table 7: Lubricating Oil Temperature at the Inlet
46
Table 8: Maximum Lubricating Oil Temperature at the Outlet
46
Exhaust Gas Temperature before Turbine
47
Turbocharger Speed
48
Fig. 25: Layout and Overview of Speed Measurement System
48
Fig. 26: Replacing the Speed Sensor
50
Table 9: Tightening Torque (86505)
50
Operation and Service
51
Noise Emission
51
Fig. 27: Noise Insulation, Bellows
52
Service Work
53
Table 10: Expected Replacement Intervals
56
Expected Replacement Intervals
56
Stopping the Engine
58
Periodic Maintenance Work
59
Foreword to Maintenance
59
Table 11: Maintenance Table
59
Cleaning the Compressor During Operation
60
Fig. 28: Carrying out Wet Cleaning of Compressor
62
Table 12: Parameters for Wet Cleaning of Compressor
62
Cleaning the Turbine During Operation
63
Fig. 29: Turbine Cleaning Devices
65
Table 13: Turbine Wet Cleaning, Recommended Operating State
65
Fig. 30: Carrying out Wet Cleaning of Turbines
66
Table 14: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
66
Cleaning Components Mechanically
67
Table 15: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
67
Fig. 31: Cleaning the Filter Silencer
68
Fig. 32: Compressor Casing
70
Fig. 33: Diffuser
71
Fig. 34: Turbine End, Non-Rotating Parts
73
Fig. 35: Soaking the Turbine End
75
Table 16: Value Table for Soaking
75
Malfunctions When Starting
78
Table 17: Malfunctions When Starting - Delayed Start-Up
78
Table 18: Malfunctions When Starting - Vibrations
78
Table 19: Malfunctions When Starting - Rubbing of Rotating Parts
78
Eliminating Malfunctions
78
Table 21: Malfunctions During Operation - Speed Reduces
79
Table 22: Malfunctions During Operation - Speed Increases
79
Table 20: Malfunctions During Operation - Lubricating Oil Pressure too Low
79
Malfunctions During Operation
79
Table 23: Malfunctions During Operation - Exhaust Gas Temperature too High
80
Table 24: Malfunctions During Operation - Charge Air Pressure too Low
80
Table 25: Malfunctions During Operation - Charge Air Pressure too High
81
Table 26: Malfunctions During Operation - Engine Performance Losses
81
Turbocharger Is Surging
82
Table 27: Malfunction - Turbocharger Pumping
82
Table 28: Malfunction - Sporadic Surge Blows
82
Table 30: Malfunctions When Stopping - Runout Time too Short
83
Table 29: Malfunctions When Stopping - Runout Noises
83
Malfunctions When Stopping
83
Table 33: Malfunction of the Speed Measurement System - Measured Speed too Low
84
Speed Measurement System
84
Table 32: Malfunction of the Speed Measurement System - Measured Speed too High
84
Table 31: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
84
Dismantling and Fitting, General
85
Introduction
85
Material Required
86
Fig. 36: Swivel Lifting Eyes
86
Table 34: Swivel Lifting Eyes
86
Fig. 37: Press-Off Screws
87
Fig. 38: Dismantling Screw
87
Table 35: Press-Off Screws
87
Table 36: Dismantling Screw
87
Disassembly and Assembly Concepts
89
Fig. 39: Removing the Cartridge Group with Compressor and Turbine Casing
89
Fig. 40: Cartridge Concept
90
Fig. 41: Optional Spanner Holder
91
Table 37: Weights of Assemblies
92
Weights of Individual Parts
92
Fig. 42: Weights of Assemblies
92
Table of Tightening Torques
93
Fig. 43 Overview of Tightening Torques
93
Table 38: Tightening Torques
93
Fig. 44: Tightening Torques for Insulation
94
Table 39: Tightening Torques for Insulation
94
Fig. 45: Removing the Air Inlets
95
Removing Air Inlets
95
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
95
Removing the Gas Outlet Casing
96
Fig. 46: Remove Gas Outlet Casing Without Support
96
Fig. 47: Removing Gas Outlet Casing with Support 1
97
Fig. 48: Removing Gas Outlet Casing with Support 1
98
Removing the Gas Outlet Flange
99
Fig. 49: Removing the Gas Outlet Flange
99
Table 40: Press-Off Screws - Gas Outlet Flange
99
Fig. 51: Remove Insulation
100
Removing the Cartridge Group with Compressor and Turbine Casing
100
Fig. 50: Turbine Cleaning Nozzle
100
Fig. 52: Removing the Cartridge Group with Compressor and Turbine Casing
101
Fig. 53: Set down the Cartridge Group with the Compressor and Turbine Casing
101
Removing the Compressor Casing
102
Fig. 54: Removing the Compressor Casing
102
Removing the Cartridge Group
103
Fig. 55: Removing Cartridge Group 1
103
Table 41: Tightening Torque (90012-01)
103
Fig. 56: Removing Cartridge Group 2
104
Fig. 57: Removing Cartridge Group 3
105
Installing the Cartridge Group on the Service Support
106
Fig. 58: Installing the Cartridge Group on the Service Support
106
Removing the Nozzle Ring
107
Fig. 59: Removing the Nozzle Ring
107
Measuring Clearance a and B
108
Fig. 60: Measuring Clearance a and B
108
Table 42: Permissible Clearances a and B
108
Table 43: Nozzle Ring Compression PD
109
Nozzle Ring Compression PD
109
Fig. 61: Nozzle Ring Compression PD
109
Installing Nozzle Ring
110
Fig. 62: Installing the Nozzle Ring
110
Installing the Cartridge Group
111
Fig. 63: Lifting the Cartridge Group and Rotating It
111
Fig. 64: Turning the Cartridge Group
112
Table 44: Tightening Torque (90012-01)
112
Fig. 65: Installing the Cartridge Group
113
Table 45: Tightening Torque (51007)
113
Installing the Compressor Casing
114
Fig. 66: Fitting the Diffuser
114
Table 46: Tightening Torque (79041)
114
Fig. 67: Installing the Compressor Casing
115
Table 47: Tightening Torque (72011)
115
Turning the Cartridge Group with Compressor and Turbine Casing
116
Fig. 68: Turning the Cartridge Group with Compressor and Turbine Casing
116
Fig. 69: Installing the Gas Outlet Flange
117
Installing the Gas Outlet Flange
117
Fig. 70: Measuring Clearances N and R
118
Table 48: Permissible Clearances N and R
118
Radial Clearances N and R
118
Fitting the Insulation
119
Fig. 71: Fitting the Insulation
119
Installing the Cartridge Group with Compressor and Turbine Casing
120
Fig. 72: Installing the Cartridge Group with Compressor and Turbine Casing
120
Fig. 73: Installing the Cartridge Group with Compressor and Turbine Casing
120
Table 49: Tightening Torque (51009)
121
Installing the Gas Outlet Casing
121
Fig. 74: Fitting Gas Outlet Casing Without Support
121
Fig. 75: Installing Gas Outlet Casing with Support 1
122
Table 50: Tightening Torque (51009)
122
Fig. 76: Installing Gas Outlet Casing with Support 2
123
Installing Air Inlets
124
Fig. 77: Installing the Air Inlets
124
Table 51: Tightening Torque (72051)
124
Dismantling and Fitting, Cartridge Concept
125
Fig. 78: Removing the Air Inlets
125
Fig. 79: Removing the Compressor Casing
126
Fig. 80: Pressing off Compressor Casing
127
Fig. 81: Remove the Diffuser
127
Fig. 82: Removing Insulation Sheets
128
Fig. 83: Removing Cartridge Group 1
128
Fig. 84: Removing Cartridge Group 2
129
Fig. 85: Removing Cartridge Group 3
130
Fig. 86: S_05180
131
Fig. 87: Measuring Clearance a and B
132
Table 52: Permissible Clearances a and B
132
Fig. 88: Nozzle Ring Compression PD
133
Table 53: Nozzle Ring Compression PD
133
Fig. 89: Installing the Nozzle Ring
134
Fig. 90: Installing the Cartridge Group
135
Fig. 91: Installing the Cartridge Group 2
136
Table 54: Tightening Torque (51007)
136
Table 55: Tightening Torque (51007) with Spanner Holder
136
Table 56: Tightening Torque (79041)
137
Fig. 92: Fitting the Diffuser
137
Table 57: Tightening Torque (72011)
138
Fig. 93: Installing the Compressor Casing
138
Fig. 94: Measuring Clearances N and R
139
Table 58: Permissible Clearances N and R
139
Fig. 95: Fitting the Insulation
140
Fig. 96: Installing the Air Inlets
141
Table 59: Tightening Torque (72051)
141
Table 60: Customer Tool
142
Dismantling and Fitting, Special Tools for Fastening Strips
142
Fig. 97: Customer Tool
142
Application, Special Tools
143
Fig. 98: Positioning the Collection Tub
143
Fig. 99: Removing the Fastening Strips
143
Fig. 100: Fitting the Upper Fastening Strips
144
Fig. 101: Fitting the Bottom Fastening Strip
144
Table 61: Tightening Torque (51007)
144
Table 62: Tightening Torque (51007) with Spanner Holder
145
Fig. 102: Fitting the Bottom Fastening Strip
145
Removing and Installing 6-Nozzle Turbine Cleaning Component (Optional)
146
Disassembly
146
Fig. 103: Initial Situation
146
Fig. 104: Disassembly of the Elbows
146
Fig. 105: Disassembly of the Elbows
147
Fig. 106: Pipe Disassembly
147
Table 63: Dismantling Screw
148
Fig. 108: Disassembly of the Cleaning Nozzle
148
Fig. 107: Disassembly of the Connecting Pieces
148
Assembly
149
Fig. 109: Assembly of the Cleaning Nozzle
149
Fig. 110: Assembly of the Connecting Pieces
149
Table 64: Dismantling Screw
149
Fig. 111: Pipe Assembly
150
Fig. 112: Elbow 1 Assembly
150
Fig. 113: Elbow 2 Assembly
151
Table 65: Tightening Torque (51314 / 51316)
151
Fig. 114: Fit the Cleaning Nozzles
152
Fitting the Cleaning Nozzles with Multi-Inlet Turbine Casings
152
Taking out of Operation at Short Notice
153
Possible Emergency Repairs
153
Installing the Replacement Turbocharger
154
Installing the Replacement Cartridge Group
154
Fitting the Cover Plate
155
Fig. 115: Fitting the Cover Plate
155
Cover Plate Drawing
156
Table 66: Cover Plate Dimensions [MM]
156
Fig. 116: Cover Plate Drawing
156
Fig. 117: Dimensions for Cover Plate
157
Table 67: Cover Plate Dimensions [MM]
157
Mothballing the Turbocharger
158
Taking the Engine out of Operation for up to 12 Months
158
Taking the Engine out of Operation for more than 12 Months
159
Disposing of Turbocharger Components
160
Required Customer Spare Part Set (97070)
161
Table 68: Customer Spare Part Set 97070
161
Ordering Spare Parts
161
Spare Parts
161
Spare Part - Illustrations
162
Table 69: Spare Parts - Cartridge, Oil Cooled
163
Table 70: Spare Parts - Bearing, Casing Oil Cooled
164
Table 71: Spare Parts - Rotor and Bearing Parts
165
Table 72: Spare Parts - Turbine Casing, 1 Inlet
166
Table 73: Spare Parts - Turbine Casing, 2 Inlets
167
Table 74: Spare Parts - Turbine Casing, 3 Inlets
168
Table 75: Spare Parts - Cleaning Device
169
Table 76: Spare Parts - Gas Outlet Casing, Radial
170
Table 77: Spare Parts - Compressor Casing
171
Table 78: Spare Parts - Filter Silencer
173
Table 79: Spare Parts - Air Suction Branch Axial
173
Table 80: Spare Parts - Air Suction Branch Radial
174
Table 81: Spare Parts - Speed Measurement System
175
Tools
176
Fig. 118: Special Tool
176
Table 82: Customer Tool Set 90000
176
Table 83: Special Tool (90160)
176
Figures
178
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