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ABB A145-M66 manuals available for free PDF download: Operation Manual
ABB A145-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.21 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
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
Advertisement
ABB A145-M66 Operation Manual (152 pages)
Turbocharging
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.21 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
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
ABB A145-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.1 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Operation Manual / A130-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
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
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
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
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
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: Fitting Threaded Rods Onto the Bracket
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
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
46
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Fig. 27: Layout and Overview of Speed Measurement System
54
Turbocharger Speed
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
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
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
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
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Surging
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Malfunctions When Stopping
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
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eye (Example)
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
Advertisement
ABB A145-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.1 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Operation Manual / A130-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
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
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
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
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
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: Fitting Threaded Rods Onto the Bracket
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
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
46
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Fig. 27: Layout and Overview of Speed Measurement System
54
Turbocharger Speed
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
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
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
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
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Surging
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Malfunctions When Stopping
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
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eye (Example)
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
ABB A145-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.1 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Operation Manual / A130-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
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
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
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
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
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: Fitting Threaded Rods Onto the Bracket
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
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
46
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Fig. 27: Layout and Overview of Speed Measurement System
54
Turbocharger Speed
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
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
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
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
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Surging
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Malfunctions When Stopping
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
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eye (Example)
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
ABB A145-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.1 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Operation Manual / A130-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
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
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
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
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
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: Fitting Threaded Rods Onto the Bracket
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
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
46
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Fig. 27: Layout and Overview of Speed Measurement System
54
Turbocharger Speed
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
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
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
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
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Surging
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Malfunctions When Stopping
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
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eye (Example)
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
ABB A145-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.1 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Operation Manual / A130-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
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
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
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
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
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: Fitting Threaded Rods Onto the Bracket
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
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
46
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Fig. 27: Layout and Overview of Speed Measurement System
54
Turbocharger Speed
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
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
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
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
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Surging
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Malfunctions When Stopping
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
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eye (Example)
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
ABB A145-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.1 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Operation Manual / A130-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
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
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
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
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
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: Fitting Threaded Rods Onto the Bracket
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
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
46
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Fig. 27: Layout and Overview of Speed Measurement System
54
Turbocharger Speed
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
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
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
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
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Surging
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Malfunctions When Stopping
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
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eye (Example)
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
ABB A145-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.1 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Operation Manual / A130-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
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
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
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
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
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: Fitting Threaded Rods Onto the Bracket
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
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
46
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Fig. 27: Layout and Overview of Speed Measurement System
54
Turbocharger Speed
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
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
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
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
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Surging
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Malfunctions When Stopping
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
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eye (Example)
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
ABB A145-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.1 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Operation Manual / A130-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
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
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
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
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
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: Fitting Threaded Rods Onto the Bracket
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
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
46
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Fig. 27: Layout and Overview of Speed Measurement System
54
Turbocharger Speed
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
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
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
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
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Surging
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Malfunctions When Stopping
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
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eye (Example)
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
ABB A145-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.1 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Operation Manual / A130-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
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
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
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
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
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: Fitting Threaded Rods Onto the Bracket
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
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
46
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Fig. 27: Layout and Overview of Speed Measurement System
54
Turbocharger Speed
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
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
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
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
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Surging
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Malfunctions When Stopping
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
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eye (Example)
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
ABB A145-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.1 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Operation Manual / A130-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
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
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
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
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
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: Fitting Threaded Rods Onto the Bracket
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
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
46
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Fig. 27: Layout and Overview of Speed Measurement System
54
Turbocharger Speed
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
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
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
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
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Surging
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Malfunctions When Stopping
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
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eye (Example)
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
ABB A145-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.1 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Operation Manual / A130-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
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
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
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
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
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: Fitting Threaded Rods Onto the Bracket
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
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
46
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Fig. 27: Layout and Overview of Speed Measurement System
54
Turbocharger Speed
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
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
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
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
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Surging
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Malfunctions When Stopping
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
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eye (Example)
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
ABB A145-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.1 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Operation Manual / A130-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
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
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
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
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
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: Fitting Threaded Rods Onto the Bracket
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
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
46
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
52
Exhaust Gas Temperature before Turbine
53
Fig. 27: Layout and Overview of Speed Measurement System
54
Turbocharger Speed
54
Fig. 28: Replacing the Speed Sensor
56
Table 11: Tightening Torque (86505)
56
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
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
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
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
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Surging
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Table 30: Malfunctions When Stopping - Runout Noises
89
Malfunctions When Stopping
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
Dismantling and Fitting
91
Introduction
91
Material Required
92
Fig. 37: Swivel Lifting Eye (Example)
92
Table 35: Swivel Lifting Eyes
92
Fig. 38: Starpoint Ring Nut VRM
93
ABB A145-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.21 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Fig. 1: Serial Number (01) on the Rating Plate
6
Operation Manual / A130-M
6
Purpose of the Manual
6
Introduction
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
Safety
15
Introduction
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
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
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
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
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
47
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
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
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
66
Table 13: Maintenance Table
66
Cleaning the Compressor During Operation
67
Table 14: Parameters for Wet Cleaning of Compressor
69
Fig. 31: Carrying out 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
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
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
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Pumping
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Malfunctions When Stopping
89
Table 30: Malfunctions When Stopping - Runout Noises
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
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
ABB A145-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.21 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Fig. 1: Serial Number (01) on the Rating Plate
6
Operation Manual / A130-M
6
Purpose of the Manual
6
Introduction
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
Safety
15
Introduction
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
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
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
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
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
47
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
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
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
66
Table 13: Maintenance Table
66
Cleaning the Compressor During Operation
67
Table 14: Parameters for Wet Cleaning of Compressor
69
Fig. 31: Carrying out 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
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
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
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Pumping
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Malfunctions When Stopping
89
Table 30: Malfunctions When Stopping - Runout Noises
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
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
ABB A145-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.21 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Fig. 1: Serial Number (01) on the Rating Plate
6
Operation Manual / A130-M
6
Purpose of the Manual
6
Introduction
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
Safety
15
Introduction
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
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
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
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
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
47
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
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
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
66
Table 13: Maintenance Table
66
Cleaning the Compressor During Operation
67
Table 14: Parameters for Wet Cleaning of Compressor
69
Fig. 31: Carrying out 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
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
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
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Pumping
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Malfunctions When Stopping
89
Table 30: Malfunctions When Stopping - Runout Noises
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
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
ABB A145-M66 Operation Manual (152 pages)
Turbocharging
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.21 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Fig. 1: Serial Number (01) on the Rating Plate
6
Operation Manual / A130-M
6
Purpose of the Manual
6
Introduction
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
Safety
15
Introduction
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
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
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
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
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
47
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
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
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
66
Table 13: Maintenance Table
66
Cleaning the Compressor During Operation
67
Table 14: Parameters for Wet Cleaning of Compressor
69
Fig. 31: Carrying out 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
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
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
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Pumping
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Malfunctions When Stopping
89
Table 30: Malfunctions When Stopping - Runout Noises
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
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
ABB A145-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.21 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Fig. 1: Serial Number (01) on the Rating Plate
6
Operation Manual / A130-M
6
Purpose of the Manual
6
Introduction
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
Safety
15
Introduction
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
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
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
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
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
47
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
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
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
66
Table 13: Maintenance Table
66
Cleaning the Compressor During Operation
67
Table 14: Parameters for Wet Cleaning of Compressor
69
Fig. 31: Carrying out 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
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
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
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Pumping
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Malfunctions When Stopping
89
Table 30: Malfunctions When Stopping - Runout Noises
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
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
ABB A145-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.21 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Fig. 1: Serial Number (01) on the Rating Plate
6
Operation Manual / A130-M
6
Purpose of the Manual
6
Introduction
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
Safety
15
Introduction
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
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
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
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
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
47
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
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
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
66
Table 13: Maintenance Table
66
Cleaning the Compressor During Operation
67
Table 14: Parameters for Wet Cleaning of Compressor
69
Fig. 31: Carrying out 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
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
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
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Pumping
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Malfunctions When Stopping
89
Table 30: Malfunctions When Stopping - Runout Noises
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
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
ABB A145-M66 Operation Manual (152 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.21 MB
Table of Contents
Operation Manual / A130-M - A145-M
3
Table of Contents
3
Fig. 1: Serial Number (01) on the Rating Plate
6
Operation Manual / A130-M
6
Purpose of the Manual
6
Introduction
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
Safety
15
Introduction
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
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
Fig. 13: Turbine Cleaning Nozzle
33
Removing the Turbocharger
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
Commissioning
46
Oil Supply
46
Fig. 26: Oil Orifice
47
Inspection Procedures
48
Commissioning after Taking out of Operation
50
Monitoring Operation
51
Oil Pressure, Oil Temperature
51
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
51
Table 9: Lubricating Oil Temperature at the Inlet
52
Table 10: Lubricating Oil Temperature at the Outlet
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
Operation and Service
57
Noise Emission
57
Fig. 29: Noise Insulation, Bellows
58
Service Work
59
Fig. 30: Replacing the Protective Grid
61
Expected Replacement Intervals
63
Table 12: Expected Replacement Intervals
63
Stopping the Engine
65
Periodic Maintenance Work
66
Foreword to Maintenance
66
Table 13: Maintenance Table
66
Cleaning the Compressor During Operation
67
Table 14: Parameters for Wet Cleaning of Compressor
69
Fig. 31: Carrying out 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
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
84
Table 19: Malfunctions When Starting - Vibrations
84
Table 18: Malfunctions When Starting - Delayed Start-Up
84
Malfunctions When Starting
84
Eliminating Malfunctions
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
Turbocharger Is Surging
88
Table 28: Malfunction - Turbocharger Pumping
88
Table 29: Malfunction - Sporadic Surge Blows
88
Table 31: Malfunctions When Stopping - Runout Time too Short
89
Malfunctions When Stopping
89
Table 30: Malfunctions When Stopping - Runout Noises
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
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
ABB A145-M66 Operation Manual (152 pages)
Turbocharging
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.21 MB
Table of Contents
Table of Contents
3
Operation Manual / A130-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
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
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
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
ABB A145-M66 Operation Manual (144 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 17.33 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
25
Product Description
31
Essential Information
33
Introduction
33
Registered Trademarks
33
Related Documents
33
Table 1: Related Documents
33
Fig. 1: Layout and Function of the Turbocharger
34
Layout and Function of the Turbocharger
34
Fig. 2: Compressor Wheel Cooling
35
Fig. 3: Warning Plate Locations
36
Warning Plates on the Turbocharger
36
Fig. 4: Locations of the Rating Plates
37
Locations of the Rating Plates
37
Fig. 5: Suspension of Complete Turbocharger Unit
38
Removing and Installing
38
Table 2: Weight of Complete Turbocharger Unit
38
Turbocharger Weight and Transportation
38
Fig. 6: Turbine Cleaning Nozzle
39
Removing the Turbocharger
39
Fig. 7: Removing the Turbocharger
40
Fig. 8: Loosening the Clamping Nut
42
Fig. 9: Turbocharger Centre of Gravity
43
Fig. 10: Inserting Gaskets into the Bracket
44
Installing the Turbocharger
44
Fig. 11: Inserting the Threaded Rods
45
Fig. 12: Requirements for Threaded Rods
45
Table 3: Requirements for Threaded Rods
45
Fig. 13: Placing the Turbocharger on the Bracket
46
Table 4: Tightening Torque for Standard Nuts
47
Fig. 14: Preparing the Clamping Nut for the Tightening Procedure
48
Fig. 15: Tightening Pressure Screws
49
Table 5: Torque-Controlled Tightening of the Pressure Screws
49
Fig. 16: Connecting the Speed Sensor
50
Fig. 17: Connecting the Compressor Cooling Air Intake
50
Fig. 18: Attaching the Support
51
Commissioning
52
Oil Supply
52
Fig. 19: Oil Orifice
53
Inspection Procedures
54
Commissioning after Taking out of Operation
56
Monitoring Operation
57
Oil Pressure, Oil Temperature
57
Table 6: Lubricating Oil Pressure at Oil Inlet before Turbocharger
57
Table 7: Lubricating Oil Temperature at the Inlet
58
Table 8: Lubricating Oil Temperature at the Outlet
58
Exhaust Gas Temperature before Turbine
59
Fig. 20: Layout and Overview of Speed Measurement System
60
Turbocharger Speed
60
Fig. 21: Replacing the Speed Sensor
62
Table 9: Tightening Torque (86505)
62
Noise Emission
63
Operation and Service
63
Fig. 22: Noise Insulation, Bellows
64
Service Work
65
Fig. 23: Replacing the Protective Grid
67
Expected Replacement Intervals
69
Table 10: Expected Replacement Intervals
69
Stopping the Engine
71
Foreword to Maintenance
72
Periodic Maintenance Work
72
Table 11: Maintenance Table
72
Cleaning the Compressor During Operation
73
Fig. 24: Carrying out Wet Cleaning of Compressor
75
Table 12: Parameters for Wet Cleaning of Compressor
75
Cleaning the Turbine During Operation
76
Table 13: Turbine Wet Cleaning, Recommended Operating State
78
Fig. 25: Carrying out Wet Cleaning of Turbine
79
Table 14: Wet Cleaning of Turbine, Parameters
79
Cleaning Components Mechanically
80
Fig. 26: Cleaning the Filter Silencer
81
Fig. 27: Compressor-End, Non-Rotating Parts
83
Fig. 28: Turbine End, Non-Rotating Parts
85
Fig. 29: Soaking the Turbine End
87
Table 15: Value Table for Soaking
87
Eliminating Malfunctions
90
Malfunctions When Starting
90
Table 16: Malfunctions When Starting - Delayed Start-Up
90
Table 17: Malfunctions When Starting - Vibrations
90
Table 18: Malfunctions When Starting - Rubbing of Rotating Parts
90
Malfunctions During Operation
91
Table 19: Malfunctions During Operation - Lubricating Oil Pressure too Low
91
Table 20: Malfunctions During Operation - Speed Reduces
91
Table 21: Malfunctions During Operation - Speed Increases
91
Table 22: Malfunctions During Operation - Exhaust Gas Temperature too High
92
Table 23: Malfunctions During Operation - Charge Air Pressure too Low
92
Table 24: Malfunctions During Operation - Charge Air Pressure too High
93
Table 25: Malfunctions During Operation - Engine Performance Losses
93
Table 26: Malfunction - Turbocharger Pumping
94
Table 27: Malfunction - Sporadic Surge Blows
94
Turbocharger Is Surging
94
Malfunctions When Stopping
95
Table 28: Malfunctions When Stopping - Runout Noises
95
Table 29: Malfunctions When Stopping - Runout Time too Short
95
Speed Measurement System
96
Table 30: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
96
Table 31: Malfunction of the Speed Measurement System - Measured Speed too High
96
Table 32: Malfunction of the Speed Measurement System - Measured Speed too Low
96
Dismantling and Fitting
97
Introduction
97
Fig. 30: Swivel Lifting Eyes
99
Fig. 31: Starpoint Ring Nut VRM
99
Table 33: Swivel Lifting Eyes
99
ABB A145-M66 Operation Manual (144 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 18.52 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
25
Product Description
31
Essential Information
33
Introduction
33
Registered Trademarks
33
Related Documents
33
Table 1: Related Documents
33
Fig. 1: Layout and Function of the Turbocharger
34
Layout and Function of the Turbocharger
34
Fig. 2: Compressor Wheel Cooling
35
Fig. 3: Warning Plate Locations
36
Warning Plates on the Turbocharger
36
Fig. 4: Locations of the Rating Plates
37
Locations of the Rating Plates
37
Fig. 5: Suspension of Complete Turbocharger Unit
38
Removing and Installing
38
Table 2: Weights of Turbochargers A130-M
38
Turbocharger Weight and Transportation
38
Fig. 6: Turbine Cleaning Nozzle
39
Removing the Turbocharger
39
Fig. 7: Removing the Turbocharger
40
Fig. 8: Loosening the Clamping Nut
42
Fig. 9: Turbocharger Centre of Gravity
43
Fig. 10: Inserting Gaskets into the Bracket
44
Installing the Turbocharger
44
Fig. 11: Inserting the Threaded Rods
45
Fig. 12: Requirements for Threaded Rods
45
Table 3: Requirements for Threaded Rods
45
Fig. 13: Placing the Turbocharger on the Bracket
46
Table 4: Tightening Torques for Standard Nuts
47
Fig. 14: Preparing the Clamping Nut for the Tightening Procedure
48
Fig. 15: Tightening Pressure Screws
49
Table 5: Pressure Screw Tightening Torques
49
Fig. 16: Connecting the Speed Sensor
50
Fig. 17: Connecting the Compressor Cooling Air Intake
50
Fig. 18: Attaching the Support
51
Commissioning
52
Oil Supply
52
Fig. 19: Oil Orifice
53
Inspection Procedures
54
Commissioning after Taking out of Operation
56
Monitoring Operation
57
Oil Pressure, Oil Temperature
57
Table 6: Lubricating Oil Pressure at Oil Inlet before Turbocharger
57
Table 7: Lubricating Oil Temperature at the Inlet
58
Table 8: Lubricating Oil Temperature at the Outlet
58
Exhaust Gas Temperature before Turbine
59
Fig. 20: Layout and Overview of Speed Measurement System
60
Turbocharger Speed
60
Fig. 21: Replacing the Speed Sensor
62
Table 9: Tightening Torque (86505)
62
Noise Emission
63
Operation and Service
63
Fig. 22: Noise Insulation, Bellows
64
Service Work
65
Fig. 23: Replacing the Protective Grid
67
Expected Replacement Intervals
69
Table 10: Expected Replacement Intervals
69
Stopping the Engine
71
Foreword to Maintenance
72
Periodic Maintenance Work
72
Table 11: Maintenance Table
72
Cleaning the Compressor During Operation
73
Fig. 24: Carrying out Wet Cleaning of Compressor
75
Table 12: Parameters for Wet Cleaning of Compressor
75
Cleaning the Turbine During Operation
76
Table 13: Turbine Wet Cleaning, Recommended Operating State
78
Fig. 25: Carrying out Wet Cleaning of Turbine
79
Table 14: Wet Cleaning of Turbine, Parameters
79
Cleaning Components Mechanically
80
Fig. 26: Cleaning the Filter Silencer
81
Fig. 27: Compressor-End, Non-Rotating Parts
83
Fig. 28: Turbine End, Non-Rotating Parts
85
Fig. 29: Soaking the Turbine End
87
Table 15: Value Table for Soaking
87
Eliminating Malfunctions
90
Malfunctions When Starting
90
Table 16: Malfunctions When Starting - Delayed Start-Up
90
Table 17: Malfunctions When Starting - Vibrations
90
Table 18: Malfunctions When Starting - Rubbing of Rotating Parts
90
Malfunctions During Operation
91
Table 19: Malfunctions During Operation - Lubricating Oil Pressure too Low
91
Table 20: Malfunctions During Operation - Speed Reduces
91
Table 21: Malfunctions During Operation - Speed Increases
91
Table 22: Malfunctions During Operation - Exhaust Gas Temperature too High
92
Table 23: Malfunctions During Operation - Charge Air Pressure too Low
92
Table 24: Malfunctions During Operation - Charge Air Pressure too High
93
Table 25: Malfunctions During Operation - Engine Performance Losses
93
Table 26: Malfunction - Turbocharger Pumping
94
Table 27: Malfunction - Sporadic Surge Blows
94
Turbocharger Is Surging
94
Malfunctions When Stopping
95
Table 28: Malfunctions When Stopping - Runout Noises
95
Table 29: Malfunctions When Stopping - Runout Time too Short
95
Speed Measurement System
96
Table 30: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
96
Table 31: Malfunction of the Speed Measurement System - Measured Speed too High
96
Table 32: Malfunction of the Speed Measurement System - Measured Speed too Low
96
Dismantling and Fitting
97
Introduction
97
Table 33: Swivel Lifting Eyes
99
Table 34: Ring Nuts to be Used
100
Fig. 30: Weights of Assemblies
101
Table 35: Weights of Assemblies
101
Weights of Individual Parts
101
Fig. 31: Removing Air Inlets
102
Removing Air Inlets
102
Fig. 32: Removing the Insulation
103
Removing the Gas Outlet Casing
103
Fig. 33: Removing the Gas Outlet Casing
104
Removing the Gas Outlet Flange
105
Fig. 34: Dismantling the Gas Outlet Flange
106
Table 36: 3 Press-Off Screws
106
Fig. 35: Removing the Gas Outlet Flange
107
Table 37: 6 Press-Off Screws
107
Fig. 36: Removing the Compressor Casing
108
Removing the Compressor Casing
108
Fig. 37: Dismantling the Wall Insert
109
Fig. 38: Press off the Casing
110
Pressing off the Casing
110
Fig. 39: Removing Insulation Sheets
111
Fig. 40: Oil Orifice
111
Removing the Cartridge Group
111
Fig. 41: Removing Cartridge Group 1
112
Fig. 42: Removing Cartridge Group 2
112
Fig. 43: Removing the Nozzle Ring
113
Removing the Nozzle Ring
113
Fig. 44: Installing the Cartridge Group on the Service Support
114
Installing the Cartridge Group on the Service Support
114
Axial Clearance a and Radial Clearance B
115
Fig. 45: Measuring Clearance a and B
115
Table 38: Permissible Clearances a and B
115
Fig. 46: Nozzle Ring Compression PD
116
Nozzle Ring Compression PD
116
Table 39: Permitted Nozzle Ring Compression PD
116
Fig. 47: Installing the Nozzle Ring
117
Installing Nozzle Ring
117
Fig. 48: Lifting the Cartridge Group and Rotating It
118
Installing the Cartridge Group
118
Fig. 49: Installing the Cartridge Group
119
Table 40: Tightening Torque (51007)
119
Fig. 50: Turbine Casing Insulation / Burst Protection
120
Installing the Compressor Casing
121
Table 41: Tightening Torque (79041)
121
Fig. 51: Installing the Compressor Casing
122
Table 42: Tightening Torque (72011)
122
Fig. 52: Measuring Clearances N and R
123
Radial Clearances N and R
123
Table 43: Permissible Clearances N and R
123
Fig. 53: Installing the Air Inlets
124
Installing Air Inlets
124
Table 44: Tightening Torque (72020)
124
Fig. 54: Installing the Gas Outlet Flange
125
Installing the Gas Outlet Flange
125
Fig. 55: Fitting the Insulation
126
Fig. 56: Installing the Gas Outlet Casing
127
Installing the Gas Outlet Casing
127
Table 45: Tightening Torque (51009)
127
Fig. 57: Fitting the Insulation
128
Fig. 58: Tightening Torques
129
Table 46: Tightening Torques
129
Table of Tightening Torques
129
Fig. 59: Tightening Torques for Insulation
130
Table 47: Tightening Torques for Insulation
130
Possible Emergency Repairs
131
Taking out of Operation at Short Notice
131
Installing the Replacement Cartridge Group
132
Installing the Replacement Turbocharger
132
Fig. 60: Fitting the Cover Plate
133
Fitting the Cover Plate
133
Cover Plate Drawing
134
Fig. 61: Cover Plate Drawing
134
Table 48: Cover Plate Dimensions [MM]
134
Mothballing the Turbocharger
135
Taking the Engine out of Operation for up to 12 Months
135
Taking the Engine out of Operation for more than 12 Months
136
Disposing of Turbocharger Components
137
Ordering Spare Parts
138
Required Customer Spare Part Set (97070)
138
Spare Parts
138
Table 49: Customer Spare Part Set 97070
138
Fig. 62: Overview of Part Numbers
140
View of Turbocharger with Part Numbers
140
Table 50: Spare Parts List
141
Fig. 63: Overview of Part Numbers
142
Table 51: Spare Parts List
142
View of Turbine Cleaning Device
142
ABB A145-M66 Operation Manual (142 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 18.93 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
25
Product Description
31
Essential Information
33
Introduction
33
Registered Trademarks
33
Related Documents
33
Table 1: Related Documents
33
Fig. 1: Layout and Function of the Turbocharger
34
Layout and Function of the Turbocharger
34
Fig. 2: Compressor Wheel Cooling
35
Fig. 3: Warning Plate Locations
36
Warning Plates on the Turbocharger
36
Fig. 4: Locations of the Rating Plates
37
Locations of the Rating Plates
37
Fig. 5: Suspension of Complete Turbocharger Unit
38
Removing and Installing
38
Table 2: Weights of Turbochargers A130-M
38
Turbocharger Weight and Transportation
38
Fig. 6: Removing the Turbocharger
39
Removing the Turbocharger
39
Fig. 7: Loosening the Clamping Nut
41
Fig. 8: Turbocharger Centre of Gravity
42
Fig. 9: Inserting Gaskets into the Bracket
43
Installing the Turbocharger
43
Fig. 10: Inserting the Threaded Rods
44
Fig. 11: Requirements for Threaded Rods
44
Table 3: Requirements for Threaded Rods
44
Fig. 12: Placing the Turbocharger on the Bracket
45
Table 4: Tightening Torques for Standard Nuts
46
Fig. 13: Preparing the Clamping Nut for the Tightening Procedure
47
Fig. 14: Tightening Pressure Screws
48
Table 5: Pressure Screw Tightening Torques
48
Fig. 15: Connecting the Compressor Cooling Air Intake
49
Fig. 16: Attaching the Support
49
Commissioning
50
Oil Supply
50
Fig. 17: Oil Orifice
51
Inspection Procedures
52
Commissioning after Taking out of Operation
54
Monitoring Operation
55
Oil Pressure, Oil Temperature
55
Table 6: Lubricating Oil Pressure, Oil Inlet
55
Table 7: Lubricating Oil Temperature at the Inlet
56
Table 8: Lubricating Oil Temperature at the Outlet
56
Exhaust Gas Temperature before Turbine
57
Fig. 18: Layout and Overview of Speed Measurement System
58
Turbocharger Speed
58
Fig. 19: Replacing the Speed Sensor
60
Table 9: Tightening Torque (86505)
60
Fig. 20: Noise Insulation, Bellows
61
Noise Emission
61
Operation and Service
61
Service Work
63
Fig. 21: Replacing the Protective Grid
65
Expected Replacement Intervals
67
Table 10: Expected Replacement Intervals
67
Stopping the Engine
69
Foreword to Maintenance
70
Periodic Maintenance Work
70
Table 11: Maintenance Table
70
Cleaning the Compressor During Operation
71
Fig. 22: Carrying out Wet Cleaning of Compressor
74
Table 12: Parameters for Wet Cleaning of Compressor
74
Cleaning the Turbine During Operation
75
Table 13: Turbine Wet Cleaning, Recommended Operating State
77
Fig. 23: Carrying out Wet Cleaning of Turbines
78
Table 14: Wet Cleaning of Turbines, Parameters
78
Cleaning Components Mechanically
79
Fig. 24: Cleaning the Filter Silencer
80
Fig. 25: Compressor-End, Non-Rotating Parts
82
Fig. 26: Turbine End, Non-Rotating Parts
83
Fig. 27: Soaking the Turbine End
86
Table 15: Value Table for Soaking
86
Eliminating Malfunctions
89
Malfunctions When Starting
89
Table 16: Malfunctions When Starting - Delayed Start-Up
89
Table 17: Malfunctions When Starting - Vibrations
89
Table 18: Malfunctions When Starting - Rubbing of Rotating Parts
89
Malfunctions During Operation
90
Table 19: Malfunctions During Operation - Lubricating Oil Pressure too Low
90
Table 20: Malfunctions During Operation - Speed Reduces
90
Table 21: Malfunctions During Operation - Speed Increases
90
Table 22: Malfunctions During Operation - Exhaust Gas Temperature too High
91
Table 23: Malfunctions During Operation - Charge Air Pressure too Low
91
Table 24: Malfunctions During Operation - Charge Air Pressure too High
92
Table 25: Malfunctions During Operation - Engine Performance Losses
92
Table 26: Malfunction - Turbocharger Pumping
93
Table 27: Malfunction - Sporadic Surge Blows
93
Turbocharger Is Surging
93
Malfunctions When Stopping
94
Table 28: Malfunctions When Stopping - Runout Noises
94
Table 29: Malfunctions When Stopping - Runout Time too Short
94
Speed Measurement System
95
Table 30: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
95
Table 31: Malfunction of the Speed Measurement System - Measured Speed too High
95
Table 32: Malfunction of the Speed Measurement System - Measured Speed too Low
95
Dismantling and Fitting
96
Introduction
96
Table 33: Swivel Lifting Eyes
98
Table 34: Ring Nuts to be Used
99
Fig. 28: Weights of Assemblies
100
Table 35: Weights of Assemblies
100
Weights of Individual Parts
100
Fig. 29: Removing Air Inlets
101
Removing Air Inlets
101
Fig. 30: Removing the Insulation
102
Removing the Gas Outlet Casing
102
Fig. 31: Removing the Gas Outlet Casing
103
Removing the Gas Outlet Flange
104
Fig. 32: Dismantling the Gas Outlet Flange
105
Table 36: 3 Press-Off Screws
105
Fig. 33: Removing the Gas Outlet Flange
106
Table 37: 6 Press-Off Screws
106
Fig. 34: Removing the Compressor Casing
107
Removing the Compressor Casing
107
Fig. 35: Dismantling the Wall Insert
108
Fig. 36: Press off the Casing
109
Pressing off the Casing
109
Fig. 37: Removing Insulation Sheets
110
Fig. 38: Oil Orifice
110
Removing the Cartridge Group
110
Fig. 39: Removing Cartridge Group 1
111
Fig. 40: Removing Cartridge Group 2
111
Fig. 41: Removing the Nozzle Ring
112
Removing the Nozzle Ring
112
Fig. 42: Installing the Cartridge Group on the Service Support
113
Installing the Cartridge Group on the Service Support
113
Axial Clearance a and Radial Clearance B
114
Fig. 43: Measuring Clearance a and B
114
Table 38: Permissible Clearances a and B
114
Fig. 44: Nozzle Ring Compression PD
115
Nozzle Ring Compression PD
115
Table 39: Permitted Nozzle Ring Compression PD
115
Fig. 45: Installing the Nozzle Ring
116
Installing Nozzle Ring
116
Fig. 46: Lifting the Cartridge Group and Rotating It
117
Installing the Cartridge Group
117
Fig. 47: Installing the Cartridge Group
118
Table 40: Tightening Torque (51007)
118
Fig. 48: Turbine Casing Insulation / Burst Protection
119
Installing the Compressor Casing
120
Table 41: Tightening Torque (79041)
120
Fig. 49: Installing the Compressor Casing
121
Table 42: Tightening Torque (72011)
121
Fig. 50: Measuring Clearances N and R
122
Radial Clearances N and R
122
Table 43: Permissible Clearances N and R
122
Fig. 51: Installing the Air Inlets
123
Installing Air Inlets
123
Table 44: Tightening Torque (72020)
123
Fig. 52: Installing the Gas Outlet Flange
124
Installing the Gas Outlet Flange
124
Fig. 53: Fitting the Insulation
125
Fig. 54: Installing the Gas Outlet Casing
126
Installing the Gas Outlet Casing
126
Table 45: Tightening Torque (51009)
126
Fig. 55: Fitting the Insulation
127
Fig. 56: Tightening Torques
128
Table 46: Tightening Torques
128
Table of Tightening Torques
128
Fig. 57: Tightening Torques for Insulation
129
Table 47: Tightening Torques for Insulation
129
Possible Emergency Repairs
130
Taking out of Operation at Short Notice
130
Installing a Replacement Cartridge Group
131
Installing a Replacement Turbocharger
131
Fig. 58: Fitting the Cover Plate
132
Fitting the Cover Plate
132
Cover Plate Drawing
133
Fig. 59: Cover Plate Drawing
133
Table 48: Cover Plate Dimensions [MM]
133
Mothballing the Turbocharger
134
Taking the Engine out of Operation for up to 12 Months
134
Taking the Engine out of Operation for more than 12 Months
135
Disposing of Turbocharger Components
136
Ordering Spare Parts
137
Required Customer Spare Part Set (97070)
137
Spare Parts
137
Table 49: Customer Spare Part Set 97070
137
Fig. 60: Overview of Part Numbers
138
View of Turbocharger with Part Numbers
138
Table 50: Spare Parts List
139
ABB A145-M66 Operation Manual (142 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 18.93 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
25
Product Description
31
Essential Information
33
Introduction
33
Registered Trademarks
33
Related Documents
33
Table 1: Related Documents
33
Fig. 1: Layout and Function of the Turbocharger
34
Layout and Function of the Turbocharger
34
Fig. 2: Compressor Wheel Cooling
35
Fig. 3: Warning Plate Locations
36
Warning Plates on the Turbocharger
36
Fig. 4: Locations of the Rating Plates
37
Locations of the Rating Plates
37
Fig. 5: Suspension of Complete Turbocharger Unit
38
Removing and Installing
38
Table 2: Weights of Turbochargers A130-M
38
Turbocharger Weight and Transportation
38
Fig. 6: Removing the Turbocharger
39
Removing the Turbocharger
39
Fig. 7: Loosening the Clamping Nut
41
Fig. 8: Turbocharger Centre of Gravity
42
Fig. 9: Inserting Gaskets into the Bracket
43
Installing the Turbocharger
43
Fig. 10: Inserting the Threaded Rods
44
Fig. 11: Requirements for Threaded Rods
44
Table 3: Requirements for Threaded Rods
44
Fig. 12: Placing the Turbocharger on the Bracket
45
Table 4: Tightening Torques for Standard Nuts
46
Fig. 13: Preparing the Clamping Nut for the Tightening Procedure
47
Fig. 14: Tightening Pressure Screws
48
Table 5: Pressure Screw Tightening Torques
48
Fig. 15: Connecting the Compressor Cooling Air Intake
49
Fig. 16: Attaching the Support
49
Commissioning
50
Oil Supply
50
Fig. 17: Oil Orifice
51
Inspection Procedures
52
Commissioning after Taking out of Operation
54
Monitoring Operation
55
Oil Pressure, Oil Temperature
55
Table 6: Lubricating Oil Pressure, Oil Inlet
55
Table 7: Lubricating Oil Temperature at the Inlet
56
Table 8: Lubricating Oil Temperature at the Outlet
56
Exhaust Gas Temperature before Turbine
57
Fig. 18: Layout and Overview of Speed Measurement System
58
Turbocharger Speed
58
Fig. 19: Replacing the Speed Sensor
60
Table 9: Tightening Torque (86505)
60
Fig. 20: Noise Insulation, Bellows
61
Noise Emission
61
Operation and Service
61
Service Work
63
Fig. 21: Replacing the Protective Grid
65
Expected Replacement Intervals
67
Table 10: Expected Replacement Intervals
67
Stopping the Engine
69
Foreword to Maintenance
70
Periodic Maintenance Work
70
Table 11: Maintenance Table
70
Cleaning the Compressor During Operation
71
Fig. 22: Carrying out Wet Cleaning of Compressor
74
Table 12: Parameters for Wet Cleaning of Compressor
74
Cleaning the Turbine During Operation
75
Table 13: Turbine Wet Cleaning, Recommended Operating State
77
Fig. 23: Carrying out Wet Cleaning of Turbines
78
Table 14: Wet Cleaning of Turbines, Parameters
78
Cleaning Components Mechanically
79
Fig. 24: Cleaning the Filter Silencer
80
Fig. 25: Compressor-End, Non-Rotating Parts
82
Fig. 26: Turbine End, Non-Rotating Parts
83
Fig. 27: Soaking the Turbine End
86
Table 15: Value Table for Soaking
86
Eliminating Malfunctions
89
Malfunctions When Starting
89
Table 16: Malfunctions When Starting - Delayed Start-Up
89
Table 17: Malfunctions When Starting - Vibrations
89
Table 18: Malfunctions When Starting - Rubbing of Rotating Parts
89
Malfunctions During Operation
90
Table 19: Malfunctions During Operation - Lubricating Oil Pressure too Low
90
Table 20: Malfunctions During Operation - Speed Reduces
90
Table 21: Malfunctions During Operation - Speed Increases
90
Table 22: Malfunctions During Operation - Exhaust Gas Temperature too High
91
Table 23: Malfunctions During Operation - Charge Air Pressure too Low
91
Table 24: Malfunctions During Operation - Charge Air Pressure too High
92
Table 25: Malfunctions During Operation - Engine Performance Losses
92
Table 26: Malfunction - Turbocharger Pumping
93
Table 27: Malfunction - Sporadic Surge Blows
93
Turbocharger Is Surging
93
Malfunctions When Stopping
94
Table 28: Malfunctions When Stopping - Runout Noises
94
Table 29: Malfunctions When Stopping - Runout Time too Short
94
Speed Measurement System
95
Table 30: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
95
Table 31: Malfunction of the Speed Measurement System - Measured Speed too High
95
Table 32: Malfunction of the Speed Measurement System - Measured Speed too Low
95
Dismantling and Fitting
96
Introduction
96
Table 33: Swivel Lifting Eyes
98
Table 34: Ring Nuts to be Used
99
Fig. 28: Weights of Assemblies
100
Table 35: Weights of Assemblies
100
Weights of Individual Parts
100
Fig. 29: Removing Air Inlets
101
Removing Air Inlets
101
Fig. 30: Removing the Insulation
102
Removing the Gas Outlet Casing
102
Fig. 31: Removing the Gas Outlet Casing
103
Removing the Gas Outlet Flange
104
Fig. 32: Dismantling the Gas Outlet Flange
105
Table 36: 3 Press-Off Screws
105
Fig. 33: Removing the Gas Outlet Flange
106
Table 37: 6 Press-Off Screws
106
Fig. 34: Removing the Compressor Casing
107
Removing the Compressor Casing
107
Fig. 35: Dismantling the Wall Insert
108
Fig. 36: Press off the Casing
109
Pressing off the Casing
109
Fig. 37: Removing Insulation Sheets
110
Fig. 38: Oil Orifice
110
Removing the Cartridge Group
110
Fig. 39: Removing Cartridge Group 1
111
Fig. 40: Removing Cartridge Group 2
111
Fig. 41: Removing the Nozzle Ring
112
Removing the Nozzle Ring
112
Fig. 42: Installing the Cartridge Group on the Service Support
113
Installing the Cartridge Group on the Service Support
113
Axial Clearance a and Radial Clearance B
114
Fig. 43: Measuring Clearance a and B
114
Table 38: Permissible Clearances a and B
114
Fig. 44: Nozzle Ring Compression PD
115
Nozzle Ring Compression PD
115
Table 39: Permitted Nozzle Ring Compression PD
115
Fig. 45: Installing the Nozzle Ring
116
Installing Nozzle Ring
116
Fig. 46: Lifting the Cartridge Group and Rotating It
117
Installing the Cartridge Group
117
Fig. 47: Installing the Cartridge Group
118
Table 40: Tightening Torque (51007)
118
Fig. 48: Turbine Casing Insulation / Burst Protection
119
Installing the Compressor Casing
120
Table 41: Tightening Torque (79041)
120
Fig. 49: Installing the Compressor Casing
121
Table 42: Tightening Torque (72011)
121
Fig. 50: Measuring Clearances N and R
122
Radial Clearances N and R
122
Table 43: Permissible Clearances N and R
122
Fig. 51: Installing the Air Inlets
123
Installing Air Inlets
123
Table 44: Tightening Torque (72020)
123
Fig. 52: Installing the Gas Outlet Flange
124
Installing the Gas Outlet Flange
124
Fig. 53: Fitting the Insulation
125
Fig. 54: Installing the Gas Outlet Casing
126
Installing the Gas Outlet Casing
126
Table 45: Tightening Torque (51009)
126
Fig. 55: Fitting the Insulation
127
Fig. 56: Tightening Torques
128
Table 46: Tightening Torques
128
Table of Tightening Torques
128
Fig. 57: Tightening Torques for Insulation
129
Table 47: Tightening Torques for Insulation
129
Possible Emergency Repairs
130
Taking out of Operation at Short Notice
130
Installing a Replacement Cartridge Group
131
Installing a Replacement Turbocharger
131
Fig. 58: Fitting the Cover Plate
132
Fitting the Cover Plate
132
Cover Plate Drawing
133
Fig. 59: Cover Plate Drawing
133
Table 48: Cover Plate Dimensions [MM]
133
Mothballing the Turbocharger
134
Taking the Engine out of Operation for up to 12 Months
134
Taking the Engine out of Operation for more than 12 Months
135
Disposing of Turbocharger Components
136
Ordering Spare Parts
137
Required Customer Spare Part Set (97070)
137
Spare Parts
137
Table 49: Customer Spare Part Set 97070
137
Fig. 60: Overview of Part Numbers
138
View of Turbocharger with Part Numbers
138
Table 50: Spare Parts List
139
ABB A145-M66 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
ABB A145-M66 Operation Manual (112 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 12.77 MB
Table of Contents
Operation Manual / Tps44-H - Tps52-H
3
Table of Contents
3
Fig. 1: Serial Number (01) on the Rating Plate
6
Operation Manual / TPS44-H
6
Purpose of the Manual
6
Introduction
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
Symbols, Definitions
9
Table 1: Definition of Pictograms
11
Fig. 3: Volatile Corrosion Inhibitor (VCI)
12
Storage of New Turbochargers and Spare Parts
12
Fig. 4: 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
Warning Plates on the Turbocharger
18
Fig. 5: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 6: Rating Plate
19
Fig. 7: Position of the Rating Plate
20
Lifting of Loads
21
Fig. 8: Attachment of Loads on the Crane Hook
21
Fig. 9: Attachment Angle
21
Prerequisites for Operation and Maintenance
22
Hazards During Operation and Maintenance
23
Safe Operation
25
Safe Maintenance
26
Removing and Installing
30
Turbocharger Weight and Transportation
30
Fig. 10: Swivel Lifting Eyes
30
Table 4: Gesamtgewicht
30
Table 5: Swivel Lifting Eyes to be Used
30
Removing the Turbocharger
31
Fig. 11: Removing the Turbocharger
32
Installing the Turbocharger
33
Fig. 12: Inserting Gaskets into the Bracket
33
Table 6: Requirements for Threaded Rods
34
Fig. 13: Inserting Threaded Rods into the Bracket
34
Fig. 14: Requirements for Threaded Rods
34
Fig. 15: Placing the Turbocharger on the Bracket
35
Table 7: Tightening Torque for Standard Nuts
35
Commissioning
36
Oil Supply
36
Inspection Procedures
37
Commissioning after Taking out of Operation
39
Monitoring Operation
40
Oil Pressure, Oil Temperature
40
Table 8: Lubricating Oil Pressure at Oil Inlet before Turbocharger
40
Table 10: Lubricating Oil Temperature at the Outlet
42
Table 9: Lubricating Oil Temperature at the Inlet
42
Exhaust Gas Temperature before Turbine
43
Turbocharger Speed
43
Fig. 16: Layout and Overview of the Speed Measurement System
44
Fig. 17: Fitting the Speed Sensor
46
Table 11: Tightening Torque (86505)
46
Operation and Service
47
Noise Emission
47
Fig. 18: Noise Insulation, Bellows
48
Service Work
49
Expected Replacement Intervals
52
Table 12: Expected Replacement Intervals
53
Stopping the Engine
54
Foreword to Maintenance
55
Cleaning Components Mechanically
55
Table 13: Maintenance Table
55
Periodic Maintenance Work
55
Fig. 19: Cleaning the Filter Silencer
56
Fig. 20: Cleaning the Compressor Casing, Diffuser Mechanically
58
Fig. 21: Cleaning the Nozzle Ring, Turbine Casing Mechanically
59
Fig. 22: Soaking Contamination of the Turbine
61
Table 14: Dimensions of the Cleaning Container
61
Table 16: Malfunctions When Starting - Vibrations
65
Table 17: Malfunctions When Starting - Rotating Parts Rubbing
65
Eliminating Malfunctions
65
Table 15: Malfunctions When Starting - Delayed Start-Up
65
Malfunctions When Starting
65
Malfunctions During Operation
66
Table 18: Malfunctions During Operation - Lubricating Oil Pressure too Low
66
Table 19: Malfunctions During Operation - Speed Reduces
66
Table 20: Malfunctions During Operation - Speed Increases
66
Table 21: Malfunctions During Operation - Exhaust Gas Temperature too High
67
Table 22: Malfunctions During Operation - Charge Air Pressure too Low
67
Table 24: Malfunctions During Operation - Engine Performance Losses
68
Table 23: Malfunctions During Operation - Charge Air Pressure too High
68
Table 25: Malfunction - Turbocharger Pumping
69
Table 26: Malfunction - Sporadic Surge Blows
69
Turbocharger Is Surging
69
Malfunctions When Stopping
70
Table 27: Malfunctions When Stopping - Runout Noises
70
Table 28: Malfunctions When Stopping - Runout Time too Short
70
Table 30: Malfunction of the Speed Measurement System - Measured Speed too High
71
Table 31: Malfunction of the Speed Measurement System - Measured Speed too Low
71
Table 29: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
71
Speed Measurement System
71
Dismantling and Fitting
72
Introduction
72
Material Required
73
Fig. 23: Swivel Lifting Eyes
73
Table 32: Swivel Lifting Eyes to be Used
73
Fig. 24: Ring Nuts
74
Table 33: Ring Nuts to be Used (VRM)
74
Weights of Individual Parts
75
Fig. 25: Overview of Assemblies
75
Table 34: Weights of the Assemblies [Kg]
75
Fig. 26: Removing the Gas Outlet Casing
76
Removing the Gas Outlet Casing
76
Removing Air Inlets
77
Fig. 27: Removing Air Inlets
77
Removing the Compressor Casing
78
Fig. 28: Removing the Compressor Casing (1/2)
78
Fig. 29: Removing the Compressor Casing (2/2)
78
Removing the Cartridge Group
79
Fig. 30
79
Fig. 31: Do Not Loosen Screw Plugs
79
Fig. 32: Removing the Cartridge Group (1)
80
Fig. 33: Removing Cartridge Group 2
80
Fig. 34: Rotating the Cartridge Group and Fitting the Service Support
81
Removing Nozzle Ring
82
Fig. 35: Removing the Nozzle Ring
82
Measuring Clearance a and B
83
Fig. 36: Measuring Clearance a and B
83
Table 35: Permissible Clearances a and B
83
Nozzle Ring Compression PD
84
Fig. 37: Measuring Nozzle Ring Compression
84
Table 36: Nozzle Ring Compression PD
84
Fitting the Diffuser
85
Fig. 38: Fitting the Diffuser
85
Table 37: Tightening Torque (72041)
85
Fig. 39: Lifting the Cartridge Group and Rotating It
86
Installing the Cartridge Group
86
Fig. 40: Fitting the Cartridge Group
87
Table 38: Tightening Torque (72011)
87
Installing the Nozzle Ring
88
Fig. 41: Installing the Nozzle Ring
88
Fitting the Turbine Casing
89
Fig. 42: Fitting the Turbine Casing
89
Table 39: Tightening Torque (51007)
89
Turning the Turbocharger
90
Fig. 43: Rotating the Turbocharger
90
Table 40: Permissible Clearances N and R
91
Fig. 44: Measuring Clearances N and R
91
Measuring Radial Clearances N and R
91
Installing the Gas Outlet Casing
92
Fig. 45: Fitting the Gas Outlet Casing
92
Table 41: Tightening Torque (51008)
92
Installing Air Inlets
93
Fig. 46: Installing the Air Inlets
93
Table 42: Tightening Torque (72020)
93
Table of Tightening Torques
94
Fig. 47: Overview of Tightening Torques
94
Table 43: Overview of Tightening Torques
94
Possible Emergency Repairs
95
Taking out of Operation at Short Notice
95
Mothballing the Turbocharger
96
Taking the Engine out of Operation for up to 12 Months
96
Taking the Engine out of Operation for more than 12 Months
97
Material and Disposal
98
REACH and Rohs Compliance Declaration for Products
98
Disposing of Turbocharger Components
99
Spare Parts
100
Ordering Spare Parts
100
Required Customer Spare Part Set (97070)
100
Table 44: Customer Spare Part Set (97070)
100
Table 45: Spare Parts - Cartridge
101
Spare Part - Illustrations
101
Table 46: Spare Parts - Turbine Casing
102
Table 47: Spare Parts - Compressor Casing
103
Table 48: Spare Parts - Filter Silencer
104
Table 49: Spare Parts - Air Suction Branch Radial
105
Table 50: Spare Parts - Air Suction Brach Axial
106
Table 51: Spare Parts - Gas Outlet Casing
107
Table 52: Spare Parts - Speed Measurement System
108
Tools
109
Table 53: TPS-H Tool
109
ABB A145-M66 Operation Manual (148 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 12.37 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
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
Table 10 Expected Replacement Intervals
31
Table 16 Malfunctions When Starting
31
Table 19 Malfunctions During Operation
32
Table 28 Malfunctions When Stopping
32
Essential Information
35
Introduction
35
Registered Trademarks
35
Related Documents
35
Table 1 Related Documents
35
Layout and Function of the Turbocharger
36
Warning Plates on the Turbocharger
38
Locations of the Rating Plates
39
Removing and Installing
41
Table 2 Turbocharger Weights
41
Turbocharger Weight and Transportation
41
Removing the Turbocharger
42
Installing the Turbocharger
46
Table 3 Requirements for Threaded Rods
47
Table 4 Tightening Torques for Stand
49
Table 5 Pressure Screw Tightening Torques
51
Commissioning
53
Oil Supply
53
Inspection Procedures
55
Commissioning after Taking out of Operation
57
Monitoring Operation
59
Oil Pressure, Oil Temperature
59
Table 6 Lubricating Oil Pressure, Oil Inlet
59
Table 7 Lubricating Oil Temperature at
60
Table 8 Lubricating Oil Temperature at the Outlet
60
Exhaust Gas Temperature before Turbine
61
Turbocharger Speed
62
Noise Emission
65
Operation and Service
65
Service Work
67
Expected Replacement Intervals
71
Stopping the Engine
73
Foreword to Maintenance
75
Periodic Maintenance Work
75
Table 11 Maintenance Table
75
Cleaning the Compressor During Operation
76
Table 12 Parameters for Wet Cleaning of
79
Cleaning the Turbine During Operation
80
Table 13: Turbine Wet Cleaning, Recommended Operating State
82
Table 14 Wet Cleaning of Turbines, Pa
83
Cleaning Components Mechanically
84
Table 15 Value Table for Soaking
91
Eliminating Malfunctions
95
Malfunctions When Starting
95
Table 17 Malfunctions When Starting
95
Table 18 Malfunctions When Starting - Rubbing of Rotating Parts
95
Malfunctions During Operation
96
Table 20 Malfunctions During Operation - Speed Reduces
96
Table 21 Malfunctions During Operation - Speed Increases
96
Table 22 Malfunctions During Operation
97
Table 23 Malfunctions During Operation - Charge Air Pressure too Low
97
Table 24 Malfunctions During Operation - Charge Air Pressure too High
98
Table 25 Malfunctions During Operation - Engine Performance Losses
98
Table 26 Malfunction - Turbocharger
99
Table 27 Malfunction - Sporadic Surge
99
Turbocharger Is Surging
99
Malfunctions When Stopping
100
Table 29 Malfunctions When Stopping - Runout Time too Short
100
Speed Measurement System
101
Table 30 Malfunction of the Speed
101
Table 31 Malfunction of the Speed
101
Table 32 Malfunction of the Speed
101
Dismantling and Fitting
103
Introduction
103
Table 33 Swivel Lifting Eyes
105
Table 34 Ring Nuts to be Used
106
Table 35 Weights of Assemblies
107
Weights of Individual Parts
107
Removing Air Inlets
108
Removing the Gas Outlet Casing
109
Removing the Gas Outlet Flange
110
Table 36 3 Press-Off Screws
111
Table 9 Tightening Torque
111
Table 37 6 Press-Off Screws - Gas Outlet
112
Removing the Compressor Casing
113
Pressing off the Casing
114
Removing the Cartridge Group
115
Removing the Nozzle Ring
117
Installing the Cartridge Group on the Service Support
118
Axial Clearance a and Radial Clearance B
119
Table 38 Permissible Clearances a and B
119
Nozzle Ring Compression PD
120
Table 39 Permitted Nozzle Ring Com
120
Installing Nozzle Ring
121
Installing the Cartridge Group
122
Table 40 Tightening Torque (51007)
123
Installing the Compressor Casing
125
Table 41 Tightening Torque (79041)
125
Table 42 Tightening Torque (72011)
126
Radial Clearances N and R
127
Table 43 Permissible Clearances N and R
127
Installing Air Inlets
128
Table 44 Tightening Torque (72020)
128
Installing the Gas Outlet Casing
129
Installing the Gas Outlet Flange
129
Table 45 Tightening Torque (51009)
129
Table 46 Tightening Torques of the Screw Fittings
130
Table of Tightening Torques
130
Table 47 Tightening Torques for Insulation
131
Possible Emergency Repairs
133
Taking out of Operation at Short Notice
133
Installing a Replacement Cartridge Group
134
Installing a Replacement Turbocharger
134
Fitting the Cover Plate
135
Cover Plate Drawing
136
Table 48 Cover Plate Dimensions [MM]
136
Mothballing the Turbocharger
137
Taking the Engine out of Operation for up to 12 Months
137
Taking the Engine out of Operation for more than 12 Months
138
Disposing of Turbocharger Components
139
Ordering Spare Parts
141
Required Customer Spare Part Set (97070)
141
Spare Parts
141
Table 49 Customer Spare Part Set 97070
141
View of Turbocharger with Part Numbers
142
Table 50 Spare Parts List
143
Figures
145
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