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ABB A140 manuals available for free PDF download: Operation Manual
ABB A140 Operation Manual (152 pages)
Turbocharging
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.21 MB
Table of Contents
Table of Contents
3
1 Introduction
6
Operation Manual / A130-M
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
CE Conformity
15
Introduction
15
2 Safety
15
Definition of Mandatory Signs
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Intended Use
17
Deflagration on Gas Engines
18
Warning Plates on the Turbocharger
19
Fig. 6: Warning Plate Locations
19
Turbocharger Rating Plate
20
Fig. 7: Rating Plate
20
Fig. 8: Locations of the Rating Plates
21
Periodic Check of the Pressure Vessels
22
Lifting of Loads
23
Fig. 9: Attachment of Loads on the Crane Hook
23
Fig. 10: Attachment Angle
23
Prerequisites for Operation and Maintenance
24
Hazards During Operation and Maintenance
25
Safe Operation
27
Fig. 11
27
Safe Maintenance
28
3 Removing and Installing
32
Turbocharger Weight and Transportation
32
Fig. 12: Suspension of Complete Turbocharger Unit
32
Table 4: Weight of Complete Turbocharger Unit
32
Removing the Turbocharger
33
Fig. 13: Turbine Cleaning Nozzle
33
Fig. 14: Removing the Turbocharger
34
Fig. 15: Loosening the Clamping Nut
36
Fig. 16: Turbocharger Centre of Gravity
37
Installing the Turbocharger
38
Fig. 17: Inserting Gaskets into the Bracket
38
Fig. 18: Inserting the Threaded Rods
39
Fig. 19: Requirements for Threaded Rods
39
Table 5: Requirements for Threaded Rods
39
Fig. 20: Placing the Turbocharger on the Bracket
40
Table 6: Tightening Torque for Standard Nuts
41
Fig. 21: Preparing the Clamping Nut for the Tightening Procedure
42
Fig. 22: Tightening Pressure Screws
43
Table 7: Torque-Controlled Tightening of the Pressure Screws
43
Fig. 23: Connecting the Speed Sensor
44
Fig. 24: Connecting the Compressor Cooling Air Intake
44
Fig. 25: Attaching the Support
45
4 Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
47
Inspection Procedures
48
Commissioning after Taking out of Operation
50
5 Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 10: Lubricating Oil Temperature at the Outlet
52
Table 9: Lubricating Oil Temperature at the Inlet
52
Exhaust Gas Temperature before Turbine
53
Turbocharger Speed
54
Fig. 27: Layout and Overview of Speed Measurement System
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
6 Operation and Service
57
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Foreword to Maintenance
66
7 Periodic Maintenance Work
66
Table 13: Maintenance Table
66
Cleaning the Compressor During Operation
67
Fig. 31: Carrying out Wet Cleaning of Compressor
69
Table 14: Parameters for Wet Cleaning of Compressor
69
Cleaning the Turbine During Operation
70
Table 15: Turbine Wet Cleaning, Recommended Operating State
72
Fig. 32: Carrying out Wet Cleaning of Turbine
73
Table 16: Wet Cleaning of Turbine, Parameters
73
Cleaning Components Mechanically
74
Fig. 33: Cleaning the Filter Silencer
75
Fig. 34: Compressor-End, Non-Rotating Parts
77
Fig. 35: Turbine End, Non-Rotating Parts
78
Fig. 36: Soaking the Turbine End
81
Table 17: Value Table for Soaking
81
8 Eliminating Malfunctions
84
Malfunctions When Starting
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Malfunctions During Operation
85
Table 21: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 22: Malfunctions During Operation - Speed Reduces
85
Table 23: Malfunctions During Operation - Speed Increases
85
Table 24: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 25: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 26: Malfunctions During Operation - Charge Air Pressure too High
87
Table 27: Malfunctions During Operation - Engine Performance Losses
87
Table 28: Malfunction - Turbocharger Pumping
88
Table 29: Malfunction - Sporadic Surge Blows
88
Turbocharger Is Surging
88
Malfunctions When Stopping
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Speed Measurement System
90
Table 32: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 33: Malfunction of the Speed Measurement System - Measured Speed too High
90
Table 34: Malfunction of the Speed Measurement System - Measured Speed too Low
90
9 Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eyes
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
Weights of Individual Parts
94
Fig. 39: Weights of Assemblies
94
Table 36: Weights of Assemblies
94
Removing the Air Inlets
95
Fig. 40: Removing the Air Inlets
95
Removing the Gas Outlet Casing
96
Fig. 41: Removing the Insulation
96
Removing the Gas Outlet Flange
97
Fig. 42: Removing the Gas Outlet Casing
97
A130 A135 A140 A145
98
Fig. 43: Dismantling the Gas Outlet Flange
98
Table 37: 3 Press-Off Screws
98
Fig. 44: Removing the Gas Outlet Flange
99
Table 38: 6 Press-Off Screws
99
Removing the Compressor Casing
100
Compressor Casing
100
Fig. 45: Removing the Compressor Casing
100
Wall Insert
101
Fig. 46: Dismantling the Wall Insert
101
Pressing off the Casing
102
Fig. 47: Press off the Casing
102
Removing the Cartridge Group
103
Cartridge Group
103
Fig. 48: Removing Insulation Sheets
103
Fig. 49: Oil Orifice
103
Fig. 50: Removing Cartridge Group 1
104
Fig. 51: Removing Cartridge Group 2
104
Removing the Nozzle Ring
105
Nozzle Ring
105
Fig. 52: Removing the Nozzle Ring
105
Installing the Cartridge Group on the Service Support
106
Fig. 53: Installing the Cartridge Group on the Service Support
106
Measuring Clearance a and B
107
Fig. 54: Measuring Clearance a and B
107
Table 39: Permissible Clearances a and B
107
Nozzle Ring Compression PD
108
Fig. 55: Nozzle Ring Compression PD
108
Table 40: Nozzle Ring Compression PD
108
Installing the Nozzle Ring
109
Fig. 56: Installing the Nozzle Ring
109
Installing the Cartridge Group
110
Fig. 57: Lifting the Cartridge Group and Rotating It by 90
110
Fig. 58: Installing the Cartridge Group
111
Table 41: Tightening Torque (51007)
111
Fig. 59: Turbine Casing Insulation / Burst Protection
112
Installing the Compressor Casing
113
Table 42: Tightening Torque (79041)
113
Fig. 60: Installing the Compressor Casing
114
Table 43: Tightening Torque (72011)
114
Measuring Radial Clearances N and R
115
Fig. 61: Measuring Clearances N and R
115
Table 44: Permissible Clearances N and R
115
Installing the Air Inlets
116
Fig. 62: Installing the Air Inlets
116
Table 45: Tightening Torque (72020)
116
Installing the Gas Outlet Flange
117
Gas Outlet Flange
117
Fig. 63: Installing the Gas Outlet Flange
117
Fitting the Insulation of the Turbine Casing
118
Fig. 64: Fitting the Insulation
118
Installing the Gas Outlet Casing
119
Fig. 65: Installing the Gas Outlet Casing
119
Table 46: Tightening Torque (51009)
119
Fig. 66: Fitting the Insulation
120
Table of Tightening Torques
121
Fig. 67: Tightening Torques
121
Table 47: Tightening Torques
121
Fig. 68: Tightening Torques for Insulation
122
Table 48: Tightening Torques for Insulation
122
10 Taking out of Operation at Short Notice
123
Possible Emergency Repairs
123
Installing the Replacement Cartridge Group
124
Installing the Replacement Turbocharger
124
Fitting the Cover Plate
125
Fig. 69: Fitting the Cover Plate
125
Cover Plate Drawing
126
Fig. 70: Cover Plate Drawing
126
Table 49: Cover Plate Dimensions [MM]
126
11 Mothballing the Turbocharger
127
Taking the Engine out of Operation for up to 12 Months
127
Taking the Engine out of Operation for more than 12 Months
128
12 Disposing of Turbocharger Components
129
Ordering Spare Parts
131
Required Customer Spare Part Set (97070)
131
13 Spare Parts
131
Table 50: Customer Spare Part Set 97070
131
Spare Part - Illustrations
132
Table 51: Spare Parts - Cartridge, Oil Cooled
133
Table 52: Spare Parts - Cartridge, Water Cooled
133
Table 53: Spare Parts - Turbine Casing, 1 Inlet
135
Table 54: Spare Parts - Turbine Casing, 2 Inlets
137
Table 55: Spare Parts - Gas Outlet Casing, Axial
138
Table 56: Spare Parts - Gas Outlet Casing, Radial
139
Table 57: Spare Parts - Compressor Casing
140
Table 58: Spare Parts - Filter Silencer
141
Table 59: Spare Parts - Air Suction Branch Axial
142
Table 60: Spare Parts - Air Suction Branch Radial
143
Table 61: Spare Parts - Bearing Casing, Oil Cooled
144
Table 62: Spare Parts - Bearing Casing, Water Cooled
145
Table 63: Spare Parts - Rotor and Bearing Parts
146
Table 64: Customer Tool Set 90000
147
14 Tools
147
Figures
148
Tables
150
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ABB A140 Operation Manual (124 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 14.15 MB
Table of Contents
Operation Manual / A130-H - A140-H
3
Table of Contents
3
Operation Manual / A130-H
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 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
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
Periodic Check of the Pressure Vessels
17
Deflagration on Gas Engines
17
Fig. 6: Warning Plate Locations
18
Warning Plates on the Turbocharger
18
Turbocharger Rating Plate
19
Fig. 7: 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
Table 4: Weight of Complete Turbocharger Unit
30
Removing and Installing
30
Fig. 11: Transportation of the Turbocharger
30
Weight and Transportation of the Turbocharger
30
Removing the Turbocharger
31
Fig. 12: Removing the Turbocharger
31
Fig. 13: Loosening the Clamping Nut
33
Fig. 14: Putting down the Turbocharger
34
Installing the Turbocharger
35
Fig. 15: Inserting Gaskets into the Bracket
35
Fig. 16: Fitting Threaded Rods Onto the Bracket
36
Fig. 17: Requirements for Threaded Rods
36
Table 5: Requirements for Threaded Rods
36
Fig. 18: Placing the Turbocharger on the Bracket
37
Table 6: Tightening Torque for Standard Nuts
38
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
39
Fig. 20: Tightening Pressure Screws
40
Table 7: Torque-Controlled Tightening of the Pressure Screws
40
Fig. 21: Connecting the Compressor Cooling Air Intake
41
Fig. 22: Attaching the Support
41
Commissioning
42
Oil Supply
42
Fig. 23: Oil Orifice
43
Inspection Procedures
44
Commissioning after Taking out of Operation
46
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
47
Oil Pressure, Oil Temperature
47
Monitoring Operation
47
Table 9: Lubricating Oil Temperature at the Inlet
48
Table 10: Lubricating Oil Temperature at the Outlet
48
Exhaust Gas Temperature before Turbine
49
Turbocharger Speed
49
Fig. 24: Layout and Overview of Speed Measurement System
50
Fig. 25: Replacing the Speed Sensor
52
Table 11: Tightening Torque (86505)
52
Operation and Service
53
Noise Emission
53
Fig. 26: Noise Insulation, Bellows
54
Service Work
55
Fig. 27: Replacing the Protective Grid
57
Expected Replacement Intervals
59
Table 12: Expected Replacement Intervals
60
Stopping the Engine
61
Periodic Maintenance Work
62
Foreword to Maintenance
62
Table 13: Maintenance Table
62
Cleaning Components Mechanically
63
Fig. 28: Cleaning the Filter Silencer
64
Fig. 29: Compressor-End, Non-Rotating Parts
66
Fig. 30: Turbine End, Non-Rotating Parts
67
Fig. 31: Soaking the Turbine End
70
Table 14: Value Table for Soaking
70
Table 16: Malfunctions When Starting - Vibrations
73
Table 17: Malfunctions When Starting - Rubbing of Rotating Parts
73
Eliminating Malfunctions
73
Table 15: Malfunctions When Starting - Delayed Start-Up
73
Malfunctions When Starting
73
Malfunctions During Operation
74
Table 18: Malfunctions During Operation - Lubricating Oil Pressure too Low
74
Table 19: Malfunctions During Operation - Speed Reduces
74
Table 20: Malfunctions During Operation - Speed Increases
74
Table 21: Malfunctions During Operation - Exhaust Gas Temperature too High
75
Table 22: Malfunctions During Operation - Charge Air Pressure too Low
75
Table 23: Malfunctions During Operation - Charge Air Pressure too High
76
Table 24: Malfunctions During Operation - Engine Performance Losses
76
Table 26: Malfunction - Sporadic Surge Blows
77
Table 25: Malfunction - Turbocharger Pumping
77
Turbocharger Is Surging
77
Malfunctions When Stopping
78
Table 27: Malfunctions When Stopping - Runout Noises
78
Table 28: Malfunctions When Stopping - Runout Time too Short
78
Speed Measurement System
79
Table 29: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
79
Table 30: Malfunction of the Speed Measurement System - Measured Speed too High
79
Table 31: Malfunction of the Speed Measurement System - Measured Speed too Low
79
Dismantling and Fitting
80
Introduction
80
Table 32: Swivel Lifting Eyes
82
Fig. 33: Starpoint Ring Nut VRM
82
Fig. 32: Swivel Lifting Eyes
82
Weights of Individual Parts
82
Fig. 34: Weights of Assemblies/Table 33: Weights of Assemblies
83
Fig. 34: Weights of Assemblies
83
Table 33: Weights of Assemblies
83
Fig. 35: Removing the Air Inlets
84
Removing the Air Inlets
84
Fig. 36: Removing the Gas Outlet Casing
85
Removing the Gas Outlet Casing
85
Removing the Gas Outlet Flange
85
A130 A135 A140
86
Fig. 37: Dismantling the Gas Outlet Flange
86
Table 34: 3 Press-Off Screws
86
Fig. 38: Removing the Gas Outlet Flange
87
Table 35: 6 Press-Off Screws
87
Compressor Casing
88
Fig. 39: Removing the Compressor Casing
88
Removing the Compressor Casing
88
Fig. 40: Dismantling the Wall Insert
89
Wall Insert
89
Fig. 41: Press off the Casing
90
Pressing off the Casing
90
Fig. 42: Oil Orifice
91
Fig. 43: Removing Cartridge Group 1
91
Removing the Cartridge Group
91
Fig. 44: Removing Cartridge Group 2
92
Fig. 45: Removing the Nozzle Ring
93
Removing the Nozzle Ring
93
Fig. 46: Installing the Cartridge Group on the Service Support
94
Installing the Cartridge Group on the Service Support
94
Fig. 47: Measuring Clearance a and B
95
Measuring Clearance a and B
95
Table 36: Permissible Clearances a and B
95
Fig. 48: Nozzle Ring Compression PD
96
Nozzle Ring Compression PD
96
Table 37: Nozzle Ring Compression PD
96
Fig. 49: Installing the Nozzle Ring
97
Installing the Nozzle Ring
97
Fig. 50: Measuring the End Position of the Nozzle Ring
98
Fig. 51: Lifting the Cartridge Group and Rotating It by 90
98
Installing the Cartridge Group
98
Table 38: End Position of the Nozzle Ring, Control Dimension H
98
Fig. 52: Installing the Cartridge Group
99
Table 39: Tightening Torque (51007)
99
Fig. 53: Fitting the Wall Insert and the Diffuser
100
Installing the Compressor Casing
100
Table 40: Tightening Torque (79041)
100
Fig. 54: Installing the Compressor Casing
101
Table 41: Tightening Torque (72011)
101
Fig. 55: Measuring Clearances N and R
102
Measuring Radial Clearances N and R
102
Table 42: Permissible Clearances N and R
102
Fig. 56: Installing the Air Inlets
103
Installing the Air Inlets
103
Table 43: Tightening Torque (72020)
103
Fig. 57: Installing the Gas Outlet Flange
104
Fig. 58: Installing the Gas Outlet Casing
104
Installing the Gas Outlet Casing
104
Installing the Gas Outlet Flange
104
Table 44: Tightening Torque (51009)
104
Fig. 59: Tightening Torques
105
Table 45: Tightening Torques of the Screw Fittings
105
Table of Tightening Torques
105
Possible Emergency Repairs
106
Taking out of Operation at Short Notice
106
Installing the Replacement Cartridge Group
107
Installing the Replacement Turbocharger
107
Mothballing the Turbocharger
108
Taking the Engine out of Operation for up to 12 Months
108
Taking the Engine out of Operation for more than 12 Months
109
Material and Disposal
110
REACH and Rohs Compliance Declaration for Products
110
Disposing of Turbocharger Components
111
Ordering Spare Parts
112
Required Customer Spare Part Set (97070)
112
Spare Parts
112
Table 46: Customer Spare Part Set 97070
112
Spare Part - Illustrations
113
Table 47
113
Gas Outlet Flange
114
Nozzle Ring 2 2
114
Turbine Casing * 45 65
114
Gas Outlet Casing
115
Table 48
115
Table 49
115
Table 50
116
Table 51
117
Fig. 60: SPI Air Suction Branch Radial
118
Table 52: Spare Parts - Air Suction Branch Radial
118
Table 53
119
Table 54
120
Tools
121
Figures
122
Tables
123
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