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ABB A150-M57 Manuals
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ABB A150-M57 manuals available for free PDF download: Operation Manual, Instruction Manual
ABB A150-M57 Operation Manual (196 pages)
Turbocharging
Brand:
ABB
| Category:
Industrial Equipment
| Size: 33.64 MB
Table of Contents
Operation Manual / A150-M - A155-M
3
Table of Contents
3
Operation Manual / A150-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
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Definition of Safety Instructions
16
Definition of Mandatory Signs
16
Intended Use
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 7: Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Periodic Check of the Pressure Vessels
21
Fig. 10: Attachment Angle
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Lifting of Loads
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
Removing and Installing
31
Turbocharger Weight and Transportation
31
Fig. 11: Suspension of Complete Turbocharger Unit
31
Table 4: Weight of Complete Turbocharger Unit
31
Fig. 13: Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Removing the Turbocharger
32
Fig. 14: Loosening the Clamping Nut
33
Fig. 15: Turbocharger Centre of Gravity
34
Installing the Turbocharger
35
Fig. 16: Inserting the Gasket
35
Fig. 17: Fitting the Turbocharger 1
36
Fig. 18: Fitting the Turbocharger 2
37
Table 5: Fitting the Turbocharger, Value X, L
37
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
38
Fig. 20: Tightening Pressure Screws
39
Table 6: Torque-Controlled Tightening of the Pressure Screws
39
Fig. 21: Connecting the Speed Sensor
40
Fig. 22: Connecting the Compressor Cooling Air Intake
40
Fig. 23: Attaching the Support
40
Commissioning
41
Oil Supply
41
Fig. 24: Oil Orifice
42
Inspection Procedures
43
Commissioning after Taking out of Operation
45
Table 7: Lubricating Oil Pressure at Oil Inlet before Turbocharger
46
Oil Pressure, Oil Temperature
46
Monitoring Operation
46
Table 8: Lubricating Oil Temperature at the Inlet
47
Table 9: Maximum Lubricating Oil Temperature at the Outlet
47
Exhaust Gas Temperature before Turbine
48
Turbocharger Speed
49
Fig. 25: Layout and Overview of Speed Measurement System
49
Fig. 26: Replacing the Speed Sensor
51
Table 10: Tightening Torque (86505)
51
Operation and Service
52
Noise Emission
52
Fig. 27: Noise Insulation, Bellows
53
Service Work
54
Expected Replacement Intervals
57
Table 11: Expected Replacement Intervals
57
Stopping the Engine
59
Periodic Maintenance Work
60
Foreword to Maintenance
60
Table 12: Maintenance Table
60
Cleaning the Compressor During Operation
61
Fig. 28: Carrying out Wet Cleaning of Compressor
63
Table 13: Parameters for Wet Cleaning of Compressor
63
Cleaning the Turbine During Operation
64
Fig. 29: Turbine Cleaning Devices
66
Table 14: Turbine Wet Cleaning, Recommended Operating State
66
Fig. 30: Carrying out Wet Cleaning of Turbines
67
Table 15: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
67
Cleaning Components Mechanically
68
Table 16: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
68
Fig. 31: Cleaning the Filter Silencer
69
Fig. 32: Compressor-End, Non-Rotating Parts
71
Fig. 33: Turbine End, Non-Rotating Parts
73
Table 17: Value Table for Soaking
75
Fig. 34: Soaking the Turbine End
75
Fig. 35: Disassembling the Absorption Element
78
Changing the Absorption Element
78
Fig. 36: Installing the Absorption Element
79
Table 18: Tightening Torque (81152 / 81154)
79
Eliminating Malfunctions
80
Malfunctions When Starting
80
Table 19: Malfunctions When Starting - Delayed Start-Up
80
Table 20: Malfunctions When Starting - Vibrations
80
Table 21: Malfunctions When Starting - Rubbing of Rotating Parts
80
Table 24: Malfunctions During Operation - Speed Increases
81
Malfunctions During Operation
81
Table 23: Malfunctions During Operation - Speed Reduces
81
Table 22: Malfunctions During Operation - Lubricating Oil Pressure too Low
81
Table 25: Malfunctions During Operation - Exhaust Gas Temperature too High
82
Table 26: Malfunctions During Operation - Charge Air Pressure too Low
82
Table 27: Malfunctions During Operation - Charge Air Pressure too High
83
Table 28: Malfunctions During Operation - Engine Performance Losses
83
Turbocharger Is Surging
84
Table 29: Malfunction - Turbocharger Pumping
84
Table 30: Malfunction - Sporadic Surge Blows
84
Table 32: Malfunctions When Stopping - Runout Time too Short
85
Malfunctions When Stopping
85
Table 31: Malfunctions When Stopping - Runout Noises
85
Speed Measurement System
86
Table 33: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
86
Table 34: Malfunction of the Speed Measurement System - Measured Speed too High
86
Table 35: Malfunction of the Speed Measurement System - Measured Speed too Low
86
Dismantling and Fitting, General
87
Introduction
87
Table 36: Swivel Lifting Eyes
88
Fig. 37: Swivel Lifting Eyes
88
Material Required
88
Fig. 38: Press-Off Screws
89
Fig. 39: Dismantling Screw
89
Table 37: Press-Off Screws
89
Table 38: Dismantling Screw
89
Disassembly and Assembly Concepts
91
Fig. 40: Removing the Cartridge Group with Compressor and Turbine Casing
91
Fig. 41: Cartridge Concept
92
Fig. 42: Optional Spanner Holder
93
Table 39: Weights of Assemblies
94
Fig. 43: Weights of Assemblies
94
Weights of Individual Parts
94
Table of Tightening Torques
95
Fig. 44: Overview of Tightening Torques
95
Table 40: Tightening Torques
95
Fig. 45: Tightening Torques for Insulation
96
Table 41: Tightening Torques for Insulation
96
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
97
Removing Air Inlets
97
Fig. 46: Removing the Air Inlets
97
Fig. 47: Removing the Uncoupled Filter Silencer
98
Removing the Gas Outlet Casing
99
Fig. 48: Remove Gas Outlet Casing Without Support
99
Fig. 49: Removing Gas Outlet Casing with Support 1
100
Fig. 50: Removing Gas Outlet Casing with Support 1
101
Removing the Gas Outlet Flange
102
Fig. 51: Dismantling the Gas Outlet Flange
103
Table 42: 3 Press-Off Screws
103
Fig. 52: Removing the Gas Outlet Flange
104
Table 43: 6 Press-Off Screws
104
Fig. 54: Remove Insulation
105
Fig. 53: Turbine Cleaning Nozzle
105
Removing the Cartridge Group with Compressor and Turbine Casing
105
Fig. 55: Removing the Cartridge Group with Compressor and Turbine Casing
106
Fig. 56: Set down the Cartridge Group with the Compressor and Turbine Casing
106
Removing the Compressor Casing
107
Fig. 57: Removing the Compressor Casing
107
Fig. 58: Dismantling the Diffuser and the Wall Insert
108
Advertisement
ABB A150-M57 Operation Manual (196 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 33.64 MB
Table of Contents
Operation Manual / A150-M - A155-M
3
Table of Contents
3
Operation Manual / A150-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
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Definition of Safety Instructions
16
Definition of Mandatory Signs
16
Intended Use
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 7: Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Periodic Check of the Pressure Vessels
21
Fig. 10: Attachment Angle
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Lifting of Loads
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
Removing and Installing
31
Turbocharger Weight and Transportation
31
Fig. 11: Suspension of Complete Turbocharger Unit
31
Table 4: Weight of Complete Turbocharger Unit
31
Fig. 13: Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Removing the Turbocharger
32
Fig. 14: Loosening the Clamping Nut
33
Fig. 15: Turbocharger Centre of Gravity
34
Installing the Turbocharger
35
Fig. 16: Inserting the Gasket
35
Fig. 17: Fitting the Turbocharger 1
36
Fig. 18: Fitting the Turbocharger 2
37
Table 5: Fitting the Turbocharger, Value X, L
37
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
38
Fig. 20: Tightening Pressure Screws
39
Table 6: Torque-Controlled Tightening of the Pressure Screws
39
Fig. 21: Connecting the Speed Sensor
40
Fig. 22: Connecting the Compressor Cooling Air Intake
40
Fig. 23: Attaching the Support
40
Commissioning
41
Oil Supply
41
Fig. 24: Oil Orifice
42
Inspection Procedures
43
Commissioning after Taking out of Operation
45
Table 7: Lubricating Oil Pressure at Oil Inlet before Turbocharger
46
Oil Pressure, Oil Temperature
46
Monitoring Operation
46
Table 8: Lubricating Oil Temperature at the Inlet
47
Table 9: Maximum Lubricating Oil Temperature at the Outlet
47
Exhaust Gas Temperature before Turbine
48
Turbocharger Speed
49
Fig. 25: Layout and Overview of Speed Measurement System
49
Fig. 26: Replacing the Speed Sensor
51
Table 10: Tightening Torque (86505)
51
Operation and Service
52
Noise Emission
52
Fig. 27: Noise Insulation, Bellows
53
Service Work
54
Expected Replacement Intervals
57
Table 11: Expected Replacement Intervals
57
Stopping the Engine
59
Periodic Maintenance Work
60
Foreword to Maintenance
60
Table 12: Maintenance Table
60
Cleaning the Compressor During Operation
61
Fig. 28: Carrying out Wet Cleaning of Compressor
63
Table 13: Parameters for Wet Cleaning of Compressor
63
Cleaning the Turbine During Operation
64
Fig. 29: Turbine Cleaning Devices
66
Table 14: Turbine Wet Cleaning, Recommended Operating State
66
Fig. 30: Carrying out Wet Cleaning of Turbines
67
Table 15: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
67
Cleaning Components Mechanically
68
Table 16: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
68
Fig. 31: Cleaning the Filter Silencer
69
Fig. 32: Compressor-End, Non-Rotating Parts
71
Fig. 33: Turbine End, Non-Rotating Parts
73
Table 17: Value Table for Soaking
75
Fig. 34: Soaking the Turbine End
75
Fig. 35: Disassembling the Absorption Element
78
Changing the Absorption Element
78
Fig. 36: Installing the Absorption Element
79
Table 18: Tightening Torque (81152 / 81154)
79
Eliminating Malfunctions
80
Malfunctions When Starting
80
Table 19: Malfunctions When Starting - Delayed Start-Up
80
Table 20: Malfunctions When Starting - Vibrations
80
Table 21: Malfunctions When Starting - Rubbing of Rotating Parts
80
Table 24: Malfunctions During Operation - Speed Increases
81
Malfunctions During Operation
81
Table 23: Malfunctions During Operation - Speed Reduces
81
Table 22: Malfunctions During Operation - Lubricating Oil Pressure too Low
81
Table 25: Malfunctions During Operation - Exhaust Gas Temperature too High
82
Table 26: Malfunctions During Operation - Charge Air Pressure too Low
82
Table 27: Malfunctions During Operation - Charge Air Pressure too High
83
Table 28: Malfunctions During Operation - Engine Performance Losses
83
Turbocharger Is Surging
84
Table 29: Malfunction - Turbocharger Pumping
84
Table 30: Malfunction - Sporadic Surge Blows
84
Table 32: Malfunctions When Stopping - Runout Time too Short
85
Malfunctions When Stopping
85
Table 31: Malfunctions When Stopping - Runout Noises
85
Speed Measurement System
86
Table 33: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
86
Table 34: Malfunction of the Speed Measurement System - Measured Speed too High
86
Table 35: Malfunction of the Speed Measurement System - Measured Speed too Low
86
Dismantling and Fitting, General
87
Introduction
87
Table 36: Swivel Lifting Eyes
88
Fig. 37: Swivel Lifting Eyes
88
Material Required
88
Fig. 38: Press-Off Screws
89
Fig. 39: Dismantling Screw
89
Table 37: Press-Off Screws
89
Table 38: Dismantling Screw
89
Disassembly and Assembly Concepts
91
Fig. 40: Removing the Cartridge Group with Compressor and Turbine Casing
91
Fig. 41: Cartridge Concept
92
Fig. 42: Optional Spanner Holder
93
Table 39: Weights of Assemblies
94
Fig. 43: Weights of Assemblies
94
Weights of Individual Parts
94
Table of Tightening Torques
95
Fig. 44: Overview of Tightening Torques
95
Table 40: Tightening Torques
95
Fig. 45: Tightening Torques for Insulation
96
Table 41: Tightening Torques for Insulation
96
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
97
Removing Air Inlets
97
Fig. 46: Removing the Air Inlets
97
Fig. 47: Removing the Uncoupled Filter Silencer
98
Removing the Gas Outlet Casing
99
Fig. 48: Remove Gas Outlet Casing Without Support
99
Fig. 49: Removing Gas Outlet Casing with Support 1
100
Fig. 50: Removing Gas Outlet Casing with Support 1
101
Removing the Gas Outlet Flange
102
Fig. 51: Dismantling the Gas Outlet Flange
103
Table 42: 3 Press-Off Screws
103
Fig. 52: Removing the Gas Outlet Flange
104
Table 43: 6 Press-Off Screws
104
Fig. 54: Remove Insulation
105
Fig. 53: Turbine Cleaning Nozzle
105
Removing the Cartridge Group with Compressor and Turbine Casing
105
Fig. 55: Removing the Cartridge Group with Compressor and Turbine Casing
106
Fig. 56: Set down the Cartridge Group with the Compressor and Turbine Casing
106
Removing the Compressor Casing
107
Fig. 57: Removing the Compressor Casing
107
Fig. 58: Dismantling the Diffuser and the Wall Insert
108
ABB A150-M57 Operation Manual (196 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 33.64 MB
Table of Contents
Operation Manual / A150-M - A155-M
3
Table of Contents
3
Operation Manual / A150-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
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Definition of Safety Instructions
16
Definition of Mandatory Signs
16
Intended Use
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 7: Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Periodic Check of the Pressure Vessels
21
Fig. 10: Attachment Angle
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Lifting of Loads
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
Removing and Installing
31
Turbocharger Weight and Transportation
31
Fig. 11: Suspension of Complete Turbocharger Unit
31
Table 4: Weight of Complete Turbocharger Unit
31
Fig. 13: Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Removing the Turbocharger
32
Fig. 14: Loosening the Clamping Nut
33
Fig. 15: Turbocharger Centre of Gravity
34
Installing the Turbocharger
35
Fig. 16: Inserting the Gasket
35
Fig. 17: Fitting the Turbocharger 1
36
Fig. 18: Fitting the Turbocharger 2
37
Table 5: Fitting the Turbocharger, Value X, L
37
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
38
Fig. 20: Tightening Pressure Screws
39
Table 6: Torque-Controlled Tightening of the Pressure Screws
39
Fig. 21: Connecting the Speed Sensor
40
Fig. 22: Connecting the Compressor Cooling Air Intake
40
Fig. 23: Attaching the Support
40
Commissioning
41
Oil Supply
41
Fig. 24: Oil Orifice
42
Inspection Procedures
43
Commissioning after Taking out of Operation
45
Table 7: Lubricating Oil Pressure at Oil Inlet before Turbocharger
46
Oil Pressure, Oil Temperature
46
Monitoring Operation
46
Table 8: Lubricating Oil Temperature at the Inlet
47
Table 9: Maximum Lubricating Oil Temperature at the Outlet
47
Exhaust Gas Temperature before Turbine
48
Turbocharger Speed
49
Fig. 25: Layout and Overview of Speed Measurement System
49
Fig. 26: Replacing the Speed Sensor
51
Table 10: Tightening Torque (86505)
51
Operation and Service
52
Noise Emission
52
Fig. 27: Noise Insulation, Bellows
53
Service Work
54
Expected Replacement Intervals
57
Table 11: Expected Replacement Intervals
57
Stopping the Engine
59
Periodic Maintenance Work
60
Foreword to Maintenance
60
Table 12: Maintenance Table
60
Cleaning the Compressor During Operation
61
Fig. 28: Carrying out Wet Cleaning of Compressor
63
Table 13: Parameters for Wet Cleaning of Compressor
63
Cleaning the Turbine During Operation
64
Fig. 29: Turbine Cleaning Devices
66
Table 14: Turbine Wet Cleaning, Recommended Operating State
66
Fig. 30: Carrying out Wet Cleaning of Turbines
67
Table 15: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
67
Cleaning Components Mechanically
68
Table 16: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
68
Fig. 31: Cleaning the Filter Silencer
69
Fig. 32: Compressor-End, Non-Rotating Parts
71
Fig. 33: Turbine End, Non-Rotating Parts
73
Table 17: Value Table for Soaking
75
Fig. 34: Soaking the Turbine End
75
Fig. 35: Disassembling the Absorption Element
78
Changing the Absorption Element
78
Fig. 36: Installing the Absorption Element
79
Table 18: Tightening Torque (81152 / 81154)
79
Eliminating Malfunctions
80
Malfunctions When Starting
80
Table 19: Malfunctions When Starting - Delayed Start-Up
80
Table 20: Malfunctions When Starting - Vibrations
80
Table 21: Malfunctions When Starting - Rubbing of Rotating Parts
80
Table 24: Malfunctions During Operation - Speed Increases
81
Malfunctions During Operation
81
Table 23: Malfunctions During Operation - Speed Reduces
81
Table 22: Malfunctions During Operation - Lubricating Oil Pressure too Low
81
Table 25: Malfunctions During Operation - Exhaust Gas Temperature too High
82
Table 26: Malfunctions During Operation - Charge Air Pressure too Low
82
Table 27: Malfunctions During Operation - Charge Air Pressure too High
83
Table 28: Malfunctions During Operation - Engine Performance Losses
83
Turbocharger Is Surging
84
Table 29: Malfunction - Turbocharger Pumping
84
Table 30: Malfunction - Sporadic Surge Blows
84
Table 32: Malfunctions When Stopping - Runout Time too Short
85
Malfunctions When Stopping
85
Table 31: Malfunctions When Stopping - Runout Noises
85
Speed Measurement System
86
Table 33: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
86
Table 34: Malfunction of the Speed Measurement System - Measured Speed too High
86
Table 35: Malfunction of the Speed Measurement System - Measured Speed too Low
86
Dismantling and Fitting, General
87
Introduction
87
Table 36: Swivel Lifting Eyes
88
Fig. 37: Swivel Lifting Eyes
88
Material Required
88
Fig. 38: Press-Off Screws
89
Fig. 39: Dismantling Screw
89
Table 37: Press-Off Screws
89
Table 38: Dismantling Screw
89
Disassembly and Assembly Concepts
91
Fig. 40: Removing the Cartridge Group with Compressor and Turbine Casing
91
Fig. 41: Cartridge Concept
92
Fig. 42: Optional Spanner Holder
93
Table 39: Weights of Assemblies
94
Fig. 43: Weights of Assemblies
94
Weights of Individual Parts
94
Table of Tightening Torques
95
Fig. 44: Overview of Tightening Torques
95
Table 40: Tightening Torques
95
Fig. 45: Tightening Torques for Insulation
96
Table 41: Tightening Torques for Insulation
96
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
97
Removing Air Inlets
97
Fig. 46: Removing the Air Inlets
97
Fig. 47: Removing the Uncoupled Filter Silencer
98
Removing the Gas Outlet Casing
99
Fig. 48: Remove Gas Outlet Casing Without Support
99
Fig. 49: Removing Gas Outlet Casing with Support 1
100
Fig. 50: Removing Gas Outlet Casing with Support 1
101
Removing the Gas Outlet Flange
102
Fig. 51: Dismantling the Gas Outlet Flange
103
Table 42: 3 Press-Off Screws
103
Fig. 52: Removing the Gas Outlet Flange
104
Table 43: 6 Press-Off Screws
104
Fig. 54: Remove Insulation
105
Fig. 53: Turbine Cleaning Nozzle
105
Removing the Cartridge Group with Compressor and Turbine Casing
105
Fig. 55: Removing the Cartridge Group with Compressor and Turbine Casing
106
Fig. 56: Set down the Cartridge Group with the Compressor and Turbine Casing
106
Removing the Compressor Casing
107
Fig. 57: Removing the Compressor Casing
107
Fig. 58: Dismantling the Diffuser and the Wall Insert
108
Advertisement
ABB A150-M57 Operation Manual (196 pages)
Turbocharging
Brand:
ABB
| Category:
Industrial Equipment
| Size: 33.64 MB
Table of Contents
Operation Manual / A150-M - A155-M
3
Table of Contents
3
Operation Manual / A150-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
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Definition of Safety Instructions
16
Definition of Mandatory Signs
16
Intended Use
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 7: Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Periodic Check of the Pressure Vessels
21
Fig. 10: Attachment Angle
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Lifting of Loads
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
Removing and Installing
31
Turbocharger Weight and Transportation
31
Fig. 11: Suspension of Complete Turbocharger Unit
31
Table 4: Weight of Complete Turbocharger Unit
31
Fig. 13: Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Removing the Turbocharger
32
Fig. 14: Loosening the Clamping Nut
33
Fig. 15: Turbocharger Centre of Gravity
34
Installing the Turbocharger
35
Fig. 16: Inserting the Gasket
35
Fig. 17: Fitting the Turbocharger 1
36
Fig. 18: Fitting the Turbocharger 2
37
Table 5: Fitting the Turbocharger, Value X, L
37
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
38
Fig. 20: Tightening Pressure Screws
39
Table 6: Torque-Controlled Tightening of the Pressure Screws
39
Fig. 21: Connecting the Speed Sensor
40
Fig. 22: Connecting the Compressor Cooling Air Intake
40
Fig. 23: Attaching the Support
40
Commissioning
41
Oil Supply
41
Fig. 24: Oil Orifice
42
Inspection Procedures
43
Commissioning after Taking out of Operation
45
Table 7: Lubricating Oil Pressure at Oil Inlet before Turbocharger
46
Oil Pressure, Oil Temperature
46
Monitoring Operation
46
Table 8: Lubricating Oil Temperature at the Inlet
47
Table 9: Maximum Lubricating Oil Temperature at the Outlet
47
Exhaust Gas Temperature before Turbine
48
Turbocharger Speed
49
Fig. 25: Layout and Overview of Speed Measurement System
49
Fig. 26: Replacing the Speed Sensor
51
Table 10: Tightening Torque (86505)
51
Operation and Service
52
Noise Emission
52
Fig. 27: Noise Insulation, Bellows
53
Service Work
54
Expected Replacement Intervals
57
Table 11: Expected Replacement Intervals
57
Stopping the Engine
59
Periodic Maintenance Work
60
Foreword to Maintenance
60
Table 12: Maintenance Table
60
Cleaning the Compressor During Operation
61
Fig. 28: Carrying out Wet Cleaning of Compressor
63
Table 13: Parameters for Wet Cleaning of Compressor
63
Cleaning the Turbine During Operation
64
Fig. 29: Turbine Cleaning Devices
66
Table 14: Turbine Wet Cleaning, Recommended Operating State
66
Fig. 30: Carrying out Wet Cleaning of Turbines
67
Table 15: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
67
Cleaning Components Mechanically
68
Table 16: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
68
Fig. 31: Cleaning the Filter Silencer
69
Fig. 32: Compressor-End, Non-Rotating Parts
71
Fig. 33: Turbine End, Non-Rotating Parts
73
Table 17: Value Table for Soaking
75
Fig. 34: Soaking the Turbine End
75
Fig. 35: Disassembling the Absorption Element
78
Changing the Absorption Element
78
Fig. 36: Installing the Absorption Element
79
Table 18: Tightening Torque (81152 / 81154)
79
Eliminating Malfunctions
80
Malfunctions When Starting
80
Table 19: Malfunctions When Starting - Delayed Start-Up
80
Table 20: Malfunctions When Starting - Vibrations
80
Table 21: Malfunctions When Starting - Rubbing of Rotating Parts
80
Table 24: Malfunctions During Operation - Speed Increases
81
Malfunctions During Operation
81
Table 23: Malfunctions During Operation - Speed Reduces
81
Table 22: Malfunctions During Operation - Lubricating Oil Pressure too Low
81
Table 25: Malfunctions During Operation - Exhaust Gas Temperature too High
82
Table 26: Malfunctions During Operation - Charge Air Pressure too Low
82
Table 27: Malfunctions During Operation - Charge Air Pressure too High
83
Table 28: Malfunctions During Operation - Engine Performance Losses
83
Turbocharger Is Surging
84
Table 29: Malfunction - Turbocharger Pumping
84
Table 30: Malfunction - Sporadic Surge Blows
84
Table 32: Malfunctions When Stopping - Runout Time too Short
85
Malfunctions When Stopping
85
Table 31: Malfunctions When Stopping - Runout Noises
85
Speed Measurement System
86
Table 33: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
86
Table 34: Malfunction of the Speed Measurement System - Measured Speed too High
86
Table 35: Malfunction of the Speed Measurement System - Measured Speed too Low
86
Dismantling and Fitting, General
87
Introduction
87
Table 36: Swivel Lifting Eyes
88
Fig. 37: Swivel Lifting Eyes
88
Material Required
88
Fig. 38: Press-Off Screws
89
Fig. 39: Dismantling Screw
89
Table 37: Press-Off Screws
89
Table 38: Dismantling Screw
89
Disassembly and Assembly Concepts
91
Fig. 40: Removing the Cartridge Group with Compressor and Turbine Casing
91
Fig. 41: Cartridge Concept
92
Fig. 42: Optional Spanner Holder
93
Table 39: Weights of Assemblies
94
Fig. 43: Weights of Assemblies
94
Weights of Individual Parts
94
Table of Tightening Torques
95
Fig. 44: Overview of Tightening Torques
95
Table 40: Tightening Torques
95
Fig. 45: Tightening Torques for Insulation
96
Table 41: Tightening Torques for Insulation
96
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
97
Removing Air Inlets
97
Fig. 46: Removing the Air Inlets
97
Fig. 47: Removing the Uncoupled Filter Silencer
98
Removing the Gas Outlet Casing
99
Fig. 48: Remove Gas Outlet Casing Without Support
99
Fig. 49: Removing Gas Outlet Casing with Support 1
100
Fig. 50: Removing Gas Outlet Casing with Support 1
101
Removing the Gas Outlet Flange
102
Fig. 51: Dismantling the Gas Outlet Flange
103
Table 42: 3 Press-Off Screws
103
Fig. 52: Removing the Gas Outlet Flange
104
Table 43: 6 Press-Off Screws
104
Fig. 54: Remove Insulation
105
Fig. 53: Turbine Cleaning Nozzle
105
Removing the Cartridge Group with Compressor and Turbine Casing
105
Fig. 55: Removing the Cartridge Group with Compressor and Turbine Casing
106
Fig. 56: Set down the Cartridge Group with the Compressor and Turbine Casing
106
Removing the Compressor Casing
107
Fig. 57: Removing the Compressor Casing
107
Fig. 58: Dismantling the Diffuser and the Wall Insert
108
ABB A150-M57 Instruction Manual (202 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 31.55 MB
Table of Contents
Introduction
3
Table of Contents
3
Purpose of the Manual
4
Symbols, Definitions
5
Storage of New Turbochargers and Spare Parts
7
Contact Information
9
Safety
11
CE Conformity
12
Safety
12
Definition of Mandatory Signs
13
Definition of Safety Instructions
13
Intended Use
14
Deflagration on Gas Engines
15
Warning Plates on the Turbocharger
16
Turbocharger Rating Plate
17
Periodic Check of the Pressure Vessels
18
Lifting of Loads
19
Prerequisites for Operation and Maintenance
20
Hazards During Operation and Maintenance
21
Safe Operation
23
Safe Maintenance
25
Product Description
31
Introduction
32
Essential Information
34
Introduction
34
Registered Trademarks
34
Related Documents
35
Table 1: Related Documents
35
Fig. 1: Layout and Function of the Turbocharger
36
Layout and Function of the Turbocharger
36
Fig. 2: Compressor Wheel Cooling
37
Fig. 3: Warning Plate Locations
38
Warning Plates on the Turbocharger
38
Fig. 4: Locations of the Rating Plates
39
Locations of the Rating Plates
39
Fig. 5: Suspension of Complete Turbocharger Unit
40
Removing and Installing
40
Table 2: Weight of Complete Turbocharger Unit
40
Turbocharger Weight and Transportation
40
Fig. 6: Turbine Cleaning Nozzle
41
Fig. 7: Removing the Turbocharger
41
Removing the Turbocharger
41
Fig. 8: Loosening the Clamping Nut
42
Fig. 9: Turbocharger Centre of Gravity
43
Fig. 10: Inserting the Gasket
44
Installing the Turbocharger
44
Fig. 11: Fitting the Turbocharger 1
45
Fig. 12: Fitting the Turbocharger 2
46
Table 3: Fitting the Turbocharger, Value X, L
46
Fig. 13: Preparing the Clamping Nut for the Tightening Procedure
47
Fig. 14: Tightening Pressure Screws
48
Table 4: Torque-Controlled Tightening of the Pressure Screws
48
Fig. 15: Connecting the Speed Sensor
49
Fig. 16: Connecting the Compressor Cooling Air Intake
49
Fig. 17: Attaching the Support
49
Commissioning
50
Oil Supply
50
Fig. 18: Oil Orifice
51
Inspection Procedures
52
Commissioning after Taking out of Operation
54
Monitoring Operation
55
Oil Pressure, Oil Temperature
55
Table 5: Lubricating Oil Pressure at Oil Inlet before Turbocharger
55
Table 6: Lubricating Oil Temperature at the Inlet
56
Table 7: Maximum Lubricating Oil Temperature at the Outlet
56
Exhaust Gas Temperature before Turbine
57
Fig. 19: Layout and Overview of Speed Measurement System
58
Turbocharger Speed
58
Fig. 20: Replacing the Speed Sensor
60
Table 8: Tightening Torque (86505)
60
Noise Emission
61
Operation and Service
61
Fig. 21: Noise Insulation, Bellows
62
Service Work
63
Expected Replacement Intervals
66
Table 9: Expected Replacement Intervals
66
Stopping the Engine
68
Foreword to Maintenance
69
Periodic Maintenance Work
69
Table 10: Maintenance Table
69
Cleaning the Compressor During Operation
70
Fig. 22: Carrying out Wet Cleaning of Compressor
72
Table 11: Parameters for Wet Cleaning of Compressor
72
Cleaning the Turbine During Operation
73
Fig. 23: Turbine Cleaning Devices
75
Table 12: Turbine Wet Cleaning, Recommended Operating State
75
Fig. 24: Carrying out Wet Cleaning of Turbines
76
Table 13: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
76
Cleaning Components Mechanically
77
Table 14: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
77
Fig. 25: Cleaning the Filter Silencer
78
Fig. 26: Compressor-End, Non-Rotating Parts
80
Fig. 27: Turbine End, Non-Rotating Parts
82
Fig. 28: Soaking the Turbine End
84
Table 15: Value Table for Soaking
84
Changing the Absorption Element
87
Fig. 29: Disassembling the Absorption Element
87
Fig. 30: Installing the Absorption Element
88
Table 16: Tightening Torque (81152 / 81154)
88
Eliminating Malfunctions
89
Malfunctions When Starting
89
Table 17: Malfunctions When Starting - Delayed Start-Up
89
Table 18: Malfunctions When Starting - Vibrations
89
Table 19: Malfunctions When Starting - Rubbing of Rotating Parts
89
Malfunctions During Operation
90
Table 20: Malfunctions During Operation - Lubricating Oil Pressure too Low
90
Table 21: Malfunctions During Operation - Speed Reduces
90
Table 22: Malfunctions During Operation - Speed Increases
90
Table 23: Malfunctions During Operation - Exhaust Gas Temperature too High
91
Table 24: Malfunctions During Operation - Charge Air Pressure too Low
91
Table 25: Malfunctions During Operation - Charge Air Pressure too High
92
Table 26: Malfunctions During Operation - Engine Performance Losses
92
Table 27: Malfunction - Turbocharger Pumping
93
Table 28: Malfunction - Sporadic Surge Blows
93
Turbocharger Is Surging
93
Malfunctions When Stopping
94
Table 29: Malfunctions When Stopping - Runout Noises
94
Table 30: Malfunctions When Stopping - Runout Time too Short
94
Speed Measurement System
95
Table 31: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
95
Table 32: Malfunction of the Speed Measurement System - Measured Speed too High
95
Table 33: Malfunction of the Speed Measurement System - Measured Speed too Low
95
Dismantling and Fitting, General
96
Introduction
96
Fig. 31: Swivel Lifting Eyes
97
Material Required
97
Table 34: Swivel Lifting Eyes
97
Fig. 32: Press-Off Screws
98
Fig. 33: Dismantling Screw
98
Table 35: Press-Off Screws
98
Table 36: Dismantling Screw
98
Disassembly and Assembly Concepts
100
Fig. 34: Removing the Cartridge Group with Compressor and Turbine Casing
100
Fig. 35: Cartridge Concept
101
Fig. 36: Optional Spanner Holder
102
Fig. 37: Weights of Assemblies
103
Table 37: Weights of Assemblies
103
Weights of Individual Parts
103
Fig. 38: Overview of Tightening Torques
104
Table of Tightening Torques
104
Table 38: Tightening Torques
105
Fig. 39: Tightening Torques for Insulation
106
Table 39: Tightening Torques for Insulation
106
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
107
Fig. 40: Removing the Air Inlets
107
Removing Air Inlets
107
Fig. 41: Removing the Uncoupled Filter Silencer
108
Fig. 42: Remove Gas Outlet Casing Without Support
109
Removing the Gas Outlet Casing
109
Fig. 43: Removing Gas Outlet Casing with Support 1
110
Fig. 44: Removing Gas Outlet Casing with Support 1
111
Removing the Gas Outlet Flange
112
Fig. 45: Dismantling the Gas Outlet Flange
113
Table 40: 3 Press-Off Screws
113
Fig. 46: Removing the Gas Outlet Flange
114
Table 41: 6 Press-Off Screws
114
Fig. 47: Turbine Cleaning Nozzle
115
Fig. 48: Remove Insulation
115
Removing the Cartridge Group with Compressor and Turbine Casing
115
Fig. 49: Removing the Cartridge Group with Compressor and Turbine Casing
116
Fig. 50: Set down the Cartridge Group with the Compressor and Turbine Casing
116
Fig. 51: Removing the Compressor Casing
117
Removing the Compressor Casing
117
Fig. 52: Dismantling the Diffuser and the Wall Insert
118
Fig. 53: Removing Cartridge Group 1
119
Removing the Cartridge Group
119
Table 42: Tightening Torque (90012-01)
119
Fig. 54: Removing Cartridge Group 2
120
Fig. 55: Removing Cartridge Group 3
121
Fig. 56: Installing the Cartridge Group on the Service Support
122
Installing the Cartridge Group on the Service Support
122
Fig. 57: Removing the Nozzle Ring
123
Removing the Nozzle Ring
123
Fig. 58: Measuring Clearance a and B
124
Measuring Clearance a and B
124
Table 43: Permissible Clearances a and B
124
Fig. 59: Nozzle Ring Compression PD
125
Nozzle Ring Compression PD
125
Table 44: Nozzle Ring Compression PD
125
Fig. 60: Installing the Nozzle Ring
126
Installing Nozzle Ring
126
Fig. 61: Lifting the Cartridge Group and Rotating It by 90
127
Installing the Cartridge Group
127
Fig. 62: Turning the Cartridge Group
128
Table 45: Tightening Torque (90012-01)
128
Fig. 63: Installing the Cartridge Group
129
Table 46: Tightening Torque (51007)
129
Fig. 64: Fitting the Wall Insert and the Diffuser
130
Installing the Compressor Casing
130
Table 47: Tightening Torque (79041)
130
Fig. 65: Installing the Compressor Casing
131
Table 48: Tightening Torque (72011)
131
Fig. 66: Turning the Cartridge Group with Compressor and Turbine Casing
132
Turning the Cartridge Group with Compressor and Turbine Casing
132
Fig. 67: Installing the Gas Outlet Flange
133
Installing the Gas Outlet Flange
133
Fig. 68: Measuring Clearances N and R
134
Radial Clearances N and R
134
Table 49: Permissible Clearances N and R
134
Fig. 69: Fitting the Insulation
135
Fitting the Insulation
135
Fig. 70: Installing the Cartridge Group with Compressor and Turbine Casing
136
Fig. 71: Installing the Cartridge Group with Compressor and Turbine Casing
136
Installing the Cartridge Group with Compressor and Turbine Casing
136
Fig. 72: Fitting Gas Outlet Casing Without Support
137
Installing the Gas Outlet Casing
137
Table 50: Tightening Torque (51009)
137
Fig. 73: Installing Gas Outlet Casing with Support 1
138
Table 51: Tightening Torque (51009)
138
Fig. 74: Installing Gas Outlet Casing with Support 2
139
Fig. 75: Installing the Air Inlets
140
Installing Air Inlets
140
Table 52: Tightening Torque (72051)
140
Fig. 76: Installing the Uncoupled Filter Silencer
141
Table 53: Tightening Torque (72054)
141
Dismantling and Fitting, Cartridge Concept
142
Fig. 77: Removing the Air Inlets
142
Removing Air Inlets
142
Fig. 78: Removing the Uncoupled Filter Silencer
143
Fig. 79: Removing the Compressor Casing
144
Removing the Compressor Casing
144
Fig. 80: Pressing off Compressor Casing
145
Fig. 81: Remove the Diffuser
145
Fig. 82: Dismantling the Diffuser and the Wall Insert
146
Fig. 83: Removing Insulation Sheets
147
Removing the Cartridge Group
147
Fig. 84: Removing Cartridge Group 1
148
Table 54: Threaded Rod, Value X
148
Fig. 85: Removing Cartridge Group 2
149
Fig. 86: Removing Cartridge Group 2
150
Fig. 87: S_05180
151
Removing the Nozzle Ring
151
Fig. 88: Measuring Clearance a and B
152
Measuring Clearance a and B
152
Table 55: Permissible Clearances a and B
152
Fig. 89: Nozzle Ring Compression PD
153
Nozzle Ring Compression PD
153
Table 56: Nozzle Ring Compression PD
153
Fig. 90: Installing the Nozzle Ring
154
Installing Nozzle Ring
154
Fig. 91: Installing the Cartridge Group 1
155
Installing the Cartridge Group
155
Fig. 92: Installing the Cartridge Group 2
156
Table 57: Threaded Rod, Value X and L
156
Table 58: Tightening Torque (51007)
156
Fig. 93: Fitting the Wall Insert and the Diffuser
157
Installing the Compressor Casing
157
Table 59: Tightening Torque (79041)
157
Fig. 94: Installing the Compressor Casing
158
Table 60: Tightening Torque (72011)
158
Fig. 95: Measuring Clearances N and R
159
Radial Clearances N and R
159
Table 61: Permissible Clearances N and R
159
Fig. 96: Fitting the Insulation
160
Fitting the Insulation
160
Fig. 97: Installing the Air Inlets
161
Installing Air Inlets
161
Table 62: Tightening Torque (72051)
161
Fig. 98: Installing the Uncoupled Filter Silencer
162
Table 63: Tightening Torque (72054)
162
Dismantling and Fitting, Special Tools for Fastening Strips
163
Fig. 100: Customer Tool
164
Fig. 99: Customer Tool
164
Table 64: Customer Tool
164
Table 65: Customer Tool
164
Application, Special Tools
165
Fig. 101: Positioning the Collection Tub
165
Fig. 102: Removing the Fastening Strips
165
Fig. 103: Fitting the Upper Fastening Strips
167
Fig. 104: Fitting the Bottom Fastening Strip
167
Table 66: Tightening Torque (51007)
167
Fig. 105: Fitting the Bottom Fastening Strip
168
Table 67: Tightening Torque (51007) with Spanner Holder
168
Fig. 106: Fitting the Cartridge Group
169
Table 68: Tightening Torque (51007)
169
Fig. 107: Positioning the Fastening Strip
170
Fig. 108: Clamping Piece
171
Fig. 109: Attach Nut
172
Table 69: Tightening Torque (51007) with Spanner Holder
172
Disassembly
173
Fig. 110: Initial Situation
173
Fig. 111: Disassembly of the Elbows
173
Removing and Installing 6-Nozzle Turbine Cleaning Component (Optional)
173
Fig. 112: Disassembly of the Elbows
174
Fig. 113: Pipe Disassembly
174
Fig. 114: Disassembly of the Connecting Pieces
175
Fig. 115: Disassembly of the Cleaning Nozzle
175
Table 70: Dismantling Screw
175
Assembly
176
Fig. 116: Assembly of the Cleaning Nozzle
176
Fig. 117: Assembly of the Connecting Pieces
176
Table 71: Dismantling Screw
176
Fig. 118: Pipe Assembly
177
Fig. 119: Elbow 1 Assembly
177
Fig. 120: Elbow 2 Assembly
178
Table 72: Tightening Torque (51314 / 51316)
178
Fig. 121: Fit the Cleaning Nozzles
179
Fitting the Cleaning Nozzles with Multi-Inlet Turbine Casings
179
Possible Emergency Repairs
180
Taking out of Operation at Short Notice
180
Installing the Replacement Cartridge Group
181
Installing the Replacement Turbocharger
181
Fig. 122: Fitting the Cover Plate
182
Fitting the Cover Plate
182
Cover Plate Drawing
183
Fig. 123: Cover Plate Drawing
183
Table 73: Cover Plate Dimensions [MM]
183
Fig. 124: Dimensions for Cover Plate
184
Table 74: Cover Plate Dimensions [MM]
184
Mothballing the Turbocharger
185
Taking the Engine out of Operation for up to 12 Months
185
Taking the Engine out of Operation for more than 12 Months
186
Disposing of Turbocharger Components
187
Ordering Spare Parts
188
Required Customer Spare Part Set (97070)
188
Spare Parts
188
Table 75: Customer Spare Part Set 97070
188
Fig. 125: Overview of Part Numbers
190
View of Turbocharger with Part Numbers
190
Table 76: Spare Parts List
191
Fig. 126: Overview of Part Numbers
192
Table 77: Spare Parts List
192
View of Turbine Cleaning Device
192
Fig. 127: Overview of Part Numbers
193
Table 78: Spare Parts List
193
Fig. 128: Overview of Part Numbers
194
Table 79: Spare Parts List
194
View of Uncoupled Filter Silencer A155
194
Fig. 129: Special Tool
195
Table 80: Customer Tool Set 90000
195
Table 81: Special Tool (90160)
195
Tools
195
Fig. 130: Special Tool
196
Table 82: Special Tool (90160)
196
ABB A150-M57 Operation Manual (200 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 34.05 MB
Table of Contents
Operation Manual / A150-M - A155-M
3
Table of Contents
3
Operation Manual / A150-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
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Definition of Mandatory Signs
16
Intended Use
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 7: Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Periodic Check of the Pressure Vessels
21
Fig. 10: Attachment Angle
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Lifting of Loads
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
Removing and Installing
31
Turbocharger Weight and Transportation
31
Fig. 11: Suspension of Complete Turbocharger Unit
31
Table 4: Weight of Complete Turbocharger Unit
31
Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Fig. 13: Removing the Turbocharger
33
Fig. 14: Loosening the Clamping Nut
34
Fig. 15: Turbocharger Centre of Gravity
35
Installing the Turbocharger
36
Fig. 16: Inserting the Gasket
36
Fig. 17: Fitting the Turbocharger 1
37
Fig. 18: Fitting the Turbocharger 2
38
Table 5: Fitting the Turbocharger, Value X, L
38
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
39
Table 6: Torque-Controlled Tightening of the Pressure Screws
40
Fig. 20: Tightening Pressure Screws
40
Fig. 21: Connecting the Speed Sensor
41
Fig. 22: Connecting the Compressor Cooling Air Intake
41
Fig. 23: Attaching the Support
41
Commissioning
42
Oil Supply
42
Fig. 24: Oil Orifice
42
Inspection Procedures
44
Commissioning after Taking out of Operation
46
Table 7: Lubricating Oil Pressure at Oil Inlet before Turbocharger
47
Monitoring Operation
47
Oil Pressure, Oil Temperature
47
Table 8: Lubricating Oil Temperature at the Inlet
48
Table 9: Maximum Lubricating Oil Temperature at the Outlet
48
Exhaust Gas Temperature before Turbine
49
Turbocharger Speed
50
Fig. 25: Layout and Overview of Speed Measurement System
50
Fig. 26: Replacing the Speed Sensor
52
Table 10: Tightening Torque (86505)
52
Noise Emission
53
Operation and Service
53
Fig. 27: Noise Insulation, Bellows
54
Service Work
55
Expected Replacement Intervals
58
Table 11: Expected Replacement Intervals
58
Stopping the Engine
60
Periodic Maintenance Work
61
Foreword to Maintenance
61
Table 12: Maintenance Table
61
Cleaning the Compressor During Operation
62
Fig. 28: Carrying out Wet Cleaning of Compressor
64
Table 13: Parameters for Wet Cleaning of Compressor
64
Cleaning the Turbine During Operation
65
Fig. 29: Turbine Cleaning Devices
67
Table 14: Turbine Wet Cleaning, Recommended Operating State
67
Fig. 30: Carrying out Wet Cleaning of Turbine
68
Table 15: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
68
Cleaning Components Mechanically
69
Table 16: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
69
Fig. 31: Cleaning the Filter Silencer
70
Fig. 32: Cleaning the Filter Silencer
72
Fig. 33: Cleaning the Filter Silencer (2)
74
Table 17: Tightening Torque (81272)
74
Table 18: Tightening Torque (81273)
74
Fig. 34: Compressor-End, Non-Rotating Parts
75
Fig. 35: Turbine End, Non-Rotating Parts
76
Fig. 36: Soaking the Turbine End
79
Table 19: Value Table for Soaking
79
Changing the Absorption Element
82
Fig. 37: Disassembling the Absorption Element
82
Table 20: Tightening Torque (81152 / 81154)
83
Fig. 38: Installing the Absorption Element
83
Eliminating Malfunctions
84
Malfunctions When Starting
84
Table 21: Malfunctions When Starting - Delayed Start-Up
84
Table 22: Malfunctions When Starting - Vibrations
84
Table 23: Malfunctions When Starting - Rubbing of Rotating Parts
84
Malfunctions During Operation
85
Table 24: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 25: Malfunctions During Operation - Speed Reduces
85
Table 26: Malfunctions During Operation - Speed Increases
85
Table 27: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 28: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 29: Malfunctions During Operation - Charge Air Pressure too High
87
Table 30: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 31: Malfunction - Turbocharger Surging
88
Table 32: Malfunction - Sporadic Surge Blows
88
Malfunctions When Stopping
89
Table 33: Malfunctions When Stopping - Runout Noises
89
Table 34: Malfunctions When Stopping - Runout Time too Short
89
Table 37: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Table 35: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 36: Malfunction of the Speed Measurement System - Measured Speed too High
90
Speed Measurement System
90
Dismantling and Fitting, General
91
Introduction
91
Material Required
92
Fig. 39: Swivel Lifting Eye (Example)
92
Table 38: Swivel Lifting Eyes
92
Table 40: Dismantling Screw
93
Table 39: Press-Off Screws
93
Fig. 41: Dismantling Screw
93
Fig. 40: Press-Off Screws
93
Disassembly and Assembly Concepts
95
Fig. 42: Removing the Cartridge Group with Compressor and Turbine Casing
95
Fig. 43: Cartridge Concept
96
Fig. 44: Optional Spanner Holder
97
Weights of Individual Parts
98
Fig. 45: Weights of Assemblies
98
Table 41: Weights of Assemblies
98
Table 42: Tightening Torques
99
Fig. 46: Overview of Tightening Torques
99
Table of Tightening Torques
99
Fig. 47: Tightening Torques for Insulation
100
Table 43: Tightening Torques for Insulation
100
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
101
Removing Air Inlets
101
Fig. 48: Removing the Air Inlets
101
Fig. 49: Removing the Uncoupled Filter Silencer
102
Removing the Gas Outlet Casing
103
Fig. 50: Remove Gas Outlet Casing Without Support
103
Fig. 51: Removing Gas Outlet Casing with Support 1
104
Fig. 52: Removing Gas Outlet Casing with Support 1
105
Removing the Gas Outlet Flange
106
Fig. 53: Dismantling the Gas Outlet Flange
107
Table 44: 3 Press-Off Screws
107
Fig. 54: Removing the Gas Outlet Flange
108
Table 45: 6 Press-Off Screws
108
Removing the Cartridge Group with Compressor and Turbine Casing
109
Fig. 55: Turbine Cleaning Nozzle
109
Fig. 56: Remove Insulation
109
Fig. 57: Removing the Cartridge Group with Compressor and Turbine Casing
110
Fig. 58: Setting down the Cartridge Group with the Compressor and Turbine Casing
110
Removing the Compressor Casing
111
Fig. 59: Removing the Compressor Casing
111
Fig. 60: Dismantling the Diffuser and the Wall Insert
112
Removing the Cartridge Group
113
Fig. 61: Removing Cartridge Group 1
113
Table 46: Tightening Torque (90012-01)
113
Fig. 62: Removing Cartridge Group 2
114
Fig. 63: Removing Cartridge Group 3
115
Installing the Cartridge Group on the Service Support
116
Fig. 64: Installing the Cartridge Group on the Service Support
116
Removing the Nozzle Ring
117
Fig. 65: Removing the Nozzle Ring
117
Measuring Clearance a and B
118
Fig. 66: Measuring Clearance a and B
118
Table 47: Permissible Clearances a and B
118
Nozzle Ring Compression PD
119
Fig. 67: Nozzle Ring Compression PD
119
Table 48: Nozzle Ring Compression PD
119
Installing Nozzle Ring
120
Fig. 68: Installing the Nozzle Ring
120
Installing the Cartridge Group
121
Fig. 69: Lifting the Cartridge Group and Rotating It
121
Fig. 70: Turning the Cartridge Group
122
Table 49: Tightening Torque (90012-01)
122
Fig. 71: Installing the Cartridge Group
123
Table 50: Tightening Torque (51007)
123
Installing the Compressor Casing
124
Fig. 72: Fitting the Wall Insert and the Diffuser
124
Table 51: Tightening Torque (79041)
124
Table 52: Tightening Torque (72011)
125
Fig. 73: Installing the Compressor Casing
125
Turning the Cartridge Group with Compressor and Turbine Casing
126
Fig. 74: Turning the Cartridge Group with Compressor and Turbine Casing
126
Installing the Gas Outlet Flange
127
Fig. 75: Installing the Gas Outlet Flange
127
Radial Clearances N and R
128
Fig. 76: Measuring Clearances N and R
128
Table 53: Permissible Clearances N and R
128
Fitting the Insulation
129
Fig. 77: Fitting the Insulation
129
Fig. 79: Installing the Cartridge Group with Compressor and Turbine Casing
130
Fig. 78: Installing the Cartridge Group with Compressor and Turbine Casing
130
Installing the Cartridge Group with Compressor and Turbine Casing
130
Installing the Gas Outlet Casing
131
Fig. 80: Fitting Gas Outlet Casing Without Support
131
Table 54: Tightening Torque (51009)
131
Fig. 81: Installing Gas Outlet Casing with Support 1
132
Table 55: Tightening Torque (51009)
132
Fig. 82: Installing Gas Outlet Casing with Support 2
133
Table 56: Tightening Torque (72051)
134
Fig. 83: Installing the Air Inlets
134
Installing Air Inlets
134
Fig. 84: Installing the Uncoupled Filter Silencer
135
Table 57: Tightening Torque (72054)
135
Dismantling and Fitting, Cartridge Concept
136
Removing Air Inlets
136
Fig. 85: Removing the Air Inlets
136
Fig. 86: Removing the Uncoupled Filter Silencer
137
Removing the Compressor Casing
138
Fig. 87: Removing the Compressor Casing
138
Fig. 88: Pressing off Compressor Casing
139
Fig. 89: Remove the Diffuser
139
Fig. 90: Dismantling the Diffuser and the Wall Insert
140
Fig. 91: Removing Insulation Sheets
141
Fig. 92: Removing Cartridge Group 1
141
Table 58: Threaded Rod, Value X
141
Fig. 93: Removing Cartridge Group 2
142
Fig. 94: Removing Cartridge Group 2
143
Fig. 95: S_05180
144
Fig. 96: Measuring Clearance a and B
145
Table 59: Permissible Clearances a and B
145
Fig. 97: Nozzle Ring Compression PD
146
Table 60: Nozzle Ring Compression PD
146
Fig. 98: Installing the Nozzle Ring
147
Fig. 99: Installing the Cartridge Group 1
148
Fig. 100: Installing the Cartridge Group 2
149
Table 61: Threaded Rod, Value X and L
149
Table 62: Tightening Torque (51007)
149
Fig. 101: Fitting the Wall Insert and the Diffuser
150
Table 63: Tightening Torque (79041)
150
Fig. 102: Installing the Compressor Casing
151
Table 64: Tightening Torque (72011)
151
Fig. 103: Measuring Clearances N and R
152
Table 65: Permissible Clearances N and R
152
Fig. 104: Fitting the Insulation
153
Fig. 105: Installing the Air Inlets
154
Table 66: Tightening Torque (72051)
154
Fig. 106: Installing the Uncoupled Filter Silencer
155
Table 67: Tightening Torque (72054)
155
Dismantling and Fitting, Special Tools for Fastening Strips
156
Fig. 107: Customer Tool
156
Fig. 108: Customer Tool
156
Table 68: Customer Tool
156
Table 69: Customer Tool
156
Fig. 110: Removing the Fastening Strips
157
Fig. 109: Positioning the Collection Tub
157
Application, Special Tools
157
Fig. 111: Fitting the Upper Fastening Strips
158
Fig. 112: Fitting the Bottom Fastening Strip
158
Table 70: Tightening Torque (51007)
158
Fig. 113: Fitting the Bottom Fastening Strip
159
Table 71: Tightening Torque (51007) with Spanner Holder
159
Fig. 114: Fitting the Cartridge Group
160
Table 72: Tightening Torque (51007)
160
Fig. 115: Positioning the Fastening Strip
161
Fig. 116: Clamping Piece
162
Fig. 117: Attach Nut
163
Table 73: Tightening Torque (51007) with Spanner Holder
163
Removing and Installing 6-Nozzle Turbine Cleaning Component (Optional)
164
Disassembly
164
Fig. 118: Initial Situation
164
Fig. 119: Disassembly of the Elbows
164
Fig. 120: Disassembly of the Elbows
165
Fig. 121: Pipe Disassembly
165
Table 74: Dismantling Screw
166
Fig. 123: Disassembly of the Cleaning Nozzle
166
Fig. 122: Disassembly of the Connecting Pieces
166
Assembly
167
Fig. 124: Assembly of the Cleaning Nozzle
167
Fig. 125: Assembly of the Connecting Pieces
167
Table 75: Dismantling Screw
167
Fig. 126: Pipe Assembly
168
Fig. 127: Elbow 1 Assembly
168
Fig. 128: Elbow 2 Assembly
169
Table 76: Tightening Torque (51314 / 51316)
169
Fig. 129: Fit the Cleaning Nozzles
170
Fitting the Cleaning Nozzles with Multi-Inlet Turbine Casings
170
Taking out of Operation at Short Notice
171
Possible Emergency Repairs
171
Installing the Replacement Turbocharger
172
Installing the Replacement Cartridge Group
172
Fitting the Cover Plate
173
Fig. 130: Fitting the Cover Plate
173
Table 77: Cover Plate Dimensions [MM]
174
Fig. 131: Cover Plate Drawing
174
Cover Plate Drawing
174
Table 78: Cover Plate Dimensions [MM]
175
Fig. 132: Dimensions for Cover Plate
175
Mothballing the Turbocharger
176
Taking the Engine out of Operation for up to 12 Months
176
Taking the Engine out of Operation for more than 12 Months
177
Material and Disposal
178
REACH and Rohs Compliance Declaration for Products
178
Disposing of Turbocharger Components
179
Required Customer Spare Part Set (97070)
180
Table 79: Customer Spare Part Set 97070
180
Ordering Spare Parts
180
Spare Parts
180
Spare Part - Illustrations
181
Table 80: Spare Parts - Cartridge, Oil Cooled
181
Table 81: Spare Parts - Bearing, Casing Oil Cooled
182
Table 82: Spare Parts - Rotor and Bearing Parts
183
Table 83: Spare Parts - Turbine Casing, 1 Inlet
184
Table 84: Spare Parts - Turbine Casing, 2 Inlets
185
Table 85: Spare Parts - Turbine Casing, 3 Inlets
186
Table 86: Spare Parts - Cleaning Device
187
Table 87: Spare Parts - Gas Outlet Casing, Radial
188
Table 88: Spare Parts - Compressor Casing
189
Table 89: Spare Parts - Filter Silencer
191
Table 90: Spare Parts - Air Suction Branch Axial
191
Table 91: Spare Parts - Air Suction Branch Radial
192
Table 92: Spare Parts - Speed Measurement System
193
Tools
194
Fig. 133: Special Tool
194
Table 93: Customer Tool Set 90000
194
Table 94: Special Tool (90160)
194
Fig. 134: Special Tool
195
Table 95: Special Tool (90160)
195
ABB A150-M57 Operation Manual (200 pages)
Turbocharging
Brand:
ABB
| Category:
Industrial Equipment
| Size: 34.18 MB
Table of Contents
Operation Manual / A150-M - A155-M
3
Table of Contents
3
Operation Manual / A150-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
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Definition of Mandatory Signs
16
Intended Use
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 7: Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Periodic Check of the Pressure Vessels
21
Fig. 10: Attachment Angle
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Lifting of Loads
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
Removing and Installing
31
Turbocharger Weight and Transportation
31
Fig. 11: Suspension of Complete Turbocharger Unit
31
Table 4: Weight of Complete Turbocharger Unit
31
Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Fig. 13: Removing the Turbocharger
33
Fig. 14: Loosening the Clamping Nut
34
Fig. 15: Turbocharger Centre of Gravity
35
Installing the Turbocharger
36
Fig. 16: Inserting the Gasket
36
Fig. 17: Fitting the Turbocharger 1
37
Fig. 18: Fitting the Turbocharger 2
38
Table 5: Fitting the Turbocharger, Value X, L
38
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
39
Table 6: Torque-Controlled Tightening of the Pressure Screws
40
Fig. 20: Tightening Pressure Screws
40
Fig. 21: Connecting the Speed Sensor
41
Fig. 22: Connecting the Compressor Cooling Air Intake
41
Fig. 23: Attaching the Support
41
Commissioning
42
Oil Supply
42
Fig. 24: Oil Orifice
42
Inspection Procedures
44
Commissioning after Taking out of Operation
46
Table 7: Lubricating Oil Pressure at Oil Inlet before Turbocharger
47
Monitoring Operation
47
Oil Pressure, Oil Temperature
47
Table 8: Lubricating Oil Temperature at the Inlet
48
Table 9: Maximum Lubricating Oil Temperature at the Outlet
48
Exhaust Gas Temperature before Turbine
49
Turbocharger Speed
50
Fig. 25: Layout and Overview of Speed Measurement System
50
Fig. 26: Replacing the Speed Sensor
52
Table 10: Tightening Torque (86505)
52
Noise Emission
53
Operation and Service
53
Fig. 27: Noise Insulation, Bellows
54
Service Work
55
Expected Replacement Intervals
58
Table 11: Expected Replacement Intervals
58
Stopping the Engine
60
Periodic Maintenance Work
61
Foreword to Maintenance
61
Table 12: Maintenance Table
61
Cleaning the Compressor During Operation
62
Fig. 28: Carrying out Wet Cleaning of Compressor
64
Table 13: Parameters for Wet Cleaning of Compressor
64
Cleaning the Turbine During Operation
65
Fig. 29: Turbine Cleaning Devices
67
Table 14: Turbine Wet Cleaning, Recommended Operating State
67
Fig. 30: Carrying out Wet Cleaning of Turbine
68
Table 15: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
68
Cleaning Components Mechanically
69
Table 16: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
69
Fig. 31: Cleaning the Filter Silencer
70
Fig. 32: Cleaning the Filter Silencer
72
Fig. 33: Cleaning the Filter Silencer (2)
74
Table 17: Tightening Torque (81272)
74
Table 18: Tightening Torque (81273)
74
Fig. 34: Compressor-End, Non-Rotating Parts
75
Fig. 35: Turbine End, Non-Rotating Parts
76
Fig. 36: Soaking the Turbine End
79
Table 19: Value Table for Soaking
79
Changing the Absorption Element
82
Fig. 37: Disassembling the Absorption Element
82
Table 20: Tightening Torque (81152 / 81154)
83
Fig. 38: Installing the Absorption Element
83
Eliminating Malfunctions
84
Malfunctions When Starting
84
Table 21: Malfunctions When Starting - Delayed Start-Up
84
Table 22: Malfunctions When Starting - Vibrations
84
Table 23: Malfunctions When Starting - Rubbing of Rotating Parts
84
Malfunctions During Operation
85
Table 24: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 25: Malfunctions During Operation - Speed Reduces
85
Table 26: Malfunctions During Operation - Speed Increases
85
Table 27: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 28: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 29: Malfunctions During Operation - Charge Air Pressure too High
87
Table 30: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 31: Malfunction - Turbocharger Pumping
88
Table 32: Malfunction - Sporadic Surge Blows
88
Malfunctions When Stopping
89
Table 33: Malfunctions When Stopping - Runout Noises
89
Table 34: Malfunctions When Stopping - Runout Time too Short
89
Table 37: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Table 35: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 36: Malfunction of the Speed Measurement System - Measured Speed too High
90
Speed Measurement System
90
Dismantling and Fitting, General
91
Introduction
91
Material Required
92
Fig. 39: Swivel Lifting Eyes
92
Table 38: Swivel Lifting Eyes
92
Table 40: Dismantling Screw
93
Table 39: Press-Off Screws
93
Fig. 41: Dismantling Screw
93
Fig. 40: Press-Off Screws
93
Disassembly and Assembly Concepts
95
Fig. 42: Removing the Cartridge Group with Compressor and Turbine Casing
95
Fig. 43: Cartridge Concept
96
Fig. 44: Optional Spanner Holder
97
Weights of Individual Parts
98
Fig. 45: Weights of Assemblies
98
Table 41: Weights of Assemblies
98
Table 42: Tightening Torques
99
Fig. 46: Overview of Tightening Torques
99
Table of Tightening Torques
99
Fig. 47: Tightening Torques for Insulation
100
Table 43: Tightening Torques for Insulation
100
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
101
Removing Air Inlets
101
Fig. 48: Removing the Air Inlets
101
Fig. 49: Removing the Uncoupled Filter Silencer
102
Removing the Gas Outlet Casing
103
Fig. 50: Remove Gas Outlet Casing Without Support
103
Fig. 51: Removing Gas Outlet Casing with Support 1
104
Fig. 52: Removing Gas Outlet Casing with Support 1
105
Removing the Gas Outlet Flange
106
Fig. 53: Dismantling the Gas Outlet Flange
107
Table 44: 3 Press-Off Screws
107
Fig. 54: Removing the Gas Outlet Flange
108
Table 45: 6 Press-Off Screws
108
Removing the Cartridge Group with Compressor and Turbine Casing
109
Fig. 55: Turbine Cleaning Nozzle
109
Fig. 56: Remove Insulation
109
Fig. 57: Removing the Cartridge Group with Compressor and Turbine Casing
110
Fig. 58: Setting down the Cartridge Group with the Compressor and Turbine Casing
110
Removing the Compressor Casing
111
Fig. 59: Removing the Compressor Casing
111
Fig. 60: Dismantling the Diffuser and the Wall Insert
112
Removing the Cartridge Group
113
Fig. 61: Removing Cartridge Group 1
113
Table 46: Tightening Torque (90012-01)
113
Fig. 62: Removing Cartridge Group 2
114
Fig. 63: Removing Cartridge Group 3
115
Installing the Cartridge Group on the Service Support
116
Fig. 64: Installing the Cartridge Group on the Service Support
116
Removing the Nozzle Ring
117
Fig. 65: Removing the Nozzle Ring
117
Measuring Clearance a and B
118
Fig. 66: Measuring Clearance a and B
118
Table 47: Permissible Clearances a and B
118
Nozzle Ring Compression PD
119
Fig. 67: Nozzle Ring Compression PD
119
Table 48: Nozzle Ring Compression PD
119
Installing Nozzle Ring
120
Fig. 68: Installing the Nozzle Ring
120
Installing the Cartridge Group
121
Fig. 69: Lifting the Cartridge Group and Rotating It
121
Fig. 70: Turning the Cartridge Group
122
Table 49: Tightening Torque (90012-01)
122
Fig. 71: Installing the Cartridge Group
123
Table 50: Tightening Torque (51007)
123
Installing the Compressor Casing
124
Fig. 72: Fitting the Wall Insert and the Diffuser
124
Table 51: Tightening Torque (79041)
124
Table 52: Tightening Torque (72011)
125
Fig. 73: Installing the Compressor Casing
125
Turning the Cartridge Group with Compressor and Turbine Casing
126
Fig. 74: Turning the Cartridge Group with Compressor and Turbine Casing
126
Installing the Gas Outlet Flange
127
Fig. 75: Installing the Gas Outlet Flange
127
Radial Clearances N and R
128
Fig. 76: Measuring Clearances N and R
128
Table 53: Permissible Clearances N and R
128
Fitting the Insulation
129
Fig. 77: Fitting the Insulation
129
Fig. 79: Installing the Cartridge Group with Compressor and Turbine Casing
130
Fig. 78: Installing the Cartridge Group with Compressor and Turbine Casing
130
Installing the Cartridge Group with Compressor and Turbine Casing
130
Installing the Gas Outlet Casing
131
Fig. 80: Fitting Gas Outlet Casing Without Support
131
Table 54: Tightening Torque (51009)
131
Fig. 81: Installing Gas Outlet Casing with Support 1
132
Table 55: Tightening Torque (51009)
132
Fig. 82: Installing Gas Outlet Casing with Support 2
133
Table 56: Tightening Torque (72051)
134
Fig. 83: Installing the Air Inlets
134
Installing Air Inlets
134
Fig. 84: Installing the Uncoupled Filter Silencer
135
Table 57: Tightening Torque (72054)
135
Dismantling and Fitting, Cartridge Concept
136
Removing Air Inlets
136
Fig. 85: Removing the Air Inlets
136
Fig. 86: Removing the Uncoupled Filter Silencer
137
Removing the Compressor Casing
138
Fig. 87: Removing the Compressor Casing
138
Fig. 88: Pressing off Compressor Casing
139
Fig. 89: Remove the Diffuser
139
Fig. 90: Dismantling the Diffuser and the Wall Insert
140
Fig. 91: Removing Insulation Sheets
141
Fig. 92: Removing Cartridge Group 1
141
Table 58: Threaded Rod, Value X
141
Fig. 93: Removing Cartridge Group 2
142
Fig. 94: Removing Cartridge Group 2
143
Fig. 95: S_05180
144
Fig. 96: Measuring Clearance a and B
145
Table 59: Permissible Clearances a and B
145
Fig. 97: Nozzle Ring Compression PD
146
Table 60: Nozzle Ring Compression PD
146
Fig. 98: Installing the Nozzle Ring
147
Fig. 99: Installing the Cartridge Group 1
148
Fig. 100: Installing the Cartridge Group 2
149
Table 61: Threaded Rod, Value X and L
149
Table 62: Tightening Torque (51007)
149
Fig. 101: Fitting the Wall Insert and the Diffuser
150
Table 63: Tightening Torque (79041)
150
Fig. 102: Installing the Compressor Casing
151
Table 64: Tightening Torque (72011)
151
Fig. 103: Measuring Clearances N and R
152
Table 65: Permissible Clearances N and R
152
Fig. 104: Fitting the Insulation
153
Fig. 105: Installing the Air Inlets
154
Table 66: Tightening Torque (72051)
154
Fig. 106: Installing the Uncoupled Filter Silencer
155
Table 67: Tightening Torque (72054)
155
Dismantling and Fitting, Special Tools for Fastening Strips
156
Fig. 107: Customer Tool
156
Fig. 108: Customer Tool
156
Table 68: Customer Tool
156
Table 69: Customer Tool
156
Fig. 110: Removing the Fastening Strips
157
Fig. 109: Positioning the Collection Tub
157
Application, Special Tools
157
Fig. 111: Fitting the Upper Fastening Strips
158
Fig. 112: Fitting the Bottom Fastening Strip
158
Table 70: Tightening Torque (51007)
158
Fig. 113: Fitting the Bottom Fastening Strip
159
Table 71: Tightening Torque (51007) with Spanner Holder
159
Fig. 114: Fitting the Cartridge Group
160
Table 72: Tightening Torque (51007)
160
Fig. 115: Positioning the Fastening Strip
161
Fig. 116: Clamping Piece
162
Fig. 117: Attach Nut
163
Table 73: Tightening Torque (51007) with Spanner Holder
163
Removing and Installing 6-Nozzle Turbine Cleaning Component (Optional)
164
Disassembly
164
Fig. 118: Initial Situation
164
Fig. 119: Disassembly of the Elbows
164
Fig. 120: Disassembly of the Elbows
165
Fig. 121: Pipe Disassembly
165
Table 74: Dismantling Screw
166
Fig. 123: Disassembly of the Cleaning Nozzle
166
Fig. 122: Disassembly of the Connecting Pieces
166
Assembly
167
Fig. 124: Assembly of the Cleaning Nozzle
167
Fig. 125: Assembly of the Connecting Pieces
167
Table 75: Dismantling Screw
167
Fig. 126: Pipe Assembly
168
Fig. 127: Elbow 1 Assembly
168
Fig. 128: Elbow 2 Assembly
169
Table 76: Tightening Torque (51314 / 51316)
169
Fig. 129: Fit the Cleaning Nozzles
170
Fitting the Cleaning Nozzles with Multi-Inlet Turbine Casings
170
Taking out of Operation at Short Notice
171
Possible Emergency Repairs
171
Installing the Replacement Turbocharger
172
Installing the Replacement Cartridge Group
172
Fitting the Cover Plate
173
Fig. 130: Fitting the Cover Plate
173
Table 77: Cover Plate Dimensions [MM]
174
Fig. 131: Cover Plate Drawing
174
Cover Plate Drawing
174
Table 78: Cover Plate Dimensions [MM]
175
Fig. 132: Dimensions for Cover Plate
175
Mothballing the Turbocharger
176
Taking the Engine out of Operation for up to 12 Months
176
Taking the Engine out of Operation for more than 12 Months
177
Material and Disposal
178
REACH and Rohs Compliance Declaration for Products
178
Disposing of Turbocharger Components
179
Required Customer Spare Part Set (97070)
180
Table 79: Customer Spare Part Set 97070
180
Ordering Spare Parts
180
Spare Parts
180
Spare Part - Illustrations
181
Table 80: Spare Parts - Cartridge, Oil Cooled
181
Table 81: Spare Parts - Bearing, Casing Oil Cooled
182
Table 82: Spare Parts - Rotor and Bearing Parts
183
Table 83: Spare Parts - Turbine Casing, 1 Inlet
184
Table 84: Spare Parts - Turbine Casing, 2 Inlets
185
Table 85: Spare Parts - Turbine Casing, 3 Inlets
186
Table 86: Spare Parts - Cleaning Device
187
Table 87: Spare Parts - Gas Outlet Casing, Radial
188
Table 88: Spare Parts - Compressor Casing
189
Table 89: Spare Parts - Filter Silencer
191
Table 90: Spare Parts - Air Suction Branch Axial
191
Table 91: Spare Parts - Air Suction Branch Radial
192
Table 92: Spare Parts - Speed Measurement System
193
Tools
194
Fig. 133: Special Tool
194
Table 93: Customer Tool Set 90000
194
Table 94: Special Tool (90160)
194
Fig. 134: Special Tool
195
Table 95: Special Tool (90160)
195
ABB A150-M57 Operation Manual (200 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 34.05 MB
Table of Contents
Operation Manual / A150-M - A155-M
3
Table of Contents
3
Operation Manual / A150-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
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Definition of Mandatory Signs
16
Intended Use
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 7: Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Periodic Check of the Pressure Vessels
21
Fig. 10: Attachment Angle
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Lifting of Loads
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
Removing and Installing
31
Turbocharger Weight and Transportation
31
Fig. 11: Suspension of Complete Turbocharger Unit
31
Table 4: Weight of Complete Turbocharger Unit
31
Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Fig. 13: Removing the Turbocharger
33
Fig. 14: Loosening the Clamping Nut
34
Fig. 15: Turbocharger Centre of Gravity
35
Installing the Turbocharger
36
Fig. 16: Inserting the Gasket
36
Fig. 17: Fitting the Turbocharger 1
37
Fig. 18: Fitting the Turbocharger 2
38
Table 5: Fitting the Turbocharger, Value X, L
38
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
39
Table 6: Torque-Controlled Tightening of the Pressure Screws
40
Fig. 20: Tightening Pressure Screws
40
Fig. 21: Connecting the Speed Sensor
41
Fig. 22: Connecting the Compressor Cooling Air Intake
41
Fig. 23: Attaching the Support
41
Commissioning
42
Oil Supply
42
Fig. 24: Oil Orifice
42
Inspection Procedures
44
Commissioning after Taking out of Operation
46
Table 7: Lubricating Oil Pressure at Oil Inlet before Turbocharger
47
Monitoring Operation
47
Oil Pressure, Oil Temperature
47
Table 8: Lubricating Oil Temperature at the Inlet
48
Table 9: Maximum Lubricating Oil Temperature at the Outlet
48
Exhaust Gas Temperature before Turbine
49
Turbocharger Speed
50
Fig. 25: Layout and Overview of Speed Measurement System
50
Fig. 26: Replacing the Speed Sensor
52
Table 10: Tightening Torque (86505)
52
Noise Emission
53
Operation and Service
53
Fig. 27: Noise Insulation, Bellows
54
Service Work
55
Expected Replacement Intervals
58
Table 11: Expected Replacement Intervals
58
Stopping the Engine
60
Periodic Maintenance Work
61
Foreword to Maintenance
61
Table 12: Maintenance Table
61
Cleaning the Compressor During Operation
62
Fig. 28: Carrying out Wet Cleaning of Compressor
64
Table 13: Parameters for Wet Cleaning of Compressor
64
Cleaning the Turbine During Operation
65
Fig. 29: Turbine Cleaning Devices
67
Table 14: Turbine Wet Cleaning, Recommended Operating State
67
Fig. 30: Carrying out Wet Cleaning of Turbine
68
Table 15: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
68
Cleaning Components Mechanically
69
Table 16: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
69
Fig. 31: Cleaning the Filter Silencer
70
Fig. 32: Cleaning the Filter Silencer
72
Fig. 33: Cleaning the Filter Silencer (2)
74
Table 17: Tightening Torque (81272)
74
Table 18: Tightening Torque (81273)
74
Fig. 34: Compressor-End, Non-Rotating Parts
75
Fig. 35: Turbine End, Non-Rotating Parts
76
Fig. 36: Soaking the Turbine End
79
Table 19: Value Table for Soaking
79
Changing the Absorption Element
82
Fig. 37: Disassembling the Absorption Element
82
Table 20: Tightening Torque (81152 / 81154)
83
Fig. 38: Installing the Absorption Element
83
Eliminating Malfunctions
84
Malfunctions When Starting
84
Table 21: Malfunctions When Starting - Delayed Start-Up
84
Table 22: Malfunctions When Starting - Vibrations
84
Table 23: Malfunctions When Starting - Rubbing of Rotating Parts
84
Malfunctions During Operation
85
Table 24: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 25: Malfunctions During Operation - Speed Reduces
85
Table 26: Malfunctions During Operation - Speed Increases
85
Table 27: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 28: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 29: Malfunctions During Operation - Charge Air Pressure too High
87
Table 30: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 31: Malfunction - Turbocharger Surging
88
Table 32: Malfunction - Sporadic Surge Blows
88
Malfunctions When Stopping
89
Table 33: Malfunctions When Stopping - Runout Noises
89
Table 34: Malfunctions When Stopping - Runout Time too Short
89
Table 37: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Table 35: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 36: Malfunction of the Speed Measurement System - Measured Speed too High
90
Speed Measurement System
90
Dismantling and Fitting, General
91
Introduction
91
Material Required
92
Fig. 39: Swivel Lifting Eye (Example)
92
Table 38: Swivel Lifting Eyes
92
Table 40: Dismantling Screw
93
Table 39: Press-Off Screws
93
Fig. 41: Dismantling Screw
93
Fig. 40: Press-Off Screws
93
Disassembly and Assembly Concepts
95
Fig. 42: Removing the Cartridge Group with Compressor and Turbine Casing
95
Fig. 43: Cartridge Concept
96
Fig. 44: Optional Spanner Holder
97
Weights of Individual Parts
98
Fig. 45: Weights of Assemblies
98
Table 41: Weights of Assemblies
98
Table 42: Tightening Torques
99
Fig. 46: Overview of Tightening Torques
99
Table of Tightening Torques
99
Fig. 47: Tightening Torques for Insulation
100
Table 43: Tightening Torques for Insulation
100
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
101
Removing Air Inlets
101
Fig. 48: Removing the Air Inlets
101
Fig. 49: Removing the Uncoupled Filter Silencer
102
Removing the Gas Outlet Casing
103
Fig. 50: Remove Gas Outlet Casing Without Support
103
Fig. 51: Removing Gas Outlet Casing with Support 1
104
Fig. 52: Removing Gas Outlet Casing with Support 1
105
Removing the Gas Outlet Flange
106
Fig. 53: Dismantling the Gas Outlet Flange
107
Table 44: 3 Press-Off Screws
107
Fig. 54: Removing the Gas Outlet Flange
108
Table 45: 6 Press-Off Screws
108
Removing the Cartridge Group with Compressor and Turbine Casing
109
Fig. 55: Turbine Cleaning Nozzle
109
Fig. 56: Remove Insulation
109
Fig. 57: Removing the Cartridge Group with Compressor and Turbine Casing
110
Fig. 58: Setting down the Cartridge Group with the Compressor and Turbine Casing
110
Removing the Compressor Casing
111
Fig. 59: Removing the Compressor Casing
111
Fig. 60: Dismantling the Diffuser and the Wall Insert
112
Removing the Cartridge Group
113
Fig. 61: Removing Cartridge Group 1
113
Table 46: Tightening Torque (90012-01)
113
Fig. 62: Removing Cartridge Group 2
114
Fig. 63: Removing Cartridge Group 3
115
Installing the Cartridge Group on the Service Support
116
Fig. 64: Installing the Cartridge Group on the Service Support
116
Removing the Nozzle Ring
117
Fig. 65: Removing the Nozzle Ring
117
Measuring Clearance a and B
118
Fig. 66: Measuring Clearance a and B
118
Table 47: Permissible Clearances a and B
118
Nozzle Ring Compression PD
119
Fig. 67: Nozzle Ring Compression PD
119
Table 48: Nozzle Ring Compression PD
119
Installing Nozzle Ring
120
Fig. 68: Installing the Nozzle Ring
120
Installing the Cartridge Group
121
Fig. 69: Lifting the Cartridge Group and Rotating It
121
Fig. 70: Turning the Cartridge Group
122
Table 49: Tightening Torque (90012-01)
122
Fig. 71: Installing the Cartridge Group
123
Table 50: Tightening Torque (51007)
123
Installing the Compressor Casing
124
Fig. 72: Fitting the Wall Insert and the Diffuser
124
Table 51: Tightening Torque (79041)
124
Table 52: Tightening Torque (72011)
125
Fig. 73: Installing the Compressor Casing
125
Turning the Cartridge Group with Compressor and Turbine Casing
126
Fig. 74: Turning the Cartridge Group with Compressor and Turbine Casing
126
Installing the Gas Outlet Flange
127
Fig. 75: Installing the Gas Outlet Flange
127
Radial Clearances N and R
128
Fig. 76: Measuring Clearances N and R
128
Table 53: Permissible Clearances N and R
128
Fitting the Insulation
129
Fig. 77: Fitting the Insulation
129
Fig. 79: Installing the Cartridge Group with Compressor and Turbine Casing
130
Fig. 78: Installing the Cartridge Group with Compressor and Turbine Casing
130
Installing the Cartridge Group with Compressor and Turbine Casing
130
Installing the Gas Outlet Casing
131
Fig. 80: Fitting Gas Outlet Casing Without Support
131
Table 54: Tightening Torque (51009)
131
Fig. 81: Installing Gas Outlet Casing with Support 1
132
Table 55: Tightening Torque (51009)
132
Fig. 82: Installing Gas Outlet Casing with Support 2
133
Table 56: Tightening Torque (72051)
134
Fig. 83: Installing the Air Inlets
134
Installing Air Inlets
134
Fig. 84: Installing the Uncoupled Filter Silencer
135
Table 57: Tightening Torque (72054)
135
Dismantling and Fitting, Cartridge Concept
136
Removing Air Inlets
136
Fig. 85: Removing the Air Inlets
136
Fig. 86: Removing the Uncoupled Filter Silencer
137
Removing the Compressor Casing
138
Fig. 87: Removing the Compressor Casing
138
Fig. 88: Pressing off Compressor Casing
139
Fig. 89: Remove the Diffuser
139
Fig. 90: Dismantling the Diffuser and the Wall Insert
140
Fig. 91: Removing Insulation Sheets
141
Fig. 92: Removing Cartridge Group 1
141
Table 58: Threaded Rod, Value X
141
Fig. 93: Removing Cartridge Group 2
142
Fig. 94: Removing Cartridge Group 2
143
Fig. 95: S_05180
144
Fig. 96: Measuring Clearance a and B
145
Table 59: Permissible Clearances a and B
145
Fig. 97: Nozzle Ring Compression PD
146
Table 60: Nozzle Ring Compression PD
146
Fig. 98: Installing the Nozzle Ring
147
Fig. 99: Installing the Cartridge Group 1
148
Fig. 100: Installing the Cartridge Group 2
149
Table 61: Threaded Rod, Value X and L
149
Table 62: Tightening Torque (51007)
149
Fig. 101: Fitting the Wall Insert and the Diffuser
150
Table 63: Tightening Torque (79041)
150
Fig. 102: Installing the Compressor Casing
151
Table 64: Tightening Torque (72011)
151
Fig. 103: Measuring Clearances N and R
152
Table 65: Permissible Clearances N and R
152
Fig. 104: Fitting the Insulation
153
Fig. 105: Installing the Air Inlets
154
Table 66: Tightening Torque (72051)
154
Fig. 106: Installing the Uncoupled Filter Silencer
155
Table 67: Tightening Torque (72054)
155
Dismantling and Fitting, Special Tools for Fastening Strips
156
Fig. 107: Customer Tool
156
Fig. 108: Customer Tool
156
Table 68: Customer Tool
156
Table 69: Customer Tool
156
Fig. 110: Removing the Fastening Strips
157
Fig. 109: Positioning the Collection Tub
157
Application, Special Tools
157
Fig. 111: Fitting the Upper Fastening Strips
158
Fig. 112: Fitting the Bottom Fastening Strip
158
Table 70: Tightening Torque (51007)
158
Fig. 113: Fitting the Bottom Fastening Strip
159
Table 71: Tightening Torque (51007) with Spanner Holder
159
Fig. 114: Fitting the Cartridge Group
160
Table 72: Tightening Torque (51007)
160
Fig. 115: Positioning the Fastening Strip
161
Fig. 116: Clamping Piece
162
Fig. 117: Attach Nut
163
Table 73: Tightening Torque (51007) with Spanner Holder
163
Removing and Installing 6-Nozzle Turbine Cleaning Component (Optional)
164
Disassembly
164
Fig. 118: Initial Situation
164
Fig. 119: Disassembly of the Elbows
164
Fig. 120: Disassembly of the Elbows
165
Fig. 121: Pipe Disassembly
165
Table 74: Dismantling Screw
166
Fig. 123: Disassembly of the Cleaning Nozzle
166
Fig. 122: Disassembly of the Connecting Pieces
166
Assembly
167
Fig. 124: Assembly of the Cleaning Nozzle
167
Fig. 125: Assembly of the Connecting Pieces
167
Table 75: Dismantling Screw
167
Fig. 126: Pipe Assembly
168
Fig. 127: Elbow 1 Assembly
168
Fig. 128: Elbow 2 Assembly
169
Table 76: Tightening Torque (51314 / 51316)
169
Fig. 129: Fit the Cleaning Nozzles
170
Fitting the Cleaning Nozzles with Multi-Inlet Turbine Casings
170
Taking out of Operation at Short Notice
171
Possible Emergency Repairs
171
Installing the Replacement Turbocharger
172
Installing the Replacement Cartridge Group
172
Fitting the Cover Plate
173
Fig. 130: Fitting the Cover Plate
173
Table 77: Cover Plate Dimensions [MM]
174
Fig. 131: Cover Plate Drawing
174
Cover Plate Drawing
174
Table 78: Cover Plate Dimensions [MM]
175
Fig. 132: Dimensions for Cover Plate
175
Mothballing the Turbocharger
176
Taking the Engine out of Operation for up to 12 Months
176
Taking the Engine out of Operation for more than 12 Months
177
Material and Disposal
178
REACH and Rohs Compliance Declaration for Products
178
Disposing of Turbocharger Components
179
Required Customer Spare Part Set (97070)
180
Table 79: Customer Spare Part Set 97070
180
Ordering Spare Parts
180
Spare Parts
180
Spare Part - Illustrations
181
Table 80: Spare Parts - Cartridge, Oil Cooled
181
Table 81: Spare Parts - Bearing, Casing Oil Cooled
182
Table 82: Spare Parts - Rotor and Bearing Parts
183
Table 83: Spare Parts - Turbine Casing, 1 Inlet
184
Table 84: Spare Parts - Turbine Casing, 2 Inlets
185
Table 85: Spare Parts - Turbine Casing, 3 Inlets
186
Table 86: Spare Parts - Cleaning Device
187
Table 87: Spare Parts - Gas Outlet Casing, Radial
188
Table 88: Spare Parts - Compressor Casing
189
Table 89: Spare Parts - Filter Silencer
191
Table 90: Spare Parts - Air Suction Branch Axial
191
Table 91: Spare Parts - Air Suction Branch Radial
192
Table 92: Spare Parts - Speed Measurement System
193
Tools
194
Fig. 133: Special Tool
194
Table 93: Customer Tool Set 90000
194
Table 94: Special Tool (90160)
194
Fig. 134: Special Tool
195
Table 95: Special Tool (90160)
195
ABB A150-M57 Operation Manual (200 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 34.05 MB
Table of Contents
Operation Manual / A150-M - A155-M
3
Table of Contents
3
Operation Manual / A150-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
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Definition of Mandatory Signs
16
Intended Use
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 7: Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Periodic Check of the Pressure Vessels
21
Fig. 10: Attachment Angle
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Lifting of Loads
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
Removing and Installing
31
Turbocharger Weight and Transportation
31
Fig. 11: Suspension of Complete Turbocharger Unit
31
Table 4: Weight of Complete Turbocharger Unit
31
Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Fig. 13: Removing the Turbocharger
33
Fig. 14: Loosening the Clamping Nut
34
Fig. 15: Turbocharger Centre of Gravity
35
Installing the Turbocharger
36
Fig. 16: Inserting the Gasket
36
Fig. 17: Fitting the Turbocharger 1
37
Fig. 18: Fitting the Turbocharger 2
38
Table 5: Fitting the Turbocharger, Value X, L
38
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
39
Table 6: Torque-Controlled Tightening of the Pressure Screws
40
Fig. 20: Tightening Pressure Screws
40
Fig. 21: Connecting the Speed Sensor
41
Fig. 22: Connecting the Compressor Cooling Air Intake
41
Fig. 23: Attaching the Support
41
Commissioning
42
Oil Supply
42
Fig. 24: Oil Orifice
42
Inspection Procedures
44
Commissioning after Taking out of Operation
46
Table 7: Lubricating Oil Pressure at Oil Inlet before Turbocharger
47
Monitoring Operation
47
Oil Pressure, Oil Temperature
47
Table 8: Lubricating Oil Temperature at the Inlet
48
Table 9: Maximum Lubricating Oil Temperature at the Outlet
48
Exhaust Gas Temperature before Turbine
49
Turbocharger Speed
50
Fig. 25: Layout and Overview of Speed Measurement System
50
Fig. 26: Replacing the Speed Sensor
52
Table 10: Tightening Torque (86505)
52
Noise Emission
53
Operation and Service
53
Fig. 27: Noise Insulation, Bellows
54
Service Work
55
Expected Replacement Intervals
58
Table 11: Expected Replacement Intervals
58
Stopping the Engine
60
Periodic Maintenance Work
61
Foreword to Maintenance
61
Table 12: Maintenance Table
61
Cleaning the Compressor During Operation
62
Fig. 28: Carrying out Wet Cleaning of Compressor
64
Table 13: Parameters for Wet Cleaning of Compressor
64
Cleaning the Turbine During Operation
65
Fig. 29: Turbine Cleaning Devices
67
Table 14: Turbine Wet Cleaning, Recommended Operating State
67
Fig. 30: Carrying out Wet Cleaning of Turbine
68
Table 15: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
68
Cleaning Components Mechanically
69
Table 16: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
69
Fig. 31: Cleaning the Filter Silencer
70
Fig. 32: Cleaning the Filter Silencer
72
Fig. 33: Cleaning the Filter Silencer (2)
74
Table 17: Tightening Torque (81272)
74
Table 18: Tightening Torque (81273)
74
Fig. 34: Compressor-End, Non-Rotating Parts
75
Fig. 35: Turbine End, Non-Rotating Parts
76
Fig. 36: Soaking the Turbine End
79
Table 19: Value Table for Soaking
79
Changing the Absorption Element
82
Fig. 37: Disassembling the Absorption Element
82
Table 20: Tightening Torque (81152 / 81154)
83
Fig. 38: Installing the Absorption Element
83
Eliminating Malfunctions
84
Malfunctions When Starting
84
Table 21: Malfunctions When Starting - Delayed Start-Up
84
Table 22: Malfunctions When Starting - Vibrations
84
Table 23: Malfunctions When Starting - Rubbing of Rotating Parts
84
Malfunctions During Operation
85
Table 24: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 25: Malfunctions During Operation - Speed Reduces
85
Table 26: Malfunctions During Operation - Speed Increases
85
Table 27: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 28: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 29: Malfunctions During Operation - Charge Air Pressure too High
87
Table 30: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 31: Malfunction - Turbocharger Surging
88
Table 32: Malfunction - Sporadic Surge Blows
88
Malfunctions When Stopping
89
Table 33: Malfunctions When Stopping - Runout Noises
89
Table 34: Malfunctions When Stopping - Runout Time too Short
89
Table 37: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Table 35: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 36: Malfunction of the Speed Measurement System - Measured Speed too High
90
Speed Measurement System
90
Dismantling and Fitting, General
91
Introduction
91
Material Required
92
Fig. 39: Swivel Lifting Eye (Example)
92
Table 38: Swivel Lifting Eyes
92
Table 40: Dismantling Screw
93
Table 39: Press-Off Screws
93
Fig. 41: Dismantling Screw
93
Fig. 40: Press-Off Screws
93
Disassembly and Assembly Concepts
95
Fig. 42: Removing the Cartridge Group with Compressor and Turbine Casing
95
Fig. 43: Cartridge Concept
96
Fig. 44: Optional Spanner Holder
97
Weights of Individual Parts
98
Fig. 45: Weights of Assemblies
98
Table 41: Weights of Assemblies
98
Table 42: Tightening Torques
99
Fig. 46: Overview of Tightening Torques
99
Table of Tightening Torques
99
Fig. 47: Tightening Torques for Insulation
100
Table 43: Tightening Torques for Insulation
100
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
101
Removing Air Inlets
101
Fig. 48: Removing the Air Inlets
101
Fig. 49: Removing the Uncoupled Filter Silencer
102
Removing the Gas Outlet Casing
103
Fig. 50: Remove Gas Outlet Casing Without Support
103
Fig. 51: Removing Gas Outlet Casing with Support 1
104
Fig. 52: Removing Gas Outlet Casing with Support 1
105
Removing the Gas Outlet Flange
106
Fig. 53: Dismantling the Gas Outlet Flange
107
Table 44: 3 Press-Off Screws
107
Fig. 54: Removing the Gas Outlet Flange
108
Table 45: 6 Press-Off Screws
108
Removing the Cartridge Group with Compressor and Turbine Casing
109
Fig. 55: Turbine Cleaning Nozzle
109
Fig. 56: Remove Insulation
109
Fig. 57: Removing the Cartridge Group with Compressor and Turbine Casing
110
Fig. 58: Setting down the Cartridge Group with the Compressor and Turbine Casing
110
Removing the Compressor Casing
111
Fig. 59: Removing the Compressor Casing
111
Fig. 60: Dismantling the Diffuser and the Wall Insert
112
Removing the Cartridge Group
113
Fig. 61: Removing Cartridge Group 1
113
Table 46: Tightening Torque (90012-01)
113
Fig. 62: Removing Cartridge Group 2
114
Fig. 63: Removing Cartridge Group 3
115
Installing the Cartridge Group on the Service Support
116
Fig. 64: Installing the Cartridge Group on the Service Support
116
Removing the Nozzle Ring
117
Fig. 65: Removing the Nozzle Ring
117
Measuring Clearance a and B
118
Fig. 66: Measuring Clearance a and B
118
Table 47: Permissible Clearances a and B
118
Nozzle Ring Compression PD
119
Fig. 67: Nozzle Ring Compression PD
119
Table 48: Nozzle Ring Compression PD
119
Installing Nozzle Ring
120
Fig. 68: Installing the Nozzle Ring
120
Installing the Cartridge Group
121
Fig. 69: Lifting the Cartridge Group and Rotating It
121
Fig. 70: Turning the Cartridge Group
122
Table 49: Tightening Torque (90012-01)
122
Fig. 71: Installing the Cartridge Group
123
Table 50: Tightening Torque (51007)
123
Installing the Compressor Casing
124
Fig. 72: Fitting the Wall Insert and the Diffuser
124
Table 51: Tightening Torque (79041)
124
Table 52: Tightening Torque (72011)
125
Fig. 73: Installing the Compressor Casing
125
Turning the Cartridge Group with Compressor and Turbine Casing
126
Fig. 74: Turning the Cartridge Group with Compressor and Turbine Casing
126
Installing the Gas Outlet Flange
127
Fig. 75: Installing the Gas Outlet Flange
127
Radial Clearances N and R
128
Fig. 76: Measuring Clearances N and R
128
Table 53: Permissible Clearances N and R
128
Fitting the Insulation
129
Fig. 77: Fitting the Insulation
129
Fig. 79: Installing the Cartridge Group with Compressor and Turbine Casing
130
Fig. 78: Installing the Cartridge Group with Compressor and Turbine Casing
130
Installing the Cartridge Group with Compressor and Turbine Casing
130
Installing the Gas Outlet Casing
131
Fig. 80: Fitting Gas Outlet Casing Without Support
131
Table 54: Tightening Torque (51009)
131
Fig. 81: Installing Gas Outlet Casing with Support 1
132
Table 55: Tightening Torque (51009)
132
Fig. 82: Installing Gas Outlet Casing with Support 2
133
Table 56: Tightening Torque (72051)
134
Fig. 83: Installing the Air Inlets
134
Installing Air Inlets
134
Fig. 84: Installing the Uncoupled Filter Silencer
135
Table 57: Tightening Torque (72054)
135
Dismantling and Fitting, Cartridge Concept
136
Removing Air Inlets
136
Fig. 85: Removing the Air Inlets
136
Fig. 86: Removing the Uncoupled Filter Silencer
137
Removing the Compressor Casing
138
Fig. 87: Removing the Compressor Casing
138
Fig. 88: Pressing off Compressor Casing
139
Fig. 89: Remove the Diffuser
139
Fig. 90: Dismantling the Diffuser and the Wall Insert
140
Fig. 91: Removing Insulation Sheets
141
Fig. 92: Removing Cartridge Group 1
141
Table 58: Threaded Rod, Value X
141
Fig. 93: Removing Cartridge Group 2
142
Fig. 94: Removing Cartridge Group 2
143
Fig. 95: S_05180
144
Fig. 96: Measuring Clearance a and B
145
Table 59: Permissible Clearances a and B
145
Fig. 97: Nozzle Ring Compression PD
146
Table 60: Nozzle Ring Compression PD
146
Fig. 98: Installing the Nozzle Ring
147
Fig. 99: Installing the Cartridge Group 1
148
Fig. 100: Installing the Cartridge Group 2
149
Table 61: Threaded Rod, Value X and L
149
Table 62: Tightening Torque (51007)
149
Fig. 101: Fitting the Wall Insert and the Diffuser
150
Table 63: Tightening Torque (79041)
150
Fig. 102: Installing the Compressor Casing
151
Table 64: Tightening Torque (72011)
151
Fig. 103: Measuring Clearances N and R
152
Table 65: Permissible Clearances N and R
152
Fig. 104: Fitting the Insulation
153
Fig. 105: Installing the Air Inlets
154
Table 66: Tightening Torque (72051)
154
Fig. 106: Installing the Uncoupled Filter Silencer
155
Table 67: Tightening Torque (72054)
155
Dismantling and Fitting, Special Tools for Fastening Strips
156
Fig. 107: Customer Tool
156
Fig. 108: Customer Tool
156
Table 68: Customer Tool
156
Table 69: Customer Tool
156
Fig. 110: Removing the Fastening Strips
157
Fig. 109: Positioning the Collection Tub
157
Application, Special Tools
157
Fig. 111: Fitting the Upper Fastening Strips
158
Fig. 112: Fitting the Bottom Fastening Strip
158
Table 70: Tightening Torque (51007)
158
Fig. 113: Fitting the Bottom Fastening Strip
159
Table 71: Tightening Torque (51007) with Spanner Holder
159
Fig. 114: Fitting the Cartridge Group
160
Table 72: Tightening Torque (51007)
160
Fig. 115: Positioning the Fastening Strip
161
Fig. 116: Clamping Piece
162
Fig. 117: Attach Nut
163
Table 73: Tightening Torque (51007) with Spanner Holder
163
Removing and Installing 6-Nozzle Turbine Cleaning Component (Optional)
164
Disassembly
164
Fig. 118: Initial Situation
164
Fig. 119: Disassembly of the Elbows
164
Fig. 120: Disassembly of the Elbows
165
Fig. 121: Pipe Disassembly
165
Table 74: Dismantling Screw
166
Fig. 123: Disassembly of the Cleaning Nozzle
166
Fig. 122: Disassembly of the Connecting Pieces
166
Assembly
167
Fig. 124: Assembly of the Cleaning Nozzle
167
Fig. 125: Assembly of the Connecting Pieces
167
Table 75: Dismantling Screw
167
Fig. 126: Pipe Assembly
168
Fig. 127: Elbow 1 Assembly
168
Fig. 128: Elbow 2 Assembly
169
Table 76: Tightening Torque (51314 / 51316)
169
Fig. 129: Fit the Cleaning Nozzles
170
Fitting the Cleaning Nozzles with Multi-Inlet Turbine Casings
170
Taking out of Operation at Short Notice
171
Possible Emergency Repairs
171
Installing the Replacement Turbocharger
172
Installing the Replacement Cartridge Group
172
Fitting the Cover Plate
173
Fig. 130: Fitting the Cover Plate
173
Table 77: Cover Plate Dimensions [MM]
174
Fig. 131: Cover Plate Drawing
174
Cover Plate Drawing
174
Table 78: Cover Plate Dimensions [MM]
175
Fig. 132: Dimensions for Cover Plate
175
Mothballing the Turbocharger
176
Taking the Engine out of Operation for up to 12 Months
176
Taking the Engine out of Operation for more than 12 Months
177
Material and Disposal
178
REACH and Rohs Compliance Declaration for Products
178
Disposing of Turbocharger Components
179
Required Customer Spare Part Set (97070)
180
Table 79: Customer Spare Part Set 97070
180
Ordering Spare Parts
180
Spare Parts
180
Spare Part - Illustrations
181
Table 80: Spare Parts - Cartridge, Oil Cooled
181
Table 81: Spare Parts - Bearing, Casing Oil Cooled
182
Table 82: Spare Parts - Rotor and Bearing Parts
183
Table 83: Spare Parts - Turbine Casing, 1 Inlet
184
Table 84: Spare Parts - Turbine Casing, 2 Inlets
185
Table 85: Spare Parts - Turbine Casing, 3 Inlets
186
Table 86: Spare Parts - Cleaning Device
187
Table 87: Spare Parts - Gas Outlet Casing, Radial
188
Table 88: Spare Parts - Compressor Casing
189
Table 89: Spare Parts - Filter Silencer
191
Table 90: Spare Parts - Air Suction Branch Axial
191
Table 91: Spare Parts - Air Suction Branch Radial
192
Table 92: Spare Parts - Speed Measurement System
193
Tools
194
Fig. 133: Special Tool
194
Table 93: Customer Tool Set 90000
194
Table 94: Special Tool (90160)
194
Fig. 134: Special Tool
195
Table 95: Special Tool (90160)
195
ABB A150-M57 Operation Manual (200 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 34.18 MB
Table of Contents
Operation Manual / A150-M - A155-M
3
Table of Contents
3
Operation Manual / A150-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
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Definition of Mandatory Signs
16
Intended Use
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 7: Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Periodic Check of the Pressure Vessels
21
Fig. 10: Attachment Angle
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Lifting of Loads
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
Removing and Installing
31
Turbocharger Weight and Transportation
31
Fig. 11: Suspension of Complete Turbocharger Unit
31
Table 4: Weight of Complete Turbocharger Unit
31
Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Fig. 13: Removing the Turbocharger
33
Fig. 14: Loosening the Clamping Nut
34
Fig. 15: Turbocharger Centre of Gravity
35
Installing the Turbocharger
36
Fig. 16: Inserting the Gasket
36
Fig. 17: Fitting the Turbocharger 1
37
Fig. 18: Fitting the Turbocharger 2
38
Table 5: Fitting the Turbocharger, Value X, L
38
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
39
Table 6: Torque-Controlled Tightening of the Pressure Screws
40
Fig. 20: Tightening Pressure Screws
40
Fig. 21: Connecting the Speed Sensor
41
Fig. 22: Connecting the Compressor Cooling Air Intake
41
Fig. 23: Attaching the Support
41
Commissioning
42
Oil Supply
42
Fig. 24: Oil Orifice
42
Inspection Procedures
44
Commissioning after Taking out of Operation
46
Table 7: Lubricating Oil Pressure at Oil Inlet before Turbocharger
47
Monitoring Operation
47
Oil Pressure, Oil Temperature
47
Table 8: Lubricating Oil Temperature at the Inlet
48
Table 9: Maximum Lubricating Oil Temperature at the Outlet
48
Exhaust Gas Temperature before Turbine
49
Turbocharger Speed
50
Fig. 25: Layout and Overview of Speed Measurement System
50
Fig. 26: Replacing the Speed Sensor
52
Table 10: Tightening Torque (86505)
52
Noise Emission
53
Operation and Service
53
Fig. 27: Noise Insulation, Bellows
54
Service Work
55
Expected Replacement Intervals
58
Table 11: Expected Replacement Intervals
58
Stopping the Engine
60
Periodic Maintenance Work
61
Foreword to Maintenance
61
Table 12: Maintenance Table
61
Cleaning the Compressor During Operation
62
Fig. 28: Carrying out Wet Cleaning of Compressor
64
Table 13: Parameters for Wet Cleaning of Compressor
64
Cleaning the Turbine During Operation
65
Fig. 29: Turbine Cleaning Devices
67
Table 14: Turbine Wet Cleaning, Recommended Operating State
67
Fig. 30: Carrying out Wet Cleaning of Turbine
68
Table 15: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
68
Cleaning Components Mechanically
69
Table 16: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
69
Fig. 31: Cleaning the Filter Silencer
70
Fig. 32: Cleaning the Filter Silencer
72
Fig. 33: Cleaning the Filter Silencer (2)
74
Table 17: Tightening Torque (81272)
74
Table 18: Tightening Torque (81273)
74
Fig. 34: Compressor-End, Non-Rotating Parts
75
Fig. 35: Turbine End, Non-Rotating Parts
76
Fig. 36: Soaking the Turbine End
79
Table 19: Value Table for Soaking
79
Changing the Absorption Element
82
Fig. 37: Disassembling the Absorption Element
82
Table 20: Tightening Torque (81152 / 81154)
83
Fig. 38: Installing the Absorption Element
83
Eliminating Malfunctions
84
Malfunctions When Starting
84
Table 21: Malfunctions When Starting - Delayed Start-Up
84
Table 22: Malfunctions When Starting - Vibrations
84
Table 23: Malfunctions When Starting - Rubbing of Rotating Parts
84
Malfunctions During Operation
85
Table 24: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 25: Malfunctions During Operation - Speed Reduces
85
Table 26: Malfunctions During Operation - Speed Increases
85
Table 27: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 28: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 29: Malfunctions During Operation - Charge Air Pressure too High
87
Table 30: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 31: Malfunction - Turbocharger Pumping
88
Table 32: Malfunction - Sporadic Surge Blows
88
Malfunctions When Stopping
89
Table 33: Malfunctions When Stopping - Runout Noises
89
Table 34: Malfunctions When Stopping - Runout Time too Short
89
Table 37: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Table 35: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 36: Malfunction of the Speed Measurement System - Measured Speed too High
90
Speed Measurement System
90
Dismantling and Fitting, General
91
Introduction
91
Material Required
92
Fig. 39: Swivel Lifting Eyes
92
Table 38: Swivel Lifting Eyes
92
Table 40: Dismantling Screw
93
Table 39: Press-Off Screws
93
Fig. 41: Dismantling Screw
93
Fig. 40: Press-Off Screws
93
Disassembly and Assembly Concepts
95
Fig. 42: Removing the Cartridge Group with Compressor and Turbine Casing
95
Fig. 43: Cartridge Concept
96
Fig. 44: Optional Spanner Holder
97
Weights of Individual Parts
98
Fig. 45: Weights of Assemblies
98
Table 41: Weights of Assemblies
98
Table 42: Tightening Torques
99
Fig. 46: Overview of Tightening Torques
99
Table of Tightening Torques
99
Fig. 47: Tightening Torques for Insulation
100
Table 43: Tightening Torques for Insulation
100
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
101
Removing Air Inlets
101
Fig. 48: Removing the Air Inlets
101
Fig. 49: Removing the Uncoupled Filter Silencer
102
Removing the Gas Outlet Casing
103
Fig. 50: Remove Gas Outlet Casing Without Support
103
Fig. 51: Removing Gas Outlet Casing with Support 1
104
Fig. 52: Removing Gas Outlet Casing with Support 1
105
Removing the Gas Outlet Flange
106
Fig. 53: Dismantling the Gas Outlet Flange
107
Table 44: 3 Press-Off Screws
107
Fig. 54: Removing the Gas Outlet Flange
108
Table 45: 6 Press-Off Screws
108
Removing the Cartridge Group with Compressor and Turbine Casing
109
Fig. 55: Turbine Cleaning Nozzle
109
Fig. 56: Remove Insulation
109
Fig. 57: Removing the Cartridge Group with Compressor and Turbine Casing
110
Fig. 58: Setting down the Cartridge Group with the Compressor and Turbine Casing
110
Removing the Compressor Casing
111
Fig. 59: Removing the Compressor Casing
111
Fig. 60: Dismantling the Diffuser and the Wall Insert
112
Removing the Cartridge Group
113
Fig. 61: Removing Cartridge Group 1
113
Table 46: Tightening Torque (90012-01)
113
Fig. 62: Removing Cartridge Group 2
114
Fig. 63: Removing Cartridge Group 3
115
Installing the Cartridge Group on the Service Support
116
Fig. 64: Installing the Cartridge Group on the Service Support
116
Removing the Nozzle Ring
117
Fig. 65: Removing the Nozzle Ring
117
Measuring Clearance a and B
118
Fig. 66: Measuring Clearance a and B
118
Table 47: Permissible Clearances a and B
118
Nozzle Ring Compression PD
119
Fig. 67: Nozzle Ring Compression PD
119
Table 48: Nozzle Ring Compression PD
119
Installing Nozzle Ring
120
Fig. 68: Installing the Nozzle Ring
120
Installing the Cartridge Group
121
Fig. 69: Lifting the Cartridge Group and Rotating It
121
Fig. 70: Turning the Cartridge Group
122
Table 49: Tightening Torque (90012-01)
122
Fig. 71: Installing the Cartridge Group
123
Table 50: Tightening Torque (51007)
123
Installing the Compressor Casing
124
Fig. 72: Fitting the Wall Insert and the Diffuser
124
Table 51: Tightening Torque (79041)
124
Table 52: Tightening Torque (72011)
125
Fig. 73: Installing the Compressor Casing
125
Turning the Cartridge Group with Compressor and Turbine Casing
126
Fig. 74: Turning the Cartridge Group with Compressor and Turbine Casing
126
Installing the Gas Outlet Flange
127
Fig. 75: Installing the Gas Outlet Flange
127
Radial Clearances N and R
128
Fig. 76: Measuring Clearances N and R
128
Table 53: Permissible Clearances N and R
128
Fitting the Insulation
129
Fig. 77: Fitting the Insulation
129
Fig. 79: Installing the Cartridge Group with Compressor and Turbine Casing
130
Fig. 78: Installing the Cartridge Group with Compressor and Turbine Casing
130
Installing the Cartridge Group with Compressor and Turbine Casing
130
Installing the Gas Outlet Casing
131
Fig. 80: Fitting Gas Outlet Casing Without Support
131
Table 54: Tightening Torque (51009)
131
Fig. 81: Installing Gas Outlet Casing with Support 1
132
Table 55: Tightening Torque (51009)
132
Fig. 82: Installing Gas Outlet Casing with Support 2
133
Table 56: Tightening Torque (72051)
134
Fig. 83: Installing the Air Inlets
134
Installing Air Inlets
134
Fig. 84: Installing the Uncoupled Filter Silencer
135
Table 57: Tightening Torque (72054)
135
Dismantling and Fitting, Cartridge Concept
136
Removing Air Inlets
136
Fig. 85: Removing the Air Inlets
136
Fig. 86: Removing the Uncoupled Filter Silencer
137
Removing the Compressor Casing
138
Fig. 87: Removing the Compressor Casing
138
Fig. 88: Pressing off Compressor Casing
139
Fig. 89: Remove the Diffuser
139
Fig. 90: Dismantling the Diffuser and the Wall Insert
140
Fig. 91: Removing Insulation Sheets
141
Fig. 92: Removing Cartridge Group 1
141
Table 58: Threaded Rod, Value X
141
Fig. 93: Removing Cartridge Group 2
142
Fig. 94: Removing Cartridge Group 2
143
Fig. 95: S_05180
144
Fig. 96: Measuring Clearance a and B
145
Table 59: Permissible Clearances a and B
145
Fig. 97: Nozzle Ring Compression PD
146
Table 60: Nozzle Ring Compression PD
146
Fig. 98: Installing the Nozzle Ring
147
Fig. 99: Installing the Cartridge Group 1
148
Fig. 100: Installing the Cartridge Group 2
149
Table 61: Threaded Rod, Value X and L
149
Table 62: Tightening Torque (51007)
149
Fig. 101: Fitting the Wall Insert and the Diffuser
150
Table 63: Tightening Torque (79041)
150
Fig. 102: Installing the Compressor Casing
151
Table 64: Tightening Torque (72011)
151
Fig. 103: Measuring Clearances N and R
152
Table 65: Permissible Clearances N and R
152
Fig. 104: Fitting the Insulation
153
Fig. 105: Installing the Air Inlets
154
Table 66: Tightening Torque (72051)
154
Fig. 106: Installing the Uncoupled Filter Silencer
155
Table 67: Tightening Torque (72054)
155
Dismantling and Fitting, Special Tools for Fastening Strips
156
Fig. 107: Customer Tool
156
Fig. 108: Customer Tool
156
Table 68: Customer Tool
156
Table 69: Customer Tool
156
Fig. 110: Removing the Fastening Strips
157
Fig. 109: Positioning the Collection Tub
157
Application, Special Tools
157
Fig. 111: Fitting the Upper Fastening Strips
158
Fig. 112: Fitting the Bottom Fastening Strip
158
Table 70: Tightening Torque (51007)
158
Fig. 113: Fitting the Bottom Fastening Strip
159
Table 71: Tightening Torque (51007) with Spanner Holder
159
Fig. 114: Fitting the Cartridge Group
160
Table 72: Tightening Torque (51007)
160
Fig. 115: Positioning the Fastening Strip
161
Fig. 116: Clamping Piece
162
Fig. 117: Attach Nut
163
Table 73: Tightening Torque (51007) with Spanner Holder
163
Removing and Installing 6-Nozzle Turbine Cleaning Component (Optional)
164
Disassembly
164
Fig. 118: Initial Situation
164
Fig. 119: Disassembly of the Elbows
164
Fig. 120: Disassembly of the Elbows
165
Fig. 121: Pipe Disassembly
165
Table 74: Dismantling Screw
166
Fig. 123: Disassembly of the Cleaning Nozzle
166
Fig. 122: Disassembly of the Connecting Pieces
166
Assembly
167
Fig. 124: Assembly of the Cleaning Nozzle
167
Fig. 125: Assembly of the Connecting Pieces
167
Table 75: Dismantling Screw
167
Fig. 126: Pipe Assembly
168
Fig. 127: Elbow 1 Assembly
168
Fig. 128: Elbow 2 Assembly
169
Table 76: Tightening Torque (51314 / 51316)
169
Fig. 129: Fit the Cleaning Nozzles
170
Fitting the Cleaning Nozzles with Multi-Inlet Turbine Casings
170
Taking out of Operation at Short Notice
171
Possible Emergency Repairs
171
Installing the Replacement Turbocharger
172
Installing the Replacement Cartridge Group
172
Fitting the Cover Plate
173
Fig. 130: Fitting the Cover Plate
173
Table 77: Cover Plate Dimensions [MM]
174
Fig. 131: Cover Plate Drawing
174
Cover Plate Drawing
174
Table 78: Cover Plate Dimensions [MM]
175
Fig. 132: Dimensions for Cover Plate
175
Mothballing the Turbocharger
176
Taking the Engine out of Operation for up to 12 Months
176
Taking the Engine out of Operation for more than 12 Months
177
Material and Disposal
178
REACH and Rohs Compliance Declaration for Products
178
Disposing of Turbocharger Components
179
Required Customer Spare Part Set (97070)
180
Table 79: Customer Spare Part Set 97070
180
Ordering Spare Parts
180
Spare Parts
180
Spare Part - Illustrations
181
Table 80: Spare Parts - Cartridge, Oil Cooled
181
Table 81: Spare Parts - Bearing, Casing Oil Cooled
182
Table 82: Spare Parts - Rotor and Bearing Parts
183
Table 83: Spare Parts - Turbine Casing, 1 Inlet
184
Table 84: Spare Parts - Turbine Casing, 2 Inlets
185
Table 85: Spare Parts - Turbine Casing, 3 Inlets
186
Table 86: Spare Parts - Cleaning Device
187
Table 87: Spare Parts - Gas Outlet Casing, Radial
188
Table 88: Spare Parts - Compressor Casing
189
Table 89: Spare Parts - Filter Silencer
191
Table 90: Spare Parts - Air Suction Branch Axial
191
Table 91: Spare Parts - Air Suction Branch Radial
192
Table 92: Spare Parts - Speed Measurement System
193
Tools
194
Fig. 133: Special Tool
194
Table 93: Customer Tool Set 90000
194
Table 94: Special Tool (90160)
194
Fig. 134: Special Tool
195
Table 95: Special Tool (90160)
195
ABB A150-M57 Operation Manual (200 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 34.05 MB
Table of Contents
Operation Manual / A150-M - A155-M
3
Table of Contents
3
Operation Manual / A150-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
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Definition of Mandatory Signs
16
Intended Use
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 7: Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Periodic Check of the Pressure Vessels
21
Fig. 10: Attachment Angle
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Lifting of Loads
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
Removing and Installing
31
Turbocharger Weight and Transportation
31
Fig. 11: Suspension of Complete Turbocharger Unit
31
Table 4: Weight of Complete Turbocharger Unit
31
Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Fig. 13: Removing the Turbocharger
33
Fig. 14: Loosening the Clamping Nut
34
Fig. 15: Turbocharger Centre of Gravity
35
Installing the Turbocharger
36
Fig. 16: Inserting the Gasket
36
Fig. 17: Fitting the Turbocharger 1
37
Fig. 18: Fitting the Turbocharger 2
38
Table 5: Fitting the Turbocharger, Value X, L
38
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
39
Table 6: Torque-Controlled Tightening of the Pressure Screws
40
Fig. 20: Tightening Pressure Screws
40
Fig. 21: Connecting the Speed Sensor
41
Fig. 22: Connecting the Compressor Cooling Air Intake
41
Fig. 23: Attaching the Support
41
Commissioning
42
Oil Supply
42
Fig. 24: Oil Orifice
42
Inspection Procedures
44
Commissioning after Taking out of Operation
46
Table 7: Lubricating Oil Pressure at Oil Inlet before Turbocharger
47
Monitoring Operation
47
Oil Pressure, Oil Temperature
47
Table 8: Lubricating Oil Temperature at the Inlet
48
Table 9: Maximum Lubricating Oil Temperature at the Outlet
48
Exhaust Gas Temperature before Turbine
49
Turbocharger Speed
50
Fig. 25: Layout and Overview of Speed Measurement System
50
Fig. 26: Replacing the Speed Sensor
52
Table 10: Tightening Torque (86505)
52
Noise Emission
53
Operation and Service
53
Fig. 27: Noise Insulation, Bellows
54
Service Work
55
Expected Replacement Intervals
58
Table 11: Expected Replacement Intervals
58
Stopping the Engine
60
Periodic Maintenance Work
61
Foreword to Maintenance
61
Table 12: Maintenance Table
61
Cleaning the Compressor During Operation
62
Fig. 28: Carrying out Wet Cleaning of Compressor
64
Table 13: Parameters for Wet Cleaning of Compressor
64
Cleaning the Turbine During Operation
65
Fig. 29: Turbine Cleaning Devices
67
Table 14: Turbine Wet Cleaning, Recommended Operating State
67
Fig. 30: Carrying out Wet Cleaning of Turbine
68
Table 15: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
68
Cleaning Components Mechanically
69
Table 16: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
69
Fig. 31: Cleaning the Filter Silencer
70
Fig. 32: Cleaning the Filter Silencer
72
Fig. 33: Cleaning the Filter Silencer (2)
74
Table 17: Tightening Torque (81272)
74
Table 18: Tightening Torque (81273)
74
Fig. 34: Compressor-End, Non-Rotating Parts
75
Fig. 35: Turbine End, Non-Rotating Parts
76
Fig. 36: Soaking the Turbine End
79
Table 19: Value Table for Soaking
79
Changing the Absorption Element
82
Fig. 37: Disassembling the Absorption Element
82
Table 20: Tightening Torque (81152 / 81154)
83
Fig. 38: Installing the Absorption Element
83
Eliminating Malfunctions
84
Malfunctions When Starting
84
Table 21: Malfunctions When Starting - Delayed Start-Up
84
Table 22: Malfunctions When Starting - Vibrations
84
Table 23: Malfunctions When Starting - Rubbing of Rotating Parts
84
Malfunctions During Operation
85
Table 24: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 25: Malfunctions During Operation - Speed Reduces
85
Table 26: Malfunctions During Operation - Speed Increases
85
Table 27: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 28: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 29: Malfunctions During Operation - Charge Air Pressure too High
87
Table 30: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 31: Malfunction - Turbocharger Surging
88
Table 32: Malfunction - Sporadic Surge Blows
88
Malfunctions When Stopping
89
Table 33: Malfunctions When Stopping - Runout Noises
89
Table 34: Malfunctions When Stopping - Runout Time too Short
89
Table 37: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Table 35: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 36: Malfunction of the Speed Measurement System - Measured Speed too High
90
Speed Measurement System
90
Dismantling and Fitting, General
91
Introduction
91
Material Required
92
Fig. 39: Swivel Lifting Eye (Example)
92
Table 38: Swivel Lifting Eyes
92
Table 40: Dismantling Screw
93
Table 39: Press-Off Screws
93
Fig. 41: Dismantling Screw
93
Fig. 40: Press-Off Screws
93
Disassembly and Assembly Concepts
95
Fig. 42: Removing the Cartridge Group with Compressor and Turbine Casing
95
Fig. 43: Cartridge Concept
96
Fig. 44: Optional Spanner Holder
97
Weights of Individual Parts
98
Fig. 45: Weights of Assemblies
98
Table 41: Weights of Assemblies
98
Table 42: Tightening Torques
99
Fig. 46: Overview of Tightening Torques
99
Table of Tightening Torques
99
Fig. 47: Tightening Torques for Insulation
100
Table 43: Tightening Torques for Insulation
100
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
101
Removing Air Inlets
101
Fig. 48: Removing the Air Inlets
101
Fig. 49: Removing the Uncoupled Filter Silencer
102
Removing the Gas Outlet Casing
103
Fig. 50: Remove Gas Outlet Casing Without Support
103
Fig. 51: Removing Gas Outlet Casing with Support 1
104
Fig. 52: Removing Gas Outlet Casing with Support 1
105
Removing the Gas Outlet Flange
106
Fig. 53: Dismantling the Gas Outlet Flange
107
Table 44: 3 Press-Off Screws
107
Fig. 54: Removing the Gas Outlet Flange
108
Table 45: 6 Press-Off Screws
108
Removing the Cartridge Group with Compressor and Turbine Casing
109
Fig. 55: Turbine Cleaning Nozzle
109
Fig. 56: Remove Insulation
109
Fig. 57: Removing the Cartridge Group with Compressor and Turbine Casing
110
Fig. 58: Setting down the Cartridge Group with the Compressor and Turbine Casing
110
Removing the Compressor Casing
111
Fig. 59: Removing the Compressor Casing
111
Fig. 60: Dismantling the Diffuser and the Wall Insert
112
Removing the Cartridge Group
113
Fig. 61: Removing Cartridge Group 1
113
Table 46: Tightening Torque (90012-01)
113
Fig. 62: Removing Cartridge Group 2
114
Fig. 63: Removing Cartridge Group 3
115
Installing the Cartridge Group on the Service Support
116
Fig. 64: Installing the Cartridge Group on the Service Support
116
Removing the Nozzle Ring
117
Fig. 65: Removing the Nozzle Ring
117
Measuring Clearance a and B
118
Fig. 66: Measuring Clearance a and B
118
Table 47: Permissible Clearances a and B
118
Nozzle Ring Compression PD
119
Fig. 67: Nozzle Ring Compression PD
119
Table 48: Nozzle Ring Compression PD
119
Installing Nozzle Ring
120
Fig. 68: Installing the Nozzle Ring
120
Installing the Cartridge Group
121
Fig. 69: Lifting the Cartridge Group and Rotating It
121
Fig. 70: Turning the Cartridge Group
122
Table 49: Tightening Torque (90012-01)
122
Fig. 71: Installing the Cartridge Group
123
Table 50: Tightening Torque (51007)
123
Installing the Compressor Casing
124
Fig. 72: Fitting the Wall Insert and the Diffuser
124
Table 51: Tightening Torque (79041)
124
Table 52: Tightening Torque (72011)
125
Fig. 73: Installing the Compressor Casing
125
Turning the Cartridge Group with Compressor and Turbine Casing
126
Fig. 74: Turning the Cartridge Group with Compressor and Turbine Casing
126
Installing the Gas Outlet Flange
127
Fig. 75: Installing the Gas Outlet Flange
127
Radial Clearances N and R
128
Fig. 76: Measuring Clearances N and R
128
Table 53: Permissible Clearances N and R
128
Fitting the Insulation
129
Fig. 77: Fitting the Insulation
129
Fig. 79: Installing the Cartridge Group with Compressor and Turbine Casing
130
Fig. 78: Installing the Cartridge Group with Compressor and Turbine Casing
130
Installing the Cartridge Group with Compressor and Turbine Casing
130
Installing the Gas Outlet Casing
131
Fig. 80: Fitting Gas Outlet Casing Without Support
131
Table 54: Tightening Torque (51009)
131
Fig. 81: Installing Gas Outlet Casing with Support 1
132
Table 55: Tightening Torque (51009)
132
Fig. 82: Installing Gas Outlet Casing with Support 2
133
Table 56: Tightening Torque (72051)
134
Fig. 83: Installing the Air Inlets
134
Installing Air Inlets
134
Fig. 84: Installing the Uncoupled Filter Silencer
135
Table 57: Tightening Torque (72054)
135
Dismantling and Fitting, Cartridge Concept
136
Removing Air Inlets
136
Fig. 85: Removing the Air Inlets
136
Fig. 86: Removing the Uncoupled Filter Silencer
137
Removing the Compressor Casing
138
Fig. 87: Removing the Compressor Casing
138
Fig. 88: Pressing off Compressor Casing
139
Fig. 89: Remove the Diffuser
139
Fig. 90: Dismantling the Diffuser and the Wall Insert
140
Fig. 91: Removing Insulation Sheets
141
Fig. 92: Removing Cartridge Group 1
141
Table 58: Threaded Rod, Value X
141
Fig. 93: Removing Cartridge Group 2
142
Fig. 94: Removing Cartridge Group 2
143
Fig. 95: S_05180
144
Fig. 96: Measuring Clearance a and B
145
Table 59: Permissible Clearances a and B
145
Fig. 97: Nozzle Ring Compression PD
146
Table 60: Nozzle Ring Compression PD
146
Fig. 98: Installing the Nozzle Ring
147
Fig. 99: Installing the Cartridge Group 1
148
Fig. 100: Installing the Cartridge Group 2
149
Table 61: Threaded Rod, Value X and L
149
Table 62: Tightening Torque (51007)
149
Fig. 101: Fitting the Wall Insert and the Diffuser
150
Table 63: Tightening Torque (79041)
150
Fig. 102: Installing the Compressor Casing
151
Table 64: Tightening Torque (72011)
151
Fig. 103: Measuring Clearances N and R
152
Table 65: Permissible Clearances N and R
152
Fig. 104: Fitting the Insulation
153
Fig. 105: Installing the Air Inlets
154
Table 66: Tightening Torque (72051)
154
Fig. 106: Installing the Uncoupled Filter Silencer
155
Table 67: Tightening Torque (72054)
155
Dismantling and Fitting, Special Tools for Fastening Strips
156
Fig. 107: Customer Tool
156
Fig. 108: Customer Tool
156
Table 68: Customer Tool
156
Table 69: Customer Tool
156
Fig. 110: Removing the Fastening Strips
157
Fig. 109: Positioning the Collection Tub
157
Application, Special Tools
157
Fig. 111: Fitting the Upper Fastening Strips
158
Fig. 112: Fitting the Bottom Fastening Strip
158
Table 70: Tightening Torque (51007)
158
Fig. 113: Fitting the Bottom Fastening Strip
159
Table 71: Tightening Torque (51007) with Spanner Holder
159
Fig. 114: Fitting the Cartridge Group
160
Table 72: Tightening Torque (51007)
160
Fig. 115: Positioning the Fastening Strip
161
Fig. 116: Clamping Piece
162
Fig. 117: Attach Nut
163
Table 73: Tightening Torque (51007) with Spanner Holder
163
Removing and Installing 6-Nozzle Turbine Cleaning Component (Optional)
164
Disassembly
164
Fig. 118: Initial Situation
164
Fig. 119: Disassembly of the Elbows
164
Fig. 120: Disassembly of the Elbows
165
Fig. 121: Pipe Disassembly
165
Table 74: Dismantling Screw
166
Fig. 123: Disassembly of the Cleaning Nozzle
166
Fig. 122: Disassembly of the Connecting Pieces
166
Assembly
167
Fig. 124: Assembly of the Cleaning Nozzle
167
Fig. 125: Assembly of the Connecting Pieces
167
Table 75: Dismantling Screw
167
Fig. 126: Pipe Assembly
168
Fig. 127: Elbow 1 Assembly
168
Fig. 128: Elbow 2 Assembly
169
Table 76: Tightening Torque (51314 / 51316)
169
Fig. 129: Fit the Cleaning Nozzles
170
Fitting the Cleaning Nozzles with Multi-Inlet Turbine Casings
170
Taking out of Operation at Short Notice
171
Possible Emergency Repairs
171
Installing the Replacement Turbocharger
172
Installing the Replacement Cartridge Group
172
Fitting the Cover Plate
173
Fig. 130: Fitting the Cover Plate
173
Table 77: Cover Plate Dimensions [MM]
174
Fig. 131: Cover Plate Drawing
174
Cover Plate Drawing
174
Table 78: Cover Plate Dimensions [MM]
175
Fig. 132: Dimensions for Cover Plate
175
Mothballing the Turbocharger
176
Taking the Engine out of Operation for up to 12 Months
176
Taking the Engine out of Operation for more than 12 Months
177
Material and Disposal
178
REACH and Rohs Compliance Declaration for Products
178
Disposing of Turbocharger Components
179
Required Customer Spare Part Set (97070)
180
Table 79: Customer Spare Part Set 97070
180
Ordering Spare Parts
180
Spare Parts
180
Spare Part - Illustrations
181
Table 80: Spare Parts - Cartridge, Oil Cooled
181
Table 81: Spare Parts - Bearing, Casing Oil Cooled
182
Table 82: Spare Parts - Rotor and Bearing Parts
183
Table 83: Spare Parts - Turbine Casing, 1 Inlet
184
Table 84: Spare Parts - Turbine Casing, 2 Inlets
185
Table 85: Spare Parts - Turbine Casing, 3 Inlets
186
Table 86: Spare Parts - Cleaning Device
187
Table 87: Spare Parts - Gas Outlet Casing, Radial
188
Table 88: Spare Parts - Compressor Casing
189
Table 89: Spare Parts - Filter Silencer
191
Table 90: Spare Parts - Air Suction Branch Axial
191
Table 91: Spare Parts - Air Suction Branch Radial
192
Table 92: Spare Parts - Speed Measurement System
193
Tools
194
Fig. 133: Special Tool
194
Table 93: Customer Tool Set 90000
194
Table 94: Special Tool (90160)
194
Fig. 134: Special Tool
195
Table 95: Special Tool (90160)
195
ABB A150-M57 Operation Manual (200 pages)
Turbocharging
Brand:
ABB
| Category:
Industrial Equipment
| Size: 34.18 MB
Table of Contents
Operation Manual / A150-M - A155-M
3
Table of Contents
3
Operation Manual / A150-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
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Definition of Mandatory Signs
16
Intended Use
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 7: Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Periodic Check of the Pressure Vessels
21
Fig. 10: Attachment Angle
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Lifting of Loads
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
Removing and Installing
31
Turbocharger Weight and Transportation
31
Fig. 11: Suspension of Complete Turbocharger Unit
31
Table 4: Weight of Complete Turbocharger Unit
31
Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Fig. 13: Removing the Turbocharger
33
Fig. 14: Loosening the Clamping Nut
34
Fig. 15: Turbocharger Centre of Gravity
35
Installing the Turbocharger
36
Fig. 16: Inserting the Gasket
36
Fig. 17: Fitting the Turbocharger 1
37
Fig. 18: Fitting the Turbocharger 2
38
Table 5: Fitting the Turbocharger, Value X, L
38
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
39
Table 6: Torque-Controlled Tightening of the Pressure Screws
40
Fig. 20: Tightening Pressure Screws
40
Fig. 21: Connecting the Speed Sensor
41
Fig. 22: Connecting the Compressor Cooling Air Intake
41
Fig. 23: Attaching the Support
41
Commissioning
42
Oil Supply
42
Fig. 24: Oil Orifice
42
Inspection Procedures
44
Commissioning after Taking out of Operation
46
Table 7: Lubricating Oil Pressure at Oil Inlet before Turbocharger
47
Monitoring Operation
47
Oil Pressure, Oil Temperature
47
Table 8: Lubricating Oil Temperature at the Inlet
48
Table 9: Maximum Lubricating Oil Temperature at the Outlet
48
Exhaust Gas Temperature before Turbine
49
Turbocharger Speed
50
Fig. 25: Layout and Overview of Speed Measurement System
50
Fig. 26: Replacing the Speed Sensor
52
Table 10: Tightening Torque (86505)
52
Noise Emission
53
Operation and Service
53
Fig. 27: Noise Insulation, Bellows
54
Service Work
55
Expected Replacement Intervals
58
Table 11: Expected Replacement Intervals
58
Stopping the Engine
60
Periodic Maintenance Work
61
Foreword to Maintenance
61
Table 12: Maintenance Table
61
Cleaning the Compressor During Operation
62
Fig. 28: Carrying out Wet Cleaning of Compressor
64
Table 13: Parameters for Wet Cleaning of Compressor
64
Cleaning the Turbine During Operation
65
Fig. 29: Turbine Cleaning Devices
67
Table 14: Turbine Wet Cleaning, Recommended Operating State
67
Fig. 30: Carrying out Wet Cleaning of Turbine
68
Table 15: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
68
Cleaning Components Mechanically
69
Table 16: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
69
Fig. 31: Cleaning the Filter Silencer
70
Fig. 32: Cleaning the Filter Silencer
72
Fig. 33: Cleaning the Filter Silencer (2)
74
Table 17: Tightening Torque (81272)
74
Table 18: Tightening Torque (81273)
74
Fig. 34: Compressor-End, Non-Rotating Parts
75
Fig. 35: Turbine End, Non-Rotating Parts
76
Fig. 36: Soaking the Turbine End
79
Table 19: Value Table for Soaking
79
Changing the Absorption Element
82
Fig. 37: Disassembling the Absorption Element
82
Table 20: Tightening Torque (81152 / 81154)
83
Fig. 38: Installing the Absorption Element
83
Eliminating Malfunctions
84
Malfunctions When Starting
84
Table 21: Malfunctions When Starting - Delayed Start-Up
84
Table 22: Malfunctions When Starting - Vibrations
84
Table 23: Malfunctions When Starting - Rubbing of Rotating Parts
84
Malfunctions During Operation
85
Table 24: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 25: Malfunctions During Operation - Speed Reduces
85
Table 26: Malfunctions During Operation - Speed Increases
85
Table 27: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 28: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 29: Malfunctions During Operation - Charge Air Pressure too High
87
Table 30: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 31: Malfunction - Turbocharger Pumping
88
Table 32: Malfunction - Sporadic Surge Blows
88
Malfunctions When Stopping
89
Table 33: Malfunctions When Stopping - Runout Noises
89
Table 34: Malfunctions When Stopping - Runout Time too Short
89
Table 37: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Table 35: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 36: Malfunction of the Speed Measurement System - Measured Speed too High
90
Speed Measurement System
90
Dismantling and Fitting, General
91
Introduction
91
Material Required
92
Fig. 39: Swivel Lifting Eyes
92
Table 38: Swivel Lifting Eyes
92
Table 40: Dismantling Screw
93
Table 39: Press-Off Screws
93
Fig. 41: Dismantling Screw
93
Fig. 40: Press-Off Screws
93
Disassembly and Assembly Concepts
95
Fig. 42: Removing the Cartridge Group with Compressor and Turbine Casing
95
Fig. 43: Cartridge Concept
96
Fig. 44: Optional Spanner Holder
97
Weights of Individual Parts
98
Fig. 45: Weights of Assemblies
98
Table 41: Weights of Assemblies
98
Table 42: Tightening Torques
99
Fig. 46: Overview of Tightening Torques
99
Table of Tightening Torques
99
Fig. 47: Tightening Torques for Insulation
100
Table 43: Tightening Torques for Insulation
100
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
101
Removing Air Inlets
101
Fig. 48: Removing the Air Inlets
101
Fig. 49: Removing the Uncoupled Filter Silencer
102
Removing the Gas Outlet Casing
103
Fig. 50: Remove Gas Outlet Casing Without Support
103
Fig. 51: Removing Gas Outlet Casing with Support 1
104
Fig. 52: Removing Gas Outlet Casing with Support 1
105
Removing the Gas Outlet Flange
106
Fig. 53: Dismantling the Gas Outlet Flange
107
Table 44: 3 Press-Off Screws
107
Fig. 54: Removing the Gas Outlet Flange
108
Table 45: 6 Press-Off Screws
108
Removing the Cartridge Group with Compressor and Turbine Casing
109
Fig. 55: Turbine Cleaning Nozzle
109
Fig. 56: Remove Insulation
109
Fig. 57: Removing the Cartridge Group with Compressor and Turbine Casing
110
Fig. 58: Setting down the Cartridge Group with the Compressor and Turbine Casing
110
Removing the Compressor Casing
111
Fig. 59: Removing the Compressor Casing
111
Fig. 60: Dismantling the Diffuser and the Wall Insert
112
Removing the Cartridge Group
113
Fig. 61: Removing Cartridge Group 1
113
Table 46: Tightening Torque (90012-01)
113
Fig. 62: Removing Cartridge Group 2
114
Fig. 63: Removing Cartridge Group 3
115
Installing the Cartridge Group on the Service Support
116
Fig. 64: Installing the Cartridge Group on the Service Support
116
Removing the Nozzle Ring
117
Fig. 65: Removing the Nozzle Ring
117
Measuring Clearance a and B
118
Fig. 66: Measuring Clearance a and B
118
Table 47: Permissible Clearances a and B
118
Nozzle Ring Compression PD
119
Fig. 67: Nozzle Ring Compression PD
119
Table 48: Nozzle Ring Compression PD
119
Installing Nozzle Ring
120
Fig. 68: Installing the Nozzle Ring
120
Installing the Cartridge Group
121
Fig. 69: Lifting the Cartridge Group and Rotating It
121
Fig. 70: Turning the Cartridge Group
122
Table 49: Tightening Torque (90012-01)
122
Fig. 71: Installing the Cartridge Group
123
Table 50: Tightening Torque (51007)
123
Installing the Compressor Casing
124
Fig. 72: Fitting the Wall Insert and the Diffuser
124
Table 51: Tightening Torque (79041)
124
Table 52: Tightening Torque (72011)
125
Fig. 73: Installing the Compressor Casing
125
Turning the Cartridge Group with Compressor and Turbine Casing
126
Fig. 74: Turning the Cartridge Group with Compressor and Turbine Casing
126
Installing the Gas Outlet Flange
127
Fig. 75: Installing the Gas Outlet Flange
127
Radial Clearances N and R
128
Fig. 76: Measuring Clearances N and R
128
Table 53: Permissible Clearances N and R
128
Fitting the Insulation
129
Fig. 77: Fitting the Insulation
129
Fig. 79: Installing the Cartridge Group with Compressor and Turbine Casing
130
Fig. 78: Installing the Cartridge Group with Compressor and Turbine Casing
130
Installing the Cartridge Group with Compressor and Turbine Casing
130
Installing the Gas Outlet Casing
131
Fig. 80: Fitting Gas Outlet Casing Without Support
131
Table 54: Tightening Torque (51009)
131
Fig. 81: Installing Gas Outlet Casing with Support 1
132
Table 55: Tightening Torque (51009)
132
Fig. 82: Installing Gas Outlet Casing with Support 2
133
Table 56: Tightening Torque (72051)
134
Fig. 83: Installing the Air Inlets
134
Installing Air Inlets
134
Fig. 84: Installing the Uncoupled Filter Silencer
135
Table 57: Tightening Torque (72054)
135
Dismantling and Fitting, Cartridge Concept
136
Removing Air Inlets
136
Fig. 85: Removing the Air Inlets
136
Fig. 86: Removing the Uncoupled Filter Silencer
137
Removing the Compressor Casing
138
Fig. 87: Removing the Compressor Casing
138
Fig. 88: Pressing off Compressor Casing
139
Fig. 89: Remove the Diffuser
139
Fig. 90: Dismantling the Diffuser and the Wall Insert
140
Fig. 91: Removing Insulation Sheets
141
Fig. 92: Removing Cartridge Group 1
141
Table 58: Threaded Rod, Value X
141
Fig. 93: Removing Cartridge Group 2
142
Fig. 94: Removing Cartridge Group 2
143
Fig. 95: S_05180
144
Fig. 96: Measuring Clearance a and B
145
Table 59: Permissible Clearances a and B
145
Fig. 97: Nozzle Ring Compression PD
146
Table 60: Nozzle Ring Compression PD
146
Fig. 98: Installing the Nozzle Ring
147
Fig. 99: Installing the Cartridge Group 1
148
Fig. 100: Installing the Cartridge Group 2
149
Table 61: Threaded Rod, Value X and L
149
Table 62: Tightening Torque (51007)
149
Fig. 101: Fitting the Wall Insert and the Diffuser
150
Table 63: Tightening Torque (79041)
150
Fig. 102: Installing the Compressor Casing
151
Table 64: Tightening Torque (72011)
151
Fig. 103: Measuring Clearances N and R
152
Table 65: Permissible Clearances N and R
152
Fig. 104: Fitting the Insulation
153
Fig. 105: Installing the Air Inlets
154
Table 66: Tightening Torque (72051)
154
Fig. 106: Installing the Uncoupled Filter Silencer
155
Table 67: Tightening Torque (72054)
155
Dismantling and Fitting, Special Tools for Fastening Strips
156
Fig. 107: Customer Tool
156
Fig. 108: Customer Tool
156
Table 68: Customer Tool
156
Table 69: Customer Tool
156
Fig. 110: Removing the Fastening Strips
157
Fig. 109: Positioning the Collection Tub
157
Application, Special Tools
157
Fig. 111: Fitting the Upper Fastening Strips
158
Fig. 112: Fitting the Bottom Fastening Strip
158
Table 70: Tightening Torque (51007)
158
Fig. 113: Fitting the Bottom Fastening Strip
159
Table 71: Tightening Torque (51007) with Spanner Holder
159
Fig. 114: Fitting the Cartridge Group
160
Table 72: Tightening Torque (51007)
160
Fig. 115: Positioning the Fastening Strip
161
Fig. 116: Clamping Piece
162
Fig. 117: Attach Nut
163
Table 73: Tightening Torque (51007) with Spanner Holder
163
Removing and Installing 6-Nozzle Turbine Cleaning Component (Optional)
164
Disassembly
164
Fig. 118: Initial Situation
164
Fig. 119: Disassembly of the Elbows
164
Fig. 120: Disassembly of the Elbows
165
Fig. 121: Pipe Disassembly
165
Table 74: Dismantling Screw
166
Fig. 123: Disassembly of the Cleaning Nozzle
166
Fig. 122: Disassembly of the Connecting Pieces
166
Assembly
167
Fig. 124: Assembly of the Cleaning Nozzle
167
Fig. 125: Assembly of the Connecting Pieces
167
Table 75: Dismantling Screw
167
Fig. 126: Pipe Assembly
168
Fig. 127: Elbow 1 Assembly
168
Fig. 128: Elbow 2 Assembly
169
Table 76: Tightening Torque (51314 / 51316)
169
Fig. 129: Fit the Cleaning Nozzles
170
Fitting the Cleaning Nozzles with Multi-Inlet Turbine Casings
170
Taking out of Operation at Short Notice
171
Possible Emergency Repairs
171
Installing the Replacement Turbocharger
172
Installing the Replacement Cartridge Group
172
Fitting the Cover Plate
173
Fig. 130: Fitting the Cover Plate
173
Table 77: Cover Plate Dimensions [MM]
174
Fig. 131: Cover Plate Drawing
174
Cover Plate Drawing
174
Table 78: Cover Plate Dimensions [MM]
175
Fig. 132: Dimensions for Cover Plate
175
Mothballing the Turbocharger
176
Taking the Engine out of Operation for up to 12 Months
176
Taking the Engine out of Operation for more than 12 Months
177
Material and Disposal
178
REACH and Rohs Compliance Declaration for Products
178
Disposing of Turbocharger Components
179
Required Customer Spare Part Set (97070)
180
Table 79: Customer Spare Part Set 97070
180
Ordering Spare Parts
180
Spare Parts
180
Spare Part - Illustrations
181
Table 80: Spare Parts - Cartridge, Oil Cooled
181
Table 81: Spare Parts - Bearing, Casing Oil Cooled
182
Table 82: Spare Parts - Rotor and Bearing Parts
183
Table 83: Spare Parts - Turbine Casing, 1 Inlet
184
Table 84: Spare Parts - Turbine Casing, 2 Inlets
185
Table 85: Spare Parts - Turbine Casing, 3 Inlets
186
Table 86: Spare Parts - Cleaning Device
187
Table 87: Spare Parts - Gas Outlet Casing, Radial
188
Table 88: Spare Parts - Compressor Casing
189
Table 89: Spare Parts - Filter Silencer
191
Table 90: Spare Parts - Air Suction Branch Axial
191
Table 91: Spare Parts - Air Suction Branch Radial
192
Table 92: Spare Parts - Speed Measurement System
193
Tools
194
Fig. 133: Special Tool
194
Table 93: Customer Tool Set 90000
194
Table 94: Special Tool (90160)
194
Fig. 134: Special Tool
195
Table 95: Special Tool (90160)
195
ABB A150-M57 Operation Manual (200 pages)
Turbocharging
Brand:
ABB
| Category:
Industrial Equipment
| Size: 34.05 MB
Table of Contents
Operation Manual / A150-M - A155-M
3
Table of Contents
3
Operation Manual / A150-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
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Definition of Mandatory Signs
16
Intended Use
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 7: Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Periodic Check of the Pressure Vessels
21
Fig. 10: Attachment Angle
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Lifting of Loads
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
Removing and Installing
31
Turbocharger Weight and Transportation
31
Fig. 11: Suspension of Complete Turbocharger Unit
31
Table 4: Weight of Complete Turbocharger Unit
31
Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Fig. 13: Removing the Turbocharger
33
Fig. 14: Loosening the Clamping Nut
34
Fig. 15: Turbocharger Centre of Gravity
35
Installing the Turbocharger
36
Fig. 16: Inserting the Gasket
36
Fig. 17: Fitting the Turbocharger 1
37
Fig. 18: Fitting the Turbocharger 2
38
Table 5: Fitting the Turbocharger, Value X, L
38
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
39
Table 6: Torque-Controlled Tightening of the Pressure Screws
40
Fig. 20: Tightening Pressure Screws
40
Fig. 21: Connecting the Speed Sensor
41
Fig. 22: Connecting the Compressor Cooling Air Intake
41
Fig. 23: Attaching the Support
41
Commissioning
42
Oil Supply
42
Fig. 24: Oil Orifice
42
Inspection Procedures
44
Commissioning after Taking out of Operation
46
Table 7: Lubricating Oil Pressure at Oil Inlet before Turbocharger
47
Monitoring Operation
47
Oil Pressure, Oil Temperature
47
Table 8: Lubricating Oil Temperature at the Inlet
48
Table 9: Maximum Lubricating Oil Temperature at the Outlet
48
Exhaust Gas Temperature before Turbine
49
Turbocharger Speed
50
Fig. 25: Layout and Overview of Speed Measurement System
50
Fig. 26: Replacing the Speed Sensor
52
Table 10: Tightening Torque (86505)
52
Noise Emission
53
Operation and Service
53
Fig. 27: Noise Insulation, Bellows
54
Service Work
55
Expected Replacement Intervals
58
Table 11: Expected Replacement Intervals
58
Stopping the Engine
60
Periodic Maintenance Work
61
Foreword to Maintenance
61
Table 12: Maintenance Table
61
Cleaning the Compressor During Operation
62
Fig. 28: Carrying out Wet Cleaning of Compressor
64
Table 13: Parameters for Wet Cleaning of Compressor
64
Cleaning the Turbine During Operation
65
Fig. 29: Turbine Cleaning Devices
67
Table 14: Turbine Wet Cleaning, Recommended Operating State
67
Fig. 30: Carrying out Wet Cleaning of Turbine
68
Table 15: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
68
Cleaning Components Mechanically
69
Table 16: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
69
Fig. 31: Cleaning the Filter Silencer
70
Fig. 32: Cleaning the Filter Silencer
72
Fig. 33: Cleaning the Filter Silencer (2)
74
Table 17: Tightening Torque (81272)
74
Table 18: Tightening Torque (81273)
74
Fig. 34: Compressor-End, Non-Rotating Parts
75
Fig. 35: Turbine End, Non-Rotating Parts
76
Fig. 36: Soaking the Turbine End
79
Table 19: Value Table for Soaking
79
Changing the Absorption Element
82
Fig. 37: Disassembling the Absorption Element
82
Table 20: Tightening Torque (81152 / 81154)
83
Fig. 38: Installing the Absorption Element
83
Eliminating Malfunctions
84
Malfunctions When Starting
84
Table 21: Malfunctions When Starting - Delayed Start-Up
84
Table 22: Malfunctions When Starting - Vibrations
84
Table 23: Malfunctions When Starting - Rubbing of Rotating Parts
84
Malfunctions During Operation
85
Table 24: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 25: Malfunctions During Operation - Speed Reduces
85
Table 26: Malfunctions During Operation - Speed Increases
85
Table 27: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 28: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 29: Malfunctions During Operation - Charge Air Pressure too High
87
Table 30: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 31: Malfunction - Turbocharger Surging
88
Table 32: Malfunction - Sporadic Surge Blows
88
Malfunctions When Stopping
89
Table 33: Malfunctions When Stopping - Runout Noises
89
Table 34: Malfunctions When Stopping - Runout Time too Short
89
Table 37: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Table 35: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 36: Malfunction of the Speed Measurement System - Measured Speed too High
90
Speed Measurement System
90
Dismantling and Fitting, General
91
Introduction
91
Material Required
92
Fig. 39: Swivel Lifting Eye (Example)
92
Table 38: Swivel Lifting Eyes
92
Table 40: Dismantling Screw
93
Table 39: Press-Off Screws
93
Fig. 41: Dismantling Screw
93
Fig. 40: Press-Off Screws
93
Disassembly and Assembly Concepts
95
Fig. 42: Removing the Cartridge Group with Compressor and Turbine Casing
95
Fig. 43: Cartridge Concept
96
Fig. 44: Optional Spanner Holder
97
Weights of Individual Parts
98
Fig. 45: Weights of Assemblies
98
Table 41: Weights of Assemblies
98
Table 42: Tightening Torques
99
Fig. 46: Overview of Tightening Torques
99
Table of Tightening Torques
99
Fig. 47: Tightening Torques for Insulation
100
Table 43: Tightening Torques for Insulation
100
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
101
Removing Air Inlets
101
Fig. 48: Removing the Air Inlets
101
Fig. 49: Removing the Uncoupled Filter Silencer
102
Removing the Gas Outlet Casing
103
Fig. 50: Remove Gas Outlet Casing Without Support
103
Fig. 51: Removing Gas Outlet Casing with Support 1
104
Fig. 52: Removing Gas Outlet Casing with Support 1
105
Removing the Gas Outlet Flange
106
Fig. 53: Dismantling the Gas Outlet Flange
107
Table 44: 3 Press-Off Screws
107
Fig. 54: Removing the Gas Outlet Flange
108
Table 45: 6 Press-Off Screws
108
Removing the Cartridge Group with Compressor and Turbine Casing
109
Fig. 55: Turbine Cleaning Nozzle
109
Fig. 56: Remove Insulation
109
Fig. 57: Removing the Cartridge Group with Compressor and Turbine Casing
110
Fig. 58: Setting down the Cartridge Group with the Compressor and Turbine Casing
110
Removing the Compressor Casing
111
Fig. 59: Removing the Compressor Casing
111
Fig. 60: Dismantling the Diffuser and the Wall Insert
112
Removing the Cartridge Group
113
Fig. 61: Removing Cartridge Group 1
113
Table 46: Tightening Torque (90012-01)
113
Fig. 62: Removing Cartridge Group 2
114
Fig. 63: Removing Cartridge Group 3
115
Installing the Cartridge Group on the Service Support
116
Fig. 64: Installing the Cartridge Group on the Service Support
116
Removing the Nozzle Ring
117
Fig. 65: Removing the Nozzle Ring
117
Measuring Clearance a and B
118
Fig. 66: Measuring Clearance a and B
118
Table 47: Permissible Clearances a and B
118
Nozzle Ring Compression PD
119
Fig. 67: Nozzle Ring Compression PD
119
Table 48: Nozzle Ring Compression PD
119
Installing Nozzle Ring
120
Fig. 68: Installing the Nozzle Ring
120
Installing the Cartridge Group
121
Fig. 69: Lifting the Cartridge Group and Rotating It
121
Fig. 70: Turning the Cartridge Group
122
Table 49: Tightening Torque (90012-01)
122
Fig. 71: Installing the Cartridge Group
123
Table 50: Tightening Torque (51007)
123
Installing the Compressor Casing
124
Fig. 72: Fitting the Wall Insert and the Diffuser
124
Table 51: Tightening Torque (79041)
124
Table 52: Tightening Torque (72011)
125
Fig. 73: Installing the Compressor Casing
125
Turning the Cartridge Group with Compressor and Turbine Casing
126
Fig. 74: Turning the Cartridge Group with Compressor and Turbine Casing
126
Installing the Gas Outlet Flange
127
Fig. 75: Installing the Gas Outlet Flange
127
Radial Clearances N and R
128
Fig. 76: Measuring Clearances N and R
128
Table 53: Permissible Clearances N and R
128
Fitting the Insulation
129
Fig. 77: Fitting the Insulation
129
Fig. 79: Installing the Cartridge Group with Compressor and Turbine Casing
130
Fig. 78: Installing the Cartridge Group with Compressor and Turbine Casing
130
Installing the Cartridge Group with Compressor and Turbine Casing
130
Installing the Gas Outlet Casing
131
Fig. 80: Fitting Gas Outlet Casing Without Support
131
Table 54: Tightening Torque (51009)
131
Fig. 81: Installing Gas Outlet Casing with Support 1
132
Table 55: Tightening Torque (51009)
132
Fig. 82: Installing Gas Outlet Casing with Support 2
133
Table 56: Tightening Torque (72051)
134
Fig. 83: Installing the Air Inlets
134
Installing Air Inlets
134
Fig. 84: Installing the Uncoupled Filter Silencer
135
Table 57: Tightening Torque (72054)
135
Dismantling and Fitting, Cartridge Concept
136
Removing Air Inlets
136
Fig. 85: Removing the Air Inlets
136
Fig. 86: Removing the Uncoupled Filter Silencer
137
Removing the Compressor Casing
138
Fig. 87: Removing the Compressor Casing
138
Fig. 88: Pressing off Compressor Casing
139
Fig. 89: Remove the Diffuser
139
Fig. 90: Dismantling the Diffuser and the Wall Insert
140
Fig. 91: Removing Insulation Sheets
141
Fig. 92: Removing Cartridge Group 1
141
Table 58: Threaded Rod, Value X
141
Fig. 93: Removing Cartridge Group 2
142
Fig. 94: Removing Cartridge Group 2
143
Fig. 95: S_05180
144
Fig. 96: Measuring Clearance a and B
145
Table 59: Permissible Clearances a and B
145
Fig. 97: Nozzle Ring Compression PD
146
Table 60: Nozzle Ring Compression PD
146
Fig. 98: Installing the Nozzle Ring
147
Fig. 99: Installing the Cartridge Group 1
148
Fig. 100: Installing the Cartridge Group 2
149
Table 61: Threaded Rod, Value X and L
149
Table 62: Tightening Torque (51007)
149
Fig. 101: Fitting the Wall Insert and the Diffuser
150
Table 63: Tightening Torque (79041)
150
Fig. 102: Installing the Compressor Casing
151
Table 64: Tightening Torque (72011)
151
Fig. 103: Measuring Clearances N and R
152
Table 65: Permissible Clearances N and R
152
Fig. 104: Fitting the Insulation
153
Fig. 105: Installing the Air Inlets
154
Table 66: Tightening Torque (72051)
154
Fig. 106: Installing the Uncoupled Filter Silencer
155
Table 67: Tightening Torque (72054)
155
Dismantling and Fitting, Special Tools for Fastening Strips
156
Fig. 107: Customer Tool
156
Fig. 108: Customer Tool
156
Table 68: Customer Tool
156
Table 69: Customer Tool
156
Fig. 110: Removing the Fastening Strips
157
Fig. 109: Positioning the Collection Tub
157
Application, Special Tools
157
Fig. 111: Fitting the Upper Fastening Strips
158
Fig. 112: Fitting the Bottom Fastening Strip
158
Table 70: Tightening Torque (51007)
158
Fig. 113: Fitting the Bottom Fastening Strip
159
Table 71: Tightening Torque (51007) with Spanner Holder
159
Fig. 114: Fitting the Cartridge Group
160
Table 72: Tightening Torque (51007)
160
Fig. 115: Positioning the Fastening Strip
161
Fig. 116: Clamping Piece
162
Fig. 117: Attach Nut
163
Table 73: Tightening Torque (51007) with Spanner Holder
163
Removing and Installing 6-Nozzle Turbine Cleaning Component (Optional)
164
Disassembly
164
Fig. 118: Initial Situation
164
Fig. 119: Disassembly of the Elbows
164
Fig. 120: Disassembly of the Elbows
165
Fig. 121: Pipe Disassembly
165
Table 74: Dismantling Screw
166
Fig. 123: Disassembly of the Cleaning Nozzle
166
Fig. 122: Disassembly of the Connecting Pieces
166
Assembly
167
Fig. 124: Assembly of the Cleaning Nozzle
167
Fig. 125: Assembly of the Connecting Pieces
167
Table 75: Dismantling Screw
167
Fig. 126: Pipe Assembly
168
Fig. 127: Elbow 1 Assembly
168
Fig. 128: Elbow 2 Assembly
169
Table 76: Tightening Torque (51314 / 51316)
169
Fig. 129: Fit the Cleaning Nozzles
170
Fitting the Cleaning Nozzles with Multi-Inlet Turbine Casings
170
Taking out of Operation at Short Notice
171
Possible Emergency Repairs
171
Installing the Replacement Turbocharger
172
Installing the Replacement Cartridge Group
172
Fitting the Cover Plate
173
Fig. 130: Fitting the Cover Plate
173
Table 77: Cover Plate Dimensions [MM]
174
Fig. 131: Cover Plate Drawing
174
Cover Plate Drawing
174
Table 78: Cover Plate Dimensions [MM]
175
Fig. 132: Dimensions for Cover Plate
175
Mothballing the Turbocharger
176
Taking the Engine out of Operation for up to 12 Months
176
Taking the Engine out of Operation for more than 12 Months
177
Material and Disposal
178
REACH and Rohs Compliance Declaration for Products
178
Disposing of Turbocharger Components
179
Required Customer Spare Part Set (97070)
180
Table 79: Customer Spare Part Set 97070
180
Ordering Spare Parts
180
Spare Parts
180
Spare Part - Illustrations
181
Table 80: Spare Parts - Cartridge, Oil Cooled
181
Table 81: Spare Parts - Bearing, Casing Oil Cooled
182
Table 82: Spare Parts - Rotor and Bearing Parts
183
Table 83: Spare Parts - Turbine Casing, 1 Inlet
184
Table 84: Spare Parts - Turbine Casing, 2 Inlets
185
Table 85: Spare Parts - Turbine Casing, 3 Inlets
186
Table 86: Spare Parts - Cleaning Device
187
Table 87: Spare Parts - Gas Outlet Casing, Radial
188
Table 88: Spare Parts - Compressor Casing
189
Table 89: Spare Parts - Filter Silencer
191
Table 90: Spare Parts - Air Suction Branch Axial
191
Table 91: Spare Parts - Air Suction Branch Radial
192
Table 92: Spare Parts - Speed Measurement System
193
Tools
194
Fig. 133: Special Tool
194
Table 93: Customer Tool Set 90000
194
Table 94: Special Tool (90160)
194
Fig. 134: Special Tool
195
Table 95: Special Tool (90160)
195
ABB A150-M57 Operation Manual (200 pages)
Turbocharging
Brand:
ABB
| Category:
Industrial Equipment
| Size: 34.05 MB
Table of Contents
Operation Manual / A150-M - A155-M
3
Table of Contents
3
Operation Manual / A150-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
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Definition of Mandatory Signs
16
Intended Use
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 7: Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Periodic Check of the Pressure Vessels
21
Fig. 10: Attachment Angle
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Lifting of Loads
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
Removing and Installing
31
Turbocharger Weight and Transportation
31
Fig. 11: Suspension of Complete Turbocharger Unit
31
Table 4: Weight of Complete Turbocharger Unit
31
Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Fig. 13: Removing the Turbocharger
33
Fig. 14: Loosening the Clamping Nut
34
Fig. 15: Turbocharger Centre of Gravity
35
Installing the Turbocharger
36
Fig. 16: Inserting the Gasket
36
Fig. 17: Fitting the Turbocharger 1
37
Fig. 18: Fitting the Turbocharger 2
38
Table 5: Fitting the Turbocharger, Value X, L
38
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
39
Table 6: Torque-Controlled Tightening of the Pressure Screws
40
Fig. 20: Tightening Pressure Screws
40
Fig. 21: Connecting the Speed Sensor
41
Fig. 22: Connecting the Compressor Cooling Air Intake
41
Fig. 23: Attaching the Support
41
Commissioning
42
Oil Supply
42
Fig. 24: Oil Orifice
42
Inspection Procedures
44
Commissioning after Taking out of Operation
46
Table 7: Lubricating Oil Pressure at Oil Inlet before Turbocharger
47
Monitoring Operation
47
Oil Pressure, Oil Temperature
47
Table 8: Lubricating Oil Temperature at the Inlet
48
Table 9: Maximum Lubricating Oil Temperature at the Outlet
48
Exhaust Gas Temperature before Turbine
49
Turbocharger Speed
50
Fig. 25: Layout and Overview of Speed Measurement System
50
Fig. 26: Replacing the Speed Sensor
52
Table 10: Tightening Torque (86505)
52
Noise Emission
53
Operation and Service
53
Fig. 27: Noise Insulation, Bellows
54
Service Work
55
Expected Replacement Intervals
58
Table 11: Expected Replacement Intervals
58
Stopping the Engine
60
Periodic Maintenance Work
61
Foreword to Maintenance
61
Table 12: Maintenance Table
61
Cleaning the Compressor During Operation
62
Fig. 28: Carrying out Wet Cleaning of Compressor
64
Table 13: Parameters for Wet Cleaning of Compressor
64
Cleaning the Turbine During Operation
65
Fig. 29: Turbine Cleaning Devices
67
Table 14: Turbine Wet Cleaning, Recommended Operating State
67
Fig. 30: Carrying out Wet Cleaning of Turbine
68
Table 15: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
68
Cleaning Components Mechanically
69
Table 16: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
69
Fig. 31: Cleaning the Filter Silencer
70
Fig. 32: Cleaning the Filter Silencer
72
Fig. 33: Cleaning the Filter Silencer (2)
74
Table 17: Tightening Torque (81272)
74
Table 18: Tightening Torque (81273)
74
Fig. 34: Compressor-End, Non-Rotating Parts
75
Fig. 35: Turbine End, Non-Rotating Parts
76
Fig. 36: Soaking the Turbine End
79
Table 19: Value Table for Soaking
79
Changing the Absorption Element
82
Fig. 37: Disassembling the Absorption Element
82
Table 20: Tightening Torque (81152 / 81154)
83
Fig. 38: Installing the Absorption Element
83
Eliminating Malfunctions
84
Malfunctions When Starting
84
Table 21: Malfunctions When Starting - Delayed Start-Up
84
Table 22: Malfunctions When Starting - Vibrations
84
Table 23: Malfunctions When Starting - Rubbing of Rotating Parts
84
Malfunctions During Operation
85
Table 24: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 25: Malfunctions During Operation - Speed Reduces
85
Table 26: Malfunctions During Operation - Speed Increases
85
Table 27: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 28: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 29: Malfunctions During Operation - Charge Air Pressure too High
87
Table 30: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 31: Malfunction - Turbocharger Surging
88
Table 32: Malfunction - Sporadic Surge Blows
88
Malfunctions When Stopping
89
Table 33: Malfunctions When Stopping - Runout Noises
89
Table 34: Malfunctions When Stopping - Runout Time too Short
89
Table 37: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Table 35: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 36: Malfunction of the Speed Measurement System - Measured Speed too High
90
Speed Measurement System
90
Dismantling and Fitting, General
91
Introduction
91
Material Required
92
Fig. 39: Swivel Lifting Eye (Example)
92
Table 38: Swivel Lifting Eyes
92
Table 40: Dismantling Screw
93
Table 39: Press-Off Screws
93
Fig. 41: Dismantling Screw
93
Fig. 40: Press-Off Screws
93
Disassembly and Assembly Concepts
95
Fig. 42: Removing the Cartridge Group with Compressor and Turbine Casing
95
Fig. 43: Cartridge Concept
96
Fig. 44: Optional Spanner Holder
97
Weights of Individual Parts
98
Fig. 45: Weights of Assemblies
98
Table 41: Weights of Assemblies
98
Table 42: Tightening Torques
99
Fig. 46: Overview of Tightening Torques
99
Table of Tightening Torques
99
Fig. 47: Tightening Torques for Insulation
100
Table 43: Tightening Torques for Insulation
100
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
101
Removing Air Inlets
101
Fig. 48: Removing the Air Inlets
101
Fig. 49: Removing the Uncoupled Filter Silencer
102
Removing the Gas Outlet Casing
103
Fig. 50: Remove Gas Outlet Casing Without Support
103
Fig. 51: Removing Gas Outlet Casing with Support 1
104
Fig. 52: Removing Gas Outlet Casing with Support 1
105
Removing the Gas Outlet Flange
106
Fig. 53: Dismantling the Gas Outlet Flange
107
Table 44: 3 Press-Off Screws
107
Fig. 54: Removing the Gas Outlet Flange
108
Table 45: 6 Press-Off Screws
108
Removing the Cartridge Group with Compressor and Turbine Casing
109
Fig. 55: Turbine Cleaning Nozzle
109
Fig. 56: Remove Insulation
109
Fig. 57: Removing the Cartridge Group with Compressor and Turbine Casing
110
Fig. 58: Setting down the Cartridge Group with the Compressor and Turbine Casing
110
Removing the Compressor Casing
111
Fig. 59: Removing the Compressor Casing
111
Fig. 60: Dismantling the Diffuser and the Wall Insert
112
Removing the Cartridge Group
113
Fig. 61: Removing Cartridge Group 1
113
Table 46: Tightening Torque (90012-01)
113
Fig. 62: Removing Cartridge Group 2
114
Fig. 63: Removing Cartridge Group 3
115
Installing the Cartridge Group on the Service Support
116
Fig. 64: Installing the Cartridge Group on the Service Support
116
Removing the Nozzle Ring
117
Fig. 65: Removing the Nozzle Ring
117
Measuring Clearance a and B
118
Fig. 66: Measuring Clearance a and B
118
Table 47: Permissible Clearances a and B
118
Nozzle Ring Compression PD
119
Fig. 67: Nozzle Ring Compression PD
119
Table 48: Nozzle Ring Compression PD
119
Installing Nozzle Ring
120
Fig. 68: Installing the Nozzle Ring
120
Installing the Cartridge Group
121
Fig. 69: Lifting the Cartridge Group and Rotating It
121
Fig. 70: Turning the Cartridge Group
122
Table 49: Tightening Torque (90012-01)
122
Fig. 71: Installing the Cartridge Group
123
Table 50: Tightening Torque (51007)
123
Installing the Compressor Casing
124
Fig. 72: Fitting the Wall Insert and the Diffuser
124
Table 51: Tightening Torque (79041)
124
Table 52: Tightening Torque (72011)
125
Fig. 73: Installing the Compressor Casing
125
Turning the Cartridge Group with Compressor and Turbine Casing
126
Fig. 74: Turning the Cartridge Group with Compressor and Turbine Casing
126
Installing the Gas Outlet Flange
127
Fig. 75: Installing the Gas Outlet Flange
127
Radial Clearances N and R
128
Fig. 76: Measuring Clearances N and R
128
Table 53: Permissible Clearances N and R
128
Fitting the Insulation
129
Fig. 77: Fitting the Insulation
129
Fig. 79: Installing the Cartridge Group with Compressor and Turbine Casing
130
Fig. 78: Installing the Cartridge Group with Compressor and Turbine Casing
130
Installing the Cartridge Group with Compressor and Turbine Casing
130
Installing the Gas Outlet Casing
131
Fig. 80: Fitting Gas Outlet Casing Without Support
131
Table 54: Tightening Torque (51009)
131
Fig. 81: Installing Gas Outlet Casing with Support 1
132
Table 55: Tightening Torque (51009)
132
Fig. 82: Installing Gas Outlet Casing with Support 2
133
Table 56: Tightening Torque (72051)
134
Fig. 83: Installing the Air Inlets
134
Installing Air Inlets
134
Fig. 84: Installing the Uncoupled Filter Silencer
135
Table 57: Tightening Torque (72054)
135
Dismantling and Fitting, Cartridge Concept
136
Removing Air Inlets
136
Fig. 85: Removing the Air Inlets
136
Fig. 86: Removing the Uncoupled Filter Silencer
137
Removing the Compressor Casing
138
Fig. 87: Removing the Compressor Casing
138
Fig. 88: Pressing off Compressor Casing
139
Fig. 89: Remove the Diffuser
139
Fig. 90: Dismantling the Diffuser and the Wall Insert
140
Fig. 91: Removing Insulation Sheets
141
Fig. 92: Removing Cartridge Group 1
141
Table 58: Threaded Rod, Value X
141
Fig. 93: Removing Cartridge Group 2
142
Fig. 94: Removing Cartridge Group 2
143
Fig. 95: S_05180
144
Fig. 96: Measuring Clearance a and B
145
Table 59: Permissible Clearances a and B
145
Fig. 97: Nozzle Ring Compression PD
146
Table 60: Nozzle Ring Compression PD
146
Fig. 98: Installing the Nozzle Ring
147
Fig. 99: Installing the Cartridge Group 1
148
Fig. 100: Installing the Cartridge Group 2
149
Table 61: Threaded Rod, Value X and L
149
Table 62: Tightening Torque (51007)
149
Fig. 101: Fitting the Wall Insert and the Diffuser
150
Table 63: Tightening Torque (79041)
150
Fig. 102: Installing the Compressor Casing
151
Table 64: Tightening Torque (72011)
151
Fig. 103: Measuring Clearances N and R
152
Table 65: Permissible Clearances N and R
152
Fig. 104: Fitting the Insulation
153
Fig. 105: Installing the Air Inlets
154
Table 66: Tightening Torque (72051)
154
Fig. 106: Installing the Uncoupled Filter Silencer
155
Table 67: Tightening Torque (72054)
155
Dismantling and Fitting, Special Tools for Fastening Strips
156
Fig. 107: Customer Tool
156
Fig. 108: Customer Tool
156
Table 68: Customer Tool
156
Table 69: Customer Tool
156
Fig. 110: Removing the Fastening Strips
157
Fig. 109: Positioning the Collection Tub
157
Application, Special Tools
157
Fig. 111: Fitting the Upper Fastening Strips
158
Fig. 112: Fitting the Bottom Fastening Strip
158
Table 70: Tightening Torque (51007)
158
Fig. 113: Fitting the Bottom Fastening Strip
159
Table 71: Tightening Torque (51007) with Spanner Holder
159
Fig. 114: Fitting the Cartridge Group
160
Table 72: Tightening Torque (51007)
160
Fig. 115: Positioning the Fastening Strip
161
Fig. 116: Clamping Piece
162
Fig. 117: Attach Nut
163
Table 73: Tightening Torque (51007) with Spanner Holder
163
Removing and Installing 6-Nozzle Turbine Cleaning Component (Optional)
164
Disassembly
164
Fig. 118: Initial Situation
164
Fig. 119: Disassembly of the Elbows
164
Fig. 120: Disassembly of the Elbows
165
Fig. 121: Pipe Disassembly
165
Table 74: Dismantling Screw
166
Fig. 123: Disassembly of the Cleaning Nozzle
166
Fig. 122: Disassembly of the Connecting Pieces
166
Assembly
167
Fig. 124: Assembly of the Cleaning Nozzle
167
Fig. 125: Assembly of the Connecting Pieces
167
Table 75: Dismantling Screw
167
Fig. 126: Pipe Assembly
168
Fig. 127: Elbow 1 Assembly
168
Fig. 128: Elbow 2 Assembly
169
Table 76: Tightening Torque (51314 / 51316)
169
Fig. 129: Fit the Cleaning Nozzles
170
Fitting the Cleaning Nozzles with Multi-Inlet Turbine Casings
170
Taking out of Operation at Short Notice
171
Possible Emergency Repairs
171
Installing the Replacement Turbocharger
172
Installing the Replacement Cartridge Group
172
Fitting the Cover Plate
173
Fig. 130: Fitting the Cover Plate
173
Table 77: Cover Plate Dimensions [MM]
174
Fig. 131: Cover Plate Drawing
174
Cover Plate Drawing
174
Table 78: Cover Plate Dimensions [MM]
175
Fig. 132: Dimensions for Cover Plate
175
Mothballing the Turbocharger
176
Taking the Engine out of Operation for up to 12 Months
176
Taking the Engine out of Operation for more than 12 Months
177
Material and Disposal
178
REACH and Rohs Compliance Declaration for Products
178
Disposing of Turbocharger Components
179
Required Customer Spare Part Set (97070)
180
Table 79: Customer Spare Part Set 97070
180
Ordering Spare Parts
180
Spare Parts
180
Spare Part - Illustrations
181
Table 80: Spare Parts - Cartridge, Oil Cooled
181
Table 81: Spare Parts - Bearing, Casing Oil Cooled
182
Table 82: Spare Parts - Rotor and Bearing Parts
183
Table 83: Spare Parts - Turbine Casing, 1 Inlet
184
Table 84: Spare Parts - Turbine Casing, 2 Inlets
185
Table 85: Spare Parts - Turbine Casing, 3 Inlets
186
Table 86: Spare Parts - Cleaning Device
187
Table 87: Spare Parts - Gas Outlet Casing, Radial
188
Table 88: Spare Parts - Compressor Casing
189
Table 89: Spare Parts - Filter Silencer
191
Table 90: Spare Parts - Air Suction Branch Axial
191
Table 91: Spare Parts - Air Suction Branch Radial
192
Table 92: Spare Parts - Speed Measurement System
193
Tools
194
Fig. 133: Special Tool
194
Table 93: Customer Tool Set 90000
194
Table 94: Special Tool (90160)
194
Fig. 134: Special Tool
195
Table 95: Special Tool (90160)
195
ABB A150-M57 Operation Manual (200 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 34.18 MB
Table of Contents
Operation Manual / A150-M - A155-M
3
Table of Contents
3
Operation Manual / A150-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
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Definition of Mandatory Signs
16
Intended Use
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 7: Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Periodic Check of the Pressure Vessels
21
Fig. 10: Attachment Angle
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Lifting of Loads
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
Removing and Installing
31
Turbocharger Weight and Transportation
31
Fig. 11: Suspension of Complete Turbocharger Unit
31
Table 4: Weight of Complete Turbocharger Unit
31
Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Fig. 13: Removing the Turbocharger
33
Fig. 14: Loosening the Clamping Nut
34
Fig. 15: Turbocharger Centre of Gravity
35
Installing the Turbocharger
36
Fig. 16: Inserting the Gasket
36
Fig. 17: Fitting the Turbocharger 1
37
Fig. 18: Fitting the Turbocharger 2
38
Table 5: Fitting the Turbocharger, Value X, L
38
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
39
Table 6: Torque-Controlled Tightening of the Pressure Screws
40
Fig. 20: Tightening Pressure Screws
40
Fig. 21: Connecting the Speed Sensor
41
Fig. 22: Connecting the Compressor Cooling Air Intake
41
Fig. 23: Attaching the Support
41
Commissioning
42
Oil Supply
42
Fig. 24: Oil Orifice
42
Inspection Procedures
44
Commissioning after Taking out of Operation
46
Table 7: Lubricating Oil Pressure at Oil Inlet before Turbocharger
47
Monitoring Operation
47
Oil Pressure, Oil Temperature
47
Table 8: Lubricating Oil Temperature at the Inlet
48
Table 9: Maximum Lubricating Oil Temperature at the Outlet
48
Exhaust Gas Temperature before Turbine
49
Turbocharger Speed
50
Fig. 25: Layout and Overview of Speed Measurement System
50
Fig. 26: Replacing the Speed Sensor
52
Table 10: Tightening Torque (86505)
52
Noise Emission
53
Operation and Service
53
Fig. 27: Noise Insulation, Bellows
54
Service Work
55
Expected Replacement Intervals
58
Table 11: Expected Replacement Intervals
58
Stopping the Engine
60
Periodic Maintenance Work
61
Foreword to Maintenance
61
Table 12: Maintenance Table
61
Cleaning the Compressor During Operation
62
Fig. 28: Carrying out Wet Cleaning of Compressor
64
Table 13: Parameters for Wet Cleaning of Compressor
64
Cleaning the Turbine During Operation
65
Fig. 29: Turbine Cleaning Devices
67
Table 14: Turbine Wet Cleaning, Recommended Operating State
67
Fig. 30: Carrying out Wet Cleaning of Turbine
68
Table 15: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
68
Cleaning Components Mechanically
69
Table 16: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
69
Fig. 31: Cleaning the Filter Silencer
70
Fig. 32: Cleaning the Filter Silencer
72
Fig. 33: Cleaning the Filter Silencer (2)
74
Table 17: Tightening Torque (81272)
74
Table 18: Tightening Torque (81273)
74
Fig. 34: Compressor-End, Non-Rotating Parts
75
Fig. 35: Turbine End, Non-Rotating Parts
76
Fig. 36: Soaking the Turbine End
79
Table 19: Value Table for Soaking
79
Changing the Absorption Element
82
Fig. 37: Disassembling the Absorption Element
82
Table 20: Tightening Torque (81152 / 81154)
83
Fig. 38: Installing the Absorption Element
83
Eliminating Malfunctions
84
Malfunctions When Starting
84
Table 21: Malfunctions When Starting - Delayed Start-Up
84
Table 22: Malfunctions When Starting - Vibrations
84
Table 23: Malfunctions When Starting - Rubbing of Rotating Parts
84
Malfunctions During Operation
85
Table 24: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 25: Malfunctions During Operation - Speed Reduces
85
Table 26: Malfunctions During Operation - Speed Increases
85
Table 27: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 28: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 29: Malfunctions During Operation - Charge Air Pressure too High
87
Table 30: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 31: Malfunction - Turbocharger Pumping
88
Table 32: Malfunction - Sporadic Surge Blows
88
Malfunctions When Stopping
89
Table 33: Malfunctions When Stopping - Runout Noises
89
Table 34: Malfunctions When Stopping - Runout Time too Short
89
Table 37: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Table 35: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 36: Malfunction of the Speed Measurement System - Measured Speed too High
90
Speed Measurement System
90
Dismantling and Fitting, General
91
Introduction
91
Material Required
92
Fig. 39: Swivel Lifting Eyes
92
Table 38: Swivel Lifting Eyes
92
Table 40: Dismantling Screw
93
Table 39: Press-Off Screws
93
Fig. 41: Dismantling Screw
93
Fig. 40: Press-Off Screws
93
Disassembly and Assembly Concepts
95
Fig. 42: Removing the Cartridge Group with Compressor and Turbine Casing
95
Fig. 43: Cartridge Concept
96
Fig. 44: Optional Spanner Holder
97
Weights of Individual Parts
98
Fig. 45: Weights of Assemblies
98
Table 41: Weights of Assemblies
98
Table 42: Tightening Torques
99
Fig. 46: Overview of Tightening Torques
99
Table of Tightening Torques
99
Fig. 47: Tightening Torques for Insulation
100
Table 43: Tightening Torques for Insulation
100
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
101
Removing Air Inlets
101
Fig. 48: Removing the Air Inlets
101
Fig. 49: Removing the Uncoupled Filter Silencer
102
Removing the Gas Outlet Casing
103
Fig. 50: Remove Gas Outlet Casing Without Support
103
Fig. 51: Removing Gas Outlet Casing with Support 1
104
Fig. 52: Removing Gas Outlet Casing with Support 1
105
Removing the Gas Outlet Flange
106
Fig. 53: Dismantling the Gas Outlet Flange
107
Table 44: 3 Press-Off Screws
107
Fig. 54: Removing the Gas Outlet Flange
108
Table 45: 6 Press-Off Screws
108
Removing the Cartridge Group with Compressor and Turbine Casing
109
Fig. 55: Turbine Cleaning Nozzle
109
Fig. 56: Remove Insulation
109
Fig. 57: Removing the Cartridge Group with Compressor and Turbine Casing
110
Fig. 58: Setting down the Cartridge Group with the Compressor and Turbine Casing
110
Removing the Compressor Casing
111
Fig. 59: Removing the Compressor Casing
111
Fig. 60: Dismantling the Diffuser and the Wall Insert
112
Removing the Cartridge Group
113
Fig. 61: Removing Cartridge Group 1
113
Table 46: Tightening Torque (90012-01)
113
Fig. 62: Removing Cartridge Group 2
114
Fig. 63: Removing Cartridge Group 3
115
Installing the Cartridge Group on the Service Support
116
Fig. 64: Installing the Cartridge Group on the Service Support
116
Removing the Nozzle Ring
117
Fig. 65: Removing the Nozzle Ring
117
Measuring Clearance a and B
118
Fig. 66: Measuring Clearance a and B
118
Table 47: Permissible Clearances a and B
118
Nozzle Ring Compression PD
119
Fig. 67: Nozzle Ring Compression PD
119
Table 48: Nozzle Ring Compression PD
119
Installing Nozzle Ring
120
Fig. 68: Installing the Nozzle Ring
120
Installing the Cartridge Group
121
Fig. 69: Lifting the Cartridge Group and Rotating It
121
Fig. 70: Turning the Cartridge Group
122
Table 49: Tightening Torque (90012-01)
122
Fig. 71: Installing the Cartridge Group
123
Table 50: Tightening Torque (51007)
123
Installing the Compressor Casing
124
Fig. 72: Fitting the Wall Insert and the Diffuser
124
Table 51: Tightening Torque (79041)
124
Table 52: Tightening Torque (72011)
125
Fig. 73: Installing the Compressor Casing
125
Turning the Cartridge Group with Compressor and Turbine Casing
126
Fig. 74: Turning the Cartridge Group with Compressor and Turbine Casing
126
Installing the Gas Outlet Flange
127
Fig. 75: Installing the Gas Outlet Flange
127
Radial Clearances N and R
128
Fig. 76: Measuring Clearances N and R
128
Table 53: Permissible Clearances N and R
128
Fitting the Insulation
129
Fig. 77: Fitting the Insulation
129
Fig. 79: Installing the Cartridge Group with Compressor and Turbine Casing
130
Fig. 78: Installing the Cartridge Group with Compressor and Turbine Casing
130
Installing the Cartridge Group with Compressor and Turbine Casing
130
Installing the Gas Outlet Casing
131
Fig. 80: Fitting Gas Outlet Casing Without Support
131
Table 54: Tightening Torque (51009)
131
Fig. 81: Installing Gas Outlet Casing with Support 1
132
Table 55: Tightening Torque (51009)
132
Fig. 82: Installing Gas Outlet Casing with Support 2
133
Table 56: Tightening Torque (72051)
134
Fig. 83: Installing the Air Inlets
134
Installing Air Inlets
134
Fig. 84: Installing the Uncoupled Filter Silencer
135
Table 57: Tightening Torque (72054)
135
Dismantling and Fitting, Cartridge Concept
136
Removing Air Inlets
136
Fig. 85: Removing the Air Inlets
136
Fig. 86: Removing the Uncoupled Filter Silencer
137
Removing the Compressor Casing
138
Fig. 87: Removing the Compressor Casing
138
Fig. 88: Pressing off Compressor Casing
139
Fig. 89: Remove the Diffuser
139
Fig. 90: Dismantling the Diffuser and the Wall Insert
140
Fig. 91: Removing Insulation Sheets
141
Fig. 92: Removing Cartridge Group 1
141
Table 58: Threaded Rod, Value X
141
Fig. 93: Removing Cartridge Group 2
142
Fig. 94: Removing Cartridge Group 2
143
Fig. 95: S_05180
144
Fig. 96: Measuring Clearance a and B
145
Table 59: Permissible Clearances a and B
145
Fig. 97: Nozzle Ring Compression PD
146
Table 60: Nozzle Ring Compression PD
146
Fig. 98: Installing the Nozzle Ring
147
Fig. 99: Installing the Cartridge Group 1
148
Fig. 100: Installing the Cartridge Group 2
149
Table 61: Threaded Rod, Value X and L
149
Table 62: Tightening Torque (51007)
149
Fig. 101: Fitting the Wall Insert and the Diffuser
150
Table 63: Tightening Torque (79041)
150
Fig. 102: Installing the Compressor Casing
151
Table 64: Tightening Torque (72011)
151
Fig. 103: Measuring Clearances N and R
152
Table 65: Permissible Clearances N and R
152
Fig. 104: Fitting the Insulation
153
Fig. 105: Installing the Air Inlets
154
Table 66: Tightening Torque (72051)
154
Fig. 106: Installing the Uncoupled Filter Silencer
155
Table 67: Tightening Torque (72054)
155
Dismantling and Fitting, Special Tools for Fastening Strips
156
Fig. 107: Customer Tool
156
Fig. 108: Customer Tool
156
Table 68: Customer Tool
156
Table 69: Customer Tool
156
Fig. 110: Removing the Fastening Strips
157
Fig. 109: Positioning the Collection Tub
157
Application, Special Tools
157
Fig. 111: Fitting the Upper Fastening Strips
158
Fig. 112: Fitting the Bottom Fastening Strip
158
Table 70: Tightening Torque (51007)
158
Fig. 113: Fitting the Bottom Fastening Strip
159
Table 71: Tightening Torque (51007) with Spanner Holder
159
Fig. 114: Fitting the Cartridge Group
160
Table 72: Tightening Torque (51007)
160
Fig. 115: Positioning the Fastening Strip
161
Fig. 116: Clamping Piece
162
Fig. 117: Attach Nut
163
Table 73: Tightening Torque (51007) with Spanner Holder
163
Removing and Installing 6-Nozzle Turbine Cleaning Component (Optional)
164
Disassembly
164
Fig. 118: Initial Situation
164
Fig. 119: Disassembly of the Elbows
164
Fig. 120: Disassembly of the Elbows
165
Fig. 121: Pipe Disassembly
165
Table 74: Dismantling Screw
166
Fig. 123: Disassembly of the Cleaning Nozzle
166
Fig. 122: Disassembly of the Connecting Pieces
166
Assembly
167
Fig. 124: Assembly of the Cleaning Nozzle
167
Fig. 125: Assembly of the Connecting Pieces
167
Table 75: Dismantling Screw
167
Fig. 126: Pipe Assembly
168
Fig. 127: Elbow 1 Assembly
168
Fig. 128: Elbow 2 Assembly
169
Table 76: Tightening Torque (51314 / 51316)
169
Fig. 129: Fit the Cleaning Nozzles
170
Fitting the Cleaning Nozzles with Multi-Inlet Turbine Casings
170
Taking out of Operation at Short Notice
171
Possible Emergency Repairs
171
Installing the Replacement Turbocharger
172
Installing the Replacement Cartridge Group
172
Fitting the Cover Plate
173
Fig. 130: Fitting the Cover Plate
173
Table 77: Cover Plate Dimensions [MM]
174
Fig. 131: Cover Plate Drawing
174
Cover Plate Drawing
174
Table 78: Cover Plate Dimensions [MM]
175
Fig. 132: Dimensions for Cover Plate
175
Mothballing the Turbocharger
176
Taking the Engine out of Operation for up to 12 Months
176
Taking the Engine out of Operation for more than 12 Months
177
Material and Disposal
178
REACH and Rohs Compliance Declaration for Products
178
Disposing of Turbocharger Components
179
Required Customer Spare Part Set (97070)
180
Table 79: Customer Spare Part Set 97070
180
Ordering Spare Parts
180
Spare Parts
180
Spare Part - Illustrations
181
Table 80: Spare Parts - Cartridge, Oil Cooled
181
Table 81: Spare Parts - Bearing, Casing Oil Cooled
182
Table 82: Spare Parts - Rotor and Bearing Parts
183
Table 83: Spare Parts - Turbine Casing, 1 Inlet
184
Table 84: Spare Parts - Turbine Casing, 2 Inlets
185
Table 85: Spare Parts - Turbine Casing, 3 Inlets
186
Table 86: Spare Parts - Cleaning Device
187
Table 87: Spare Parts - Gas Outlet Casing, Radial
188
Table 88: Spare Parts - Compressor Casing
189
Table 89: Spare Parts - Filter Silencer
191
Table 90: Spare Parts - Air Suction Branch Axial
191
Table 91: Spare Parts - Air Suction Branch Radial
192
Table 92: Spare Parts - Speed Measurement System
193
Tools
194
Fig. 133: Special Tool
194
Table 93: Customer Tool Set 90000
194
Table 94: Special Tool (90160)
194
Fig. 134: Special Tool
195
Table 95: Special Tool (90160)
195
ABB A150-M57 Operation Manual (200 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 34.05 MB
Table of Contents
Operation Manual / A150-M - A155-M
3
Table of Contents
3
Operation Manual / A150-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
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Definition of Mandatory Signs
16
Intended Use
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 7: Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Periodic Check of the Pressure Vessels
21
Fig. 10: Attachment Angle
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Lifting of Loads
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
Removing and Installing
31
Turbocharger Weight and Transportation
31
Fig. 11: Suspension of Complete Turbocharger Unit
31
Table 4: Weight of Complete Turbocharger Unit
31
Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Fig. 13: Removing the Turbocharger
33
Fig. 14: Loosening the Clamping Nut
34
Fig. 15: Turbocharger Centre of Gravity
35
Installing the Turbocharger
36
Fig. 16: Inserting the Gasket
36
Fig. 17: Fitting the Turbocharger 1
37
Fig. 18: Fitting the Turbocharger 2
38
Table 5: Fitting the Turbocharger, Value X, L
38
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
39
Table 6: Torque-Controlled Tightening of the Pressure Screws
40
Fig. 20: Tightening Pressure Screws
40
Fig. 21: Connecting the Speed Sensor
41
Fig. 22: Connecting the Compressor Cooling Air Intake
41
Fig. 23: Attaching the Support
41
Commissioning
42
Oil Supply
42
Fig. 24: Oil Orifice
42
Inspection Procedures
44
Commissioning after Taking out of Operation
46
Table 7: Lubricating Oil Pressure at Oil Inlet before Turbocharger
47
Monitoring Operation
47
Oil Pressure, Oil Temperature
47
Table 8: Lubricating Oil Temperature at the Inlet
48
Table 9: Maximum Lubricating Oil Temperature at the Outlet
48
Exhaust Gas Temperature before Turbine
49
Turbocharger Speed
50
Fig. 25: Layout and Overview of Speed Measurement System
50
Fig. 26: Replacing the Speed Sensor
52
Table 10: Tightening Torque (86505)
52
Noise Emission
53
Operation and Service
53
Fig. 27: Noise Insulation, Bellows
54
Service Work
55
Expected Replacement Intervals
58
Table 11: Expected Replacement Intervals
58
Stopping the Engine
60
Periodic Maintenance Work
61
Foreword to Maintenance
61
Table 12: Maintenance Table
61
Cleaning the Compressor During Operation
62
Fig. 28: Carrying out Wet Cleaning of Compressor
64
Table 13: Parameters for Wet Cleaning of Compressor
64
Cleaning the Turbine During Operation
65
Fig. 29: Turbine Cleaning Devices
67
Table 14: Turbine Wet Cleaning, Recommended Operating State
67
Fig. 30: Carrying out Wet Cleaning of Turbine
68
Table 15: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
68
Cleaning Components Mechanically
69
Table 16: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
69
Fig. 31: Cleaning the Filter Silencer
70
Fig. 32: Cleaning the Filter Silencer
72
Fig. 33: Cleaning the Filter Silencer (2)
74
Table 17: Tightening Torque (81272)
74
Table 18: Tightening Torque (81273)
74
Fig. 34: Compressor-End, Non-Rotating Parts
75
Fig. 35: Turbine End, Non-Rotating Parts
76
Fig. 36: Soaking the Turbine End
79
Table 19: Value Table for Soaking
79
Changing the Absorption Element
82
Fig. 37: Disassembling the Absorption Element
82
Table 20: Tightening Torque (81152 / 81154)
83
Fig. 38: Installing the Absorption Element
83
Eliminating Malfunctions
84
Malfunctions When Starting
84
Table 21: Malfunctions When Starting - Delayed Start-Up
84
Table 22: Malfunctions When Starting - Vibrations
84
Table 23: Malfunctions When Starting - Rubbing of Rotating Parts
84
Malfunctions During Operation
85
Table 24: Malfunctions During Operation - Lubricating Oil Pressure too Low
85
Table 25: Malfunctions During Operation - Speed Reduces
85
Table 26: Malfunctions During Operation - Speed Increases
85
Table 27: Malfunctions During Operation - Exhaust Gas Temperature too High
86
Table 28: Malfunctions During Operation - Charge Air Pressure too Low
86
Table 29: Malfunctions During Operation - Charge Air Pressure too High
87
Table 30: Malfunctions During Operation - Engine Performance Losses
87
Turbocharger Is Surging
88
Table 31: Malfunction - Turbocharger Surging
88
Table 32: Malfunction - Sporadic Surge Blows
88
Malfunctions When Stopping
89
Table 33: Malfunctions When Stopping - Runout Noises
89
Table 34: Malfunctions When Stopping - Runout Time too Short
89
Table 37: Malfunction of the Speed Measurement System - Measured Speed too Low
90
Table 35: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
90
Table 36: Malfunction of the Speed Measurement System - Measured Speed too High
90
Speed Measurement System
90
Dismantling and Fitting, General
91
Introduction
91
Material Required
92
Fig. 39: Swivel Lifting Eye (Example)
92
Table 38: Swivel Lifting Eyes
92
Table 40: Dismantling Screw
93
Table 39: Press-Off Screws
93
Fig. 41: Dismantling Screw
93
Fig. 40: Press-Off Screws
93
Disassembly and Assembly Concepts
95
Fig. 42: Removing the Cartridge Group with Compressor and Turbine Casing
95
Fig. 43: Cartridge Concept
96
Fig. 44: Optional Spanner Holder
97
Weights of Individual Parts
98
Fig. 45: Weights of Assemblies
98
Table 41: Weights of Assemblies
98
Table 42: Tightening Torques
99
Fig. 46: Overview of Tightening Torques
99
Table of Tightening Torques
99
Fig. 47: Tightening Torques for Insulation
100
Table 43: Tightening Torques for Insulation
100
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
101
Removing Air Inlets
101
Fig. 48: Removing the Air Inlets
101
Fig. 49: Removing the Uncoupled Filter Silencer
102
Removing the Gas Outlet Casing
103
Fig. 50: Remove Gas Outlet Casing Without Support
103
Fig. 51: Removing Gas Outlet Casing with Support 1
104
Fig. 52: Removing Gas Outlet Casing with Support 1
105
Removing the Gas Outlet Flange
106
Fig. 53: Dismantling the Gas Outlet Flange
107
Table 44: 3 Press-Off Screws
107
Fig. 54: Removing the Gas Outlet Flange
108
Table 45: 6 Press-Off Screws
108
Removing the Cartridge Group with Compressor and Turbine Casing
109
Fig. 55: Turbine Cleaning Nozzle
109
Fig. 56: Remove Insulation
109
Fig. 57: Removing the Cartridge Group with Compressor and Turbine Casing
110
Fig. 58: Setting down the Cartridge Group with the Compressor and Turbine Casing
110
Removing the Compressor Casing
111
Fig. 59: Removing the Compressor Casing
111
Fig. 60: Dismantling the Diffuser and the Wall Insert
112
Removing the Cartridge Group
113
Fig. 61: Removing Cartridge Group 1
113
Table 46: Tightening Torque (90012-01)
113
Fig. 62: Removing Cartridge Group 2
114
Fig. 63: Removing Cartridge Group 3
115
Installing the Cartridge Group on the Service Support
116
Fig. 64: Installing the Cartridge Group on the Service Support
116
Removing the Nozzle Ring
117
Fig. 65: Removing the Nozzle Ring
117
Measuring Clearance a and B
118
Fig. 66: Measuring Clearance a and B
118
Table 47: Permissible Clearances a and B
118
Nozzle Ring Compression PD
119
Fig. 67: Nozzle Ring Compression PD
119
Table 48: Nozzle Ring Compression PD
119
Installing Nozzle Ring
120
Fig. 68: Installing the Nozzle Ring
120
Installing the Cartridge Group
121
Fig. 69: Lifting the Cartridge Group and Rotating It
121
Fig. 70: Turning the Cartridge Group
122
Table 49: Tightening Torque (90012-01)
122
Fig. 71: Installing the Cartridge Group
123
Table 50: Tightening Torque (51007)
123
Installing the Compressor Casing
124
Fig. 72: Fitting the Wall Insert and the Diffuser
124
Table 51: Tightening Torque (79041)
124
Table 52: Tightening Torque (72011)
125
Fig. 73: Installing the Compressor Casing
125
Turning the Cartridge Group with Compressor and Turbine Casing
126
Fig. 74: Turning the Cartridge Group with Compressor and Turbine Casing
126
Installing the Gas Outlet Flange
127
Fig. 75: Installing the Gas Outlet Flange
127
Radial Clearances N and R
128
Fig. 76: Measuring Clearances N and R
128
Table 53: Permissible Clearances N and R
128
Fitting the Insulation
129
Fig. 77: Fitting the Insulation
129
Fig. 79: Installing the Cartridge Group with Compressor and Turbine Casing
130
Fig. 78: Installing the Cartridge Group with Compressor and Turbine Casing
130
Installing the Cartridge Group with Compressor and Turbine Casing
130
Installing the Gas Outlet Casing
131
Fig. 80: Fitting Gas Outlet Casing Without Support
131
Table 54: Tightening Torque (51009)
131
Fig. 81: Installing Gas Outlet Casing with Support 1
132
Table 55: Tightening Torque (51009)
132
Fig. 82: Installing Gas Outlet Casing with Support 2
133
Table 56: Tightening Torque (72051)
134
Fig. 83: Installing the Air Inlets
134
Installing Air Inlets
134
Fig. 84: Installing the Uncoupled Filter Silencer
135
Table 57: Tightening Torque (72054)
135
Dismantling and Fitting, Cartridge Concept
136
Removing Air Inlets
136
Fig. 85: Removing the Air Inlets
136
Fig. 86: Removing the Uncoupled Filter Silencer
137
Removing the Compressor Casing
138
Fig. 87: Removing the Compressor Casing
138
Fig. 88: Pressing off Compressor Casing
139
Fig. 89: Remove the Diffuser
139
Fig. 90: Dismantling the Diffuser and the Wall Insert
140
Fig. 91: Removing Insulation Sheets
141
Fig. 92: Removing Cartridge Group 1
141
Table 58: Threaded Rod, Value X
141
Fig. 93: Removing Cartridge Group 2
142
Fig. 94: Removing Cartridge Group 2
143
Fig. 95: S_05180
144
Fig. 96: Measuring Clearance a and B
145
Table 59: Permissible Clearances a and B
145
Fig. 97: Nozzle Ring Compression PD
146
Table 60: Nozzle Ring Compression PD
146
Fig. 98: Installing the Nozzle Ring
147
Fig. 99: Installing the Cartridge Group 1
148
Fig. 100: Installing the Cartridge Group 2
149
Table 61: Threaded Rod, Value X and L
149
Table 62: Tightening Torque (51007)
149
Fig. 101: Fitting the Wall Insert and the Diffuser
150
Table 63: Tightening Torque (79041)
150
Fig. 102: Installing the Compressor Casing
151
Table 64: Tightening Torque (72011)
151
Fig. 103: Measuring Clearances N and R
152
Table 65: Permissible Clearances N and R
152
Fig. 104: Fitting the Insulation
153
Fig. 105: Installing the Air Inlets
154
Table 66: Tightening Torque (72051)
154
Fig. 106: Installing the Uncoupled Filter Silencer
155
Table 67: Tightening Torque (72054)
155
Dismantling and Fitting, Special Tools for Fastening Strips
156
Fig. 107: Customer Tool
156
Fig. 108: Customer Tool
156
Table 68: Customer Tool
156
Table 69: Customer Tool
156
Fig. 110: Removing the Fastening Strips
157
Fig. 109: Positioning the Collection Tub
157
Application, Special Tools
157
Fig. 111: Fitting the Upper Fastening Strips
158
Fig. 112: Fitting the Bottom Fastening Strip
158
Table 70: Tightening Torque (51007)
158
Fig. 113: Fitting the Bottom Fastening Strip
159
Table 71: Tightening Torque (51007) with Spanner Holder
159
Fig. 114: Fitting the Cartridge Group
160
Table 72: Tightening Torque (51007)
160
Fig. 115: Positioning the Fastening Strip
161
Fig. 116: Clamping Piece
162
Fig. 117: Attach Nut
163
Table 73: Tightening Torque (51007) with Spanner Holder
163
Removing and Installing 6-Nozzle Turbine Cleaning Component (Optional)
164
Disassembly
164
Fig. 118: Initial Situation
164
Fig. 119: Disassembly of the Elbows
164
Fig. 120: Disassembly of the Elbows
165
Fig. 121: Pipe Disassembly
165
Table 74: Dismantling Screw
166
Fig. 123: Disassembly of the Cleaning Nozzle
166
Fig. 122: Disassembly of the Connecting Pieces
166
Assembly
167
Fig. 124: Assembly of the Cleaning Nozzle
167
Fig. 125: Assembly of the Connecting Pieces
167
Table 75: Dismantling Screw
167
Fig. 126: Pipe Assembly
168
Fig. 127: Elbow 1 Assembly
168
Fig. 128: Elbow 2 Assembly
169
Table 76: Tightening Torque (51314 / 51316)
169
Fig. 129: Fit the Cleaning Nozzles
170
Fitting the Cleaning Nozzles with Multi-Inlet Turbine Casings
170
Taking out of Operation at Short Notice
171
Possible Emergency Repairs
171
Installing the Replacement Turbocharger
172
Installing the Replacement Cartridge Group
172
Fitting the Cover Plate
173
Fig. 130: Fitting the Cover Plate
173
Table 77: Cover Plate Dimensions [MM]
174
Fig. 131: Cover Plate Drawing
174
Cover Plate Drawing
174
Table 78: Cover Plate Dimensions [MM]
175
Fig. 132: Dimensions for Cover Plate
175
Mothballing the Turbocharger
176
Taking the Engine out of Operation for up to 12 Months
176
Taking the Engine out of Operation for more than 12 Months
177
Material and Disposal
178
REACH and Rohs Compliance Declaration for Products
178
Disposing of Turbocharger Components
179
Required Customer Spare Part Set (97070)
180
Table 79: Customer Spare Part Set 97070
180
Ordering Spare Parts
180
Spare Parts
180
Spare Part - Illustrations
181
Table 80: Spare Parts - Cartridge, Oil Cooled
181
Table 81: Spare Parts - Bearing, Casing Oil Cooled
182
Table 82: Spare Parts - Rotor and Bearing Parts
183
Table 83: Spare Parts - Turbine Casing, 1 Inlet
184
Table 84: Spare Parts - Turbine Casing, 2 Inlets
185
Table 85: Spare Parts - Turbine Casing, 3 Inlets
186
Table 86: Spare Parts - Cleaning Device
187
Table 87: Spare Parts - Gas Outlet Casing, Radial
188
Table 88: Spare Parts - Compressor Casing
189
Table 89: Spare Parts - Filter Silencer
191
Table 90: Spare Parts - Air Suction Branch Axial
191
Table 91: Spare Parts - Air Suction Branch Radial
192
Table 92: Spare Parts - Speed Measurement System
193
Tools
194
Fig. 133: Special Tool
194
Table 93: Customer Tool Set 90000
194
Table 94: Special Tool (90160)
194
Fig. 134: Special Tool
195
Table 95: Special Tool (90160)
195
ABB A150-M57 Operation Manual (202 pages)
Turbocharger
Brand:
ABB
| Category:
Battery Charger
| Size: 31.56 MB
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