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ABB A165-L35 manuals available for free PDF download: Operation Manual
ABB A165-L35 Operation Manual (144 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 23.46 MB
Table of Contents
Operation Manual / A100-L
3
Table of Contents
3
Introduction
6
Essential Information
7
Registered Trademarks
7
Layout and Function of the Turbocharger
8
Fig. 1: Layout and Function of the Turbocharger
8
Locations of the Rating Plates
10
Fig. 2: Locations of the Rating Plates
10
Safety
11
Introduction
11
CE Conformity
11
Table 2: Personal Protective Equipment to be Worn Specific to the Respective Task
12
Table 1: Personal Protective Equipment to be Worn at All Times
12
Definition of Safety Instructions
12
Definition of Mandatory Signs
12
Intended Use
13
Deflagration on Gas Engines
14
Warning Plates on the Turbocharger
15
Turbocharger Rating Plate
15
Fig. 3: Warning Plate Locations
15
Fig. 4: Rating Plate
15
Periodic Check of the Pressure Vessels
17
Lifting of Loads
18
Fig. 5: Attachment of Loads on the Crane Hook
18
Fig. 6: Attachment Angle
18
Prerequisites for Operation and Maintenance
19
Hazards During Operation and Maintenance
20
Safe Operation
21
Safe Maintenance
22
Turbocharger Weight
27
Removing the Turbocharger
27
Table 3: Total Weight
27
Removal and Installation
27
Fig. 7: Fitting the Lifting Gear
28
Installing the Turbocharger
29
Fig. 8: Placing the Turbocharger
29
Fig. 9: Compressor-End Foot
30
Fig. 10: Turbine-End Foot
30
Table 4: General Information about Fastening the Turbocharger
30
Table 5: Tightening Torques (Foot Screws)
31
Table 6: Tightening Angle (Foot Screws)
31
Inspection Procedures
32
Commissioning
32
Oil Supply
32
Commissioning after Taking out of Operation
34
Monitoring During Operation
35
Oil Pressure, Oil Temperature
35
Table 7: Lubricating Oil Pressure, Oil Inlet
35
Fig. 11: Oil Temperature at the Outlet
36
Table 8: Lubricating Oil Temperature at the Inlet
36
Table 9: Lubricating Oil Temperature at the Outlet
36
Admissible Air Inlet Temperature
38
Turbocharger Speed
38
Fig. 12: Layout and Overview of the Speed Measurement System
38
Table 10: Tightening Torques (86505)
40
Fig. 13: Replacing the Speed Sensor
40
Low Pressure Measurement at the Filter Silencer
41
Fig. 14: U-Tube Manometer at the Filter Silencer
41
Operation and Service
42
Noise Emission
42
Service Work
43
Fig. 15: Noise Insulation, Bellows
43
Expected Replacement Intervals
47
Table 11: Expected Replacement Intervals for Turbocharger Parts
47
Table 12: Recommended Replacement Intervals for Turbocharger Parts
47
Flexible Turbocharger Cut-Out
48
Stopping the Engine
49
Periodic Maintenance
50
Foreword to Maintenance
50
Cleaning the Filter Silencer
51
Fig. 16: Layout and Overview of Filter Silencer
51
Changing the Filter Strip on the Filter Silencer Casing
53
Fig. 17: Dismantling Filter Ring Circumferential Part
53
Fig. 18: Opening Filter Ring Lock
53
Fig. 19: Attaching New Filter Ring
54
Fig. 20: Fitting New Filter Ring
54
Cleaning the Compressor During Operation
55
Fig. 21: Overview of Wet Cleaning of Compressor
57
Fig. 22: Filter Plug View
58
Table 13: Volume of Water Per Cleaning Process
58
Table 14: Tightening Torques (81125)
58
Cleaning the Turbine During Operation
59
Fig. 23: Dry Cleaning Device
60
Table 15: Amount of Granulate
62
Draining the Gas Outlet Casing
63
Fig. 24: Drain Pipe Diagram
63
Troubleshooting
64
Malfunctions When Starting
64
Table 16: Malfunctions When Starting - Delayed Start-Up
64
Table 17: Malfunctions When Starting - Vibrations
64
Table 18: Malfunctions When Starting - Rubbing of Rotating Parts
64
Malfunctions During Operation
65
Table 19: Malfunctions During Operation - Lubricating Oil Pressure too Low
65
Table 20: Malfunctions During Operation - Drop in Speed
65
Table 21: Malfunctions During Operation - Exhaust Gas Temperature too High
66
Table 22: Malfunctions During Operation - Charge Air Pressure too Low
66
Table 24: Surging of the Turbocharger
67
Table 23: Malfunctions During Operation - Charge Air Pressure too High
67
Surging of the Turbocharger
67
Malfunctions When Stopping
68
Table 25: Malfunctions When Stopping - Runout Noises
68
Table 26: Malfunctions When Stopping - Shortened Runout Time
68
Speed Measurement System
69
Table 27: Malfunctions of the Speed Measurement System
69
Disassembly and Assembly
70
Introduction
70
Material Required
71
Weights of Assemblies
72
Fig. 25: Weights of Assemblies
72
Table 28: Weights of Assemblies [Kg]
72
Table 29: Weight of Wall Insert [Kg]
72
Fig. 26: Dismantling the Filter Silencer Casing
73
Disassembly and Assembly of the Filter Silencer Casing
73
Fig. 27: Fitting the Filter Silencer Casing
74
Fig. 28: Fitting the Filter Silencer Casing
75
Fig. 29: Fitting the Filter Silencer Casing
75
Fig. 30: Fitting the Filter Silencer Casing
76
Fig. 31: Fitting the Filter Silencer Casing
76
Fig. 32: Fitting the Bellows
77
Table 30: Tightening Torques (Filter Silencer Screws)
77
Dismantling the Filter Silencer
78
Fig. 33: Dismantling the Filter Silencer
78
Fig. 34: Dismantling the Filter Silencer
79
Dismantling the Filter Silencer with Noise Package
80
Fig. 35: Dismantling the Filter Silencer with Noise Package
80
Dismantling Wall Insert and Diffuser
81
Fig. 36: Dismantling the Wall Insert
81
Fig. 37: Moving out Wall Insert
82
Fig. 38: Putting down Wall Insert
82
Fig. 39: Putting down Wall Insert
83
Fig. 40: Dismantling the Diffuser
84
Axial Clearance a Prior to Disassembly
85
Fig. 41: Measuring Axial Clearance a
85
Table 31: Axial Clearance a
85
Dismantling the Insulation (≤ A175-L)
86
Fig. 42: Removing the Insulation (A175-L and Smaller)
86
Dismantling the Gas Inlet Casing (≤ A175-L)
87
Fig. 43: Dismantling the Gas Inlet Casing (A175-L and Smaller)
87
Table 32: Maximum Admissible Loosening Torque (51087)
87
Dismantling the Nozzle Ring (≤ A175-L)
88
Fig. 44: Dismantling the Nozzle Ring (A175-L and Smaller)
88
Dismantling the Gas Inlet Casing (≥ A180-L)
89
Fig. 45: Dismantling the Gas Inlet Casing (180-L and Larger)
89
Table 33: Maximum Admissible Loosening Torque (51087)
89
Dismantling the Nozzle Ring (≥ A180-L)
90
Fig. 46: Fitting the Nozzle Ring Holder
90
Fig. 47: Dismantling the Nozzle Ring
91
Fig. 48: Put down the Nozzle Ring
91
Fitting the Nozzle Ring (≤ A175-L)
92
Fig. 49: Fitting the Nozzle Ring (A175-L and Smaller)
92
Table 34: Tightening Torque (56014)
92
Table 35: Tightening Torque (51087)
93
Fig. 50: Fitting the Gas Outlet Casing (A175-L and Smaller)
93
Fitting the Gas Inlet Casing (≤ A175-L)
93
Fitting the Insulation (≤ A175-L)
94
Fig. 51: Fitting the Insulation (A175-L and Smaller)
94
Fitting the Nozzle Ring (≥ A180-L)
95
Fig. 52: Looping Around the Nozzle Ring (A180-L and Larger)
95
Fig. 53: Fitting the Nozzle Ring (A180-L and Larger)
96
Table 36: Tightening Torque (56014)
96
Fitting the Gas Inlet Casing (≥ A180-L)
97
Fig. 54: Fitting the Gas Inlet Casing (A180-L and Larger)
97
Table 37: Tightening Torque (51087)
97
Axial Clearance a after Assembly
98
Fig. 55: Measuring Axial Clearance a
98
Table 38: Axial Clearance a
98
Table 39: Tightening Torque (77015)
99
Fig. 56: Fitting the Diffuser
99
Fitting the Diffuser
99
Fitting Wall Insert
100
Fig. 57: Positioning Wall Insert
100
Fig. 58: Fitting Wall Insert
101
Table 40: Tightening Torque (72011)
101
Fitting the Filter Silencer
102
Fig. 59: Fitting the Filter Silencer
103
Table 41: Tightening Torque (72004)
103
Fig. 60: Fitting the Filter Silencer
104
Table 42: Tightening Torque (72004)
104
Fitting the Filter Silencer with Noise Package
105
Fig. 61: Fitting the Filter Silencer with Noise Package
105
Table 43: Tightening Torque (51087)
105
Table of Tightening Torques
107
Fig. 63: Tightening Torques of Speed Sensor
107
Fig. 62: Overview of Tightening Torques
108
Table 44: Overview of Tightening Torques
108
Table 45: Tightening Torque, Insulation
108
Taking a Turbocharger out of Operation
109
Possible Emergency Repairs
109
Taking Defective Turbochargers out of Operation
110
Table 46: Bypass Procedure
110
Fig. 64: Locking the Rotor
111
Table 47: Tightening Torque
111
Fig. 65: Ensuring Clamping of the Cover Ring
113
Table 48: Required Washers (01)
113
Table 49: Tightening Torque (57005)
113
Fig. 66: Position of Cover Plates
114
Mothballing the Turbocharger
115
Taking the Engine out of Operation for up to 12 Months
115
Taking the Engine out of Operation for more than 12 Months
116
Material and Disposal
117
REACH and Rohs Compliance Declaration for Products
117
Disposing of Turbocharger Components
118
Spare Parts
119
Ordering Spare Parts
119
Table 50: Customer Spare Part Set (97070)
119
Table 51: Customer Spare Part Set (97071)
120
Spare Part - Illustrations
121
Table 52: Spare Parts - Bearing Casing Common Parts
122
Table 53: Spare Parts - Bearing Casing Oil Tank
124
Table 54: Spare Parts - Cartridge
125
Table 55: Spare Parts - Compressor Casing
127
Table 56: Spare Parts - Filter Silencer
128
Table 57: Spare Parts - Gas Inlet Casing Axial
129
Table 58: Spare Parts - Gas Inlet Casing Radial
130
Table 59: Spare Parts - Gas Outlet Casing
131
Table 60: Spare Parts - Rotor and Bearing Parts
133
Table 61: Spare Parts - Sealing Air Supply for Flexible Cut-Out
134
Table 62: Spare Parts - Speed Measurement
135
Table 63: Spare Parts - U-Tube Manometer
136
Table 64: Spare Parts - Turbine Dry Cleaning Radial
138
Tools
139
Table 65: Customer Tool Set 90000
139
Advertisement
ABB A165-L35 Operation Manual (144 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 23.46 MB
Table of Contents
Operation Manual / A100-L
3
Table of Contents
3
Introduction
6
Essential Information
7
Registered Trademarks
7
Layout and Function of the Turbocharger
8
Fig. 1: Layout and Function of the Turbocharger
8
Locations of the Rating Plates
10
Fig. 2: Locations of the Rating Plates
10
Safety
11
Introduction
11
CE Conformity
11
Table 2: Personal Protective Equipment to be Worn Specific to the Respective Task
12
Table 1: Personal Protective Equipment to be Worn at All Times
12
Definition of Safety Instructions
12
Definition of Mandatory Signs
12
Intended Use
13
Deflagration on Gas Engines
14
Warning Plates on the Turbocharger
15
Turbocharger Rating Plate
15
Fig. 3: Warning Plate Locations
15
Fig. 4: Rating Plate
15
Periodic Check of the Pressure Vessels
17
Lifting of Loads
18
Fig. 5: Attachment of Loads on the Crane Hook
18
Fig. 6: Attachment Angle
18
Prerequisites for Operation and Maintenance
19
Hazards During Operation and Maintenance
20
Safe Operation
21
Safe Maintenance
22
Turbocharger Weight
27
Removing the Turbocharger
27
Table 3: Total Weight
27
Removal and Installation
27
Fig. 7: Fitting the Lifting Gear
28
Installing the Turbocharger
29
Fig. 8: Placing the Turbocharger
29
Fig. 9: Compressor-End Foot
30
Fig. 10: Turbine-End Foot
30
Table 4: General Information about Fastening the Turbocharger
30
Table 5: Tightening Torques (Foot Screws)
31
Table 6: Tightening Angle (Foot Screws)
31
Inspection Procedures
32
Commissioning
32
Oil Supply
32
Commissioning after Taking out of Operation
34
Monitoring During Operation
35
Oil Pressure, Oil Temperature
35
Table 7: Lubricating Oil Pressure, Oil Inlet
35
Fig. 11: Oil Temperature at the Outlet
36
Table 8: Lubricating Oil Temperature at the Inlet
36
Table 9: Lubricating Oil Temperature at the Outlet
36
Admissible Air Inlet Temperature
38
Turbocharger Speed
38
Fig. 12: Layout and Overview of the Speed Measurement System
38
Table 10: Tightening Torques (86505)
40
Fig. 13: Replacing the Speed Sensor
40
Low Pressure Measurement at the Filter Silencer
41
Fig. 14: U-Tube Manometer at the Filter Silencer
41
Operation and Service
42
Noise Emission
42
Service Work
43
Fig. 15: Noise Insulation, Bellows
43
Expected Replacement Intervals
47
Table 11: Expected Replacement Intervals for Turbocharger Parts
47
Table 12: Recommended Replacement Intervals for Turbocharger Parts
47
Flexible Turbocharger Cut-Out
48
Stopping the Engine
49
Periodic Maintenance
50
Foreword to Maintenance
50
Cleaning the Filter Silencer
51
Fig. 16: Layout and Overview of Filter Silencer
51
Changing the Filter Strip on the Filter Silencer Casing
53
Fig. 17: Dismantling Filter Ring Circumferential Part
53
Fig. 18: Opening Filter Ring Lock
53
Fig. 19: Attaching New Filter Ring
54
Fig. 20: Fitting New Filter Ring
54
Cleaning the Compressor During Operation
55
Fig. 21: Overview of Wet Cleaning of Compressor
57
Fig. 22: Filter Plug View
58
Table 13: Volume of Water Per Cleaning Process
58
Table 14: Tightening Torques (81125)
58
Cleaning the Turbine During Operation
59
Fig. 23: Dry Cleaning Device
60
Table 15: Amount of Granulate
62
Draining the Gas Outlet Casing
63
Fig. 24: Drain Pipe Diagram
63
Troubleshooting
64
Malfunctions When Starting
64
Table 16: Malfunctions When Starting - Delayed Start-Up
64
Table 17: Malfunctions When Starting - Vibrations
64
Table 18: Malfunctions When Starting - Rubbing of Rotating Parts
64
Malfunctions During Operation
65
Table 19: Malfunctions During Operation - Lubricating Oil Pressure too Low
65
Table 20: Malfunctions During Operation - Drop in Speed
65
Table 21: Malfunctions During Operation - Exhaust Gas Temperature too High
66
Table 22: Malfunctions During Operation - Charge Air Pressure too Low
66
Table 24: Surging of the Turbocharger
67
Table 23: Malfunctions During Operation - Charge Air Pressure too High
67
Surging of the Turbocharger
67
Malfunctions When Stopping
68
Table 25: Malfunctions When Stopping - Runout Noises
68
Table 26: Malfunctions When Stopping - Shortened Runout Time
68
Speed Measurement System
69
Table 27: Malfunctions of the Speed Measurement System
69
Disassembly and Assembly
70
Introduction
70
Material Required
71
Weights of Assemblies
72
Fig. 25: Weights of Assemblies
72
Table 28: Weights of Assemblies [Kg]
72
Table 29: Weight of Wall Insert [Kg]
72
Fig. 26: Dismantling the Filter Silencer Casing
73
Disassembly and Assembly of the Filter Silencer Casing
73
Fig. 27: Fitting the Filter Silencer Casing
74
Fig. 28: Fitting the Filter Silencer Casing
75
Fig. 29: Fitting the Filter Silencer Casing
75
Fig. 30: Fitting the Filter Silencer Casing
76
Fig. 31: Fitting the Filter Silencer Casing
76
Fig. 32: Fitting the Bellows
77
Table 30: Tightening Torques (Filter Silencer Screws)
77
Dismantling the Filter Silencer
78
Fig. 33: Dismantling the Filter Silencer
78
Fig. 34: Dismantling the Filter Silencer
79
Dismantling the Filter Silencer with Noise Package
80
Fig. 35: Dismantling the Filter Silencer with Noise Package
80
Dismantling Wall Insert and Diffuser
81
Fig. 36: Dismantling the Wall Insert
81
Fig. 37: Moving out Wall Insert
82
Fig. 38: Putting down Wall Insert
82
Fig. 39: Putting down Wall Insert
83
Fig. 40: Dismantling the Diffuser
84
Axial Clearance a Prior to Disassembly
85
Fig. 41: Measuring Axial Clearance a
85
Table 31: Axial Clearance a
85
Dismantling the Insulation (≤ A175-L)
86
Fig. 42: Removing the Insulation (A175-L and Smaller)
86
Dismantling the Gas Inlet Casing (≤ A175-L)
87
Fig. 43: Dismantling the Gas Inlet Casing (A175-L and Smaller)
87
Table 32: Maximum Admissible Loosening Torque (51087)
87
Dismantling the Nozzle Ring (≤ A175-L)
88
Fig. 44: Dismantling the Nozzle Ring (A175-L and Smaller)
88
Dismantling the Gas Inlet Casing (≥ A180-L)
89
Fig. 45: Dismantling the Gas Inlet Casing (180-L and Larger)
89
Table 33: Maximum Admissible Loosening Torque (51087)
89
Dismantling the Nozzle Ring (≥ A180-L)
90
Fig. 46: Fitting the Nozzle Ring Holder
90
Fig. 47: Dismantling the Nozzle Ring
91
Fig. 48: Put down the Nozzle Ring
91
Fitting the Nozzle Ring (≤ A175-L)
92
Fig. 49: Fitting the Nozzle Ring (A175-L and Smaller)
92
Table 34: Tightening Torque (56014)
92
Table 35: Tightening Torque (51087)
93
Fig. 50: Fitting the Gas Outlet Casing (A175-L and Smaller)
93
Fitting the Gas Inlet Casing (≤ A175-L)
93
Fitting the Insulation (≤ A175-L)
94
Fig. 51: Fitting the Insulation (A175-L and Smaller)
94
Fitting the Nozzle Ring (≥ A180-L)
95
Fig. 52: Looping Around the Nozzle Ring (A180-L and Larger)
95
Fig. 53: Fitting the Nozzle Ring (A180-L and Larger)
96
Table 36: Tightening Torque (56014)
96
Fitting the Gas Inlet Casing (≥ A180-L)
97
Fig. 54: Fitting the Gas Inlet Casing (A180-L and Larger)
97
Table 37: Tightening Torque (51087)
97
Axial Clearance a after Assembly
98
Fig. 55: Measuring Axial Clearance a
98
Table 38: Axial Clearance a
98
Table 39: Tightening Torque (77015)
99
Fig. 56: Fitting the Diffuser
99
Fitting the Diffuser
99
Fitting Wall Insert
100
Fig. 57: Positioning Wall Insert
100
Fig. 58: Fitting Wall Insert
101
Table 40: Tightening Torque (72011)
101
Fitting the Filter Silencer
102
Fig. 59: Fitting the Filter Silencer
103
Table 41: Tightening Torque (72004)
103
Fig. 60: Fitting the Filter Silencer
104
Table 42: Tightening Torque (72004)
104
Fitting the Filter Silencer with Noise Package
105
Fig. 61: Fitting the Filter Silencer with Noise Package
105
Table 43: Tightening Torque (51087)
105
Table of Tightening Torques
107
Fig. 63: Tightening Torques of Speed Sensor
107
Fig. 62: Overview of Tightening Torques
108
Table 44: Overview of Tightening Torques
108
Table 45: Tightening Torque, Insulation
108
Taking a Turbocharger out of Operation
109
Possible Emergency Repairs
109
Taking Defective Turbochargers out of Operation
110
Table 46: Bypass Procedure
110
Fig. 64: Locking the Rotor
111
Table 47: Tightening Torque
111
Fig. 65: Ensuring Clamping of the Cover Ring
113
Table 48: Required Washers (01)
113
Table 49: Tightening Torque (57005)
113
Fig. 66: Position of Cover Plates
114
Mothballing the Turbocharger
115
Taking the Engine out of Operation for up to 12 Months
115
Taking the Engine out of Operation for more than 12 Months
116
Material and Disposal
117
REACH and Rohs Compliance Declaration for Products
117
Disposing of Turbocharger Components
118
Spare Parts
119
Ordering Spare Parts
119
Table 50: Customer Spare Part Set (97070)
119
Table 51: Customer Spare Part Set (97071)
120
Spare Part - Illustrations
121
Table 52: Spare Parts - Bearing Casing Common Parts
122
Table 53: Spare Parts - Bearing Casing Oil Tank
124
Table 54: Spare Parts - Cartridge
125
Table 55: Spare Parts - Compressor Casing
127
Table 56: Spare Parts - Filter Silencer
128
Table 57: Spare Parts - Gas Inlet Casing Axial
129
Table 58: Spare Parts - Gas Inlet Casing Radial
130
Table 59: Spare Parts - Gas Outlet Casing
131
Table 60: Spare Parts - Rotor and Bearing Parts
133
Table 61: Spare Parts - Sealing Air Supply for Flexible Cut-Out
134
Table 62: Spare Parts - Speed Measurement
135
Table 63: Spare Parts - U-Tube Manometer
136
Table 64: Spare Parts - Turbine Dry Cleaning Radial
138
Tools
139
Table 65: Customer Tool Set 90000
139
ABB A165-L35 Operation Manual (144 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 23.46 MB
Table of Contents
Operation Manual / A100-L
3
Table of Contents
3
Introduction
6
Essential Information
7
Registered Trademarks
7
Layout and Function of the Turbocharger
8
Fig. 1: Layout and Function of the Turbocharger
8
Locations of the Rating Plates
10
Fig. 2: Locations of the Rating Plates
10
Safety
11
Introduction
11
CE Conformity
11
Table 2: Personal Protective Equipment to be Worn Specific to the Respective Task
12
Table 1: Personal Protective Equipment to be Worn at All Times
12
Definition of Safety Instructions
12
Definition of Mandatory Signs
12
Intended Use
13
Deflagration on Gas Engines
14
Warning Plates on the Turbocharger
15
Turbocharger Rating Plate
15
Fig. 3: Warning Plate Locations
15
Fig. 4: Rating Plate
15
Periodic Check of the Pressure Vessels
17
Lifting of Loads
18
Fig. 5: Attachment of Loads on the Crane Hook
18
Fig. 6: Attachment Angle
18
Prerequisites for Operation and Maintenance
19
Hazards During Operation and Maintenance
20
Safe Operation
21
Safe Maintenance
22
Turbocharger Weight
27
Removing the Turbocharger
27
Table 3: Total Weight
27
Removal and Installation
27
Fig. 7: Fitting the Lifting Gear
28
Installing the Turbocharger
29
Fig. 8: Placing the Turbocharger
29
Fig. 9: Compressor-End Foot
30
Fig. 10: Turbine-End Foot
30
Table 4: General Information about Fastening the Turbocharger
30
Table 5: Tightening Torques (Foot Screws)
31
Table 6: Tightening Angle (Foot Screws)
31
Inspection Procedures
32
Commissioning
32
Oil Supply
32
Commissioning after Taking out of Operation
34
Monitoring During Operation
35
Oil Pressure, Oil Temperature
35
Table 7: Lubricating Oil Pressure, Oil Inlet
35
Fig. 11: Oil Temperature at the Outlet
36
Table 8: Lubricating Oil Temperature at the Inlet
36
Table 9: Lubricating Oil Temperature at the Outlet
36
Admissible Air Inlet Temperature
38
Turbocharger Speed
38
Fig. 12: Layout and Overview of the Speed Measurement System
38
Table 10: Tightening Torques (86505)
40
Fig. 13: Replacing the Speed Sensor
40
Low Pressure Measurement at the Filter Silencer
41
Fig. 14: U-Tube Manometer at the Filter Silencer
41
Operation and Service
42
Noise Emission
42
Service Work
43
Fig. 15: Noise Insulation, Bellows
43
Expected Replacement Intervals
47
Table 11: Expected Replacement Intervals for Turbocharger Parts
47
Table 12: Recommended Replacement Intervals for Turbocharger Parts
47
Flexible Turbocharger Cut-Out
48
Stopping the Engine
49
Periodic Maintenance
50
Foreword to Maintenance
50
Cleaning the Filter Silencer
51
Fig. 16: Layout and Overview of Filter Silencer
51
Changing the Filter Strip on the Filter Silencer Casing
53
Fig. 17: Dismantling Filter Ring Circumferential Part
53
Fig. 18: Opening Filter Ring Lock
53
Fig. 19: Attaching New Filter Ring
54
Fig. 20: Fitting New Filter Ring
54
Cleaning the Compressor During Operation
55
Fig. 21: Overview of Wet Cleaning of Compressor
57
Fig. 22: Filter Plug View
58
Table 13: Volume of Water Per Cleaning Process
58
Table 14: Tightening Torques (81125)
58
Cleaning the Turbine During Operation
59
Fig. 23: Dry Cleaning Device
60
Table 15: Amount of Granulate
62
Draining the Gas Outlet Casing
63
Fig. 24: Drain Pipe Diagram
63
Troubleshooting
64
Malfunctions When Starting
64
Table 16: Malfunctions When Starting - Delayed Start-Up
64
Table 17: Malfunctions When Starting - Vibrations
64
Table 18: Malfunctions When Starting - Rubbing of Rotating Parts
64
Malfunctions During Operation
65
Table 19: Malfunctions During Operation - Lubricating Oil Pressure too Low
65
Table 20: Malfunctions During Operation - Drop in Speed
65
Table 21: Malfunctions During Operation - Exhaust Gas Temperature too High
66
Table 22: Malfunctions During Operation - Charge Air Pressure too Low
66
Table 24: Surging of the Turbocharger
67
Table 23: Malfunctions During Operation - Charge Air Pressure too High
67
Surging of the Turbocharger
67
Malfunctions When Stopping
68
Table 25: Malfunctions When Stopping - Runout Noises
68
Table 26: Malfunctions When Stopping - Shortened Runout Time
68
Speed Measurement System
69
Table 27: Malfunctions of the Speed Measurement System
69
Disassembly and Assembly
70
Introduction
70
Material Required
71
Weights of Assemblies
72
Fig. 25: Weights of Assemblies
72
Table 28: Weights of Assemblies [Kg]
72
Table 29: Weight of Wall Insert [Kg]
72
Fig. 26: Dismantling the Filter Silencer Casing
73
Disassembly and Assembly of the Filter Silencer Casing
73
Fig. 27: Fitting the Filter Silencer Casing
74
Fig. 28: Fitting the Filter Silencer Casing
75
Fig. 29: Fitting the Filter Silencer Casing
75
Fig. 30: Fitting the Filter Silencer Casing
76
Fig. 31: Fitting the Filter Silencer Casing
76
Fig. 32: Fitting the Bellows
77
Table 30: Tightening Torques (Filter Silencer Screws)
77
Dismantling the Filter Silencer
78
Fig. 33: Dismantling the Filter Silencer
78
Fig. 34: Dismantling the Filter Silencer
79
Dismantling the Filter Silencer with Noise Package
80
Fig. 35: Dismantling the Filter Silencer with Noise Package
80
Dismantling Wall Insert and Diffuser
81
Fig. 36: Dismantling the Wall Insert
81
Fig. 37: Moving out Wall Insert
82
Fig. 38: Putting down Wall Insert
82
Fig. 39: Putting down Wall Insert
83
Fig. 40: Dismantling the Diffuser
84
Axial Clearance a Prior to Disassembly
85
Fig. 41: Measuring Axial Clearance a
85
Table 31: Axial Clearance a
85
Dismantling the Insulation (≤ A175-L)
86
Fig. 42: Removing the Insulation (A175-L and Smaller)
86
Dismantling the Gas Inlet Casing (≤ A175-L)
87
Fig. 43: Dismantling the Gas Inlet Casing (A175-L and Smaller)
87
Table 32: Maximum Admissible Loosening Torque (51087)
87
Dismantling the Nozzle Ring (≤ A175-L)
88
Fig. 44: Dismantling the Nozzle Ring (A175-L and Smaller)
88
Dismantling the Gas Inlet Casing (≥ A180-L)
89
Fig. 45: Dismantling the Gas Inlet Casing (180-L and Larger)
89
Table 33: Maximum Admissible Loosening Torque (51087)
89
Dismantling the Nozzle Ring (≥ A180-L)
90
Fig. 46: Fitting the Nozzle Ring Holder
90
Fig. 47: Dismantling the Nozzle Ring
91
Fig. 48: Put down the Nozzle Ring
91
Fitting the Nozzle Ring (≤ A175-L)
92
Fig. 49: Fitting the Nozzle Ring (A175-L and Smaller)
92
Table 34: Tightening Torque (56014)
92
Table 35: Tightening Torque (51087)
93
Fig. 50: Fitting the Gas Outlet Casing (A175-L and Smaller)
93
Fitting the Gas Inlet Casing (≤ A175-L)
93
Fitting the Insulation (≤ A175-L)
94
Fig. 51: Fitting the Insulation (A175-L and Smaller)
94
Fitting the Nozzle Ring (≥ A180-L)
95
Fig. 52: Looping Around the Nozzle Ring (A180-L and Larger)
95
Fig. 53: Fitting the Nozzle Ring (A180-L and Larger)
96
Table 36: Tightening Torque (56014)
96
Fitting the Gas Inlet Casing (≥ A180-L)
97
Fig. 54: Fitting the Gas Inlet Casing (A180-L and Larger)
97
Table 37: Tightening Torque (51087)
97
Axial Clearance a after Assembly
98
Fig. 55: Measuring Axial Clearance a
98
Table 38: Axial Clearance a
98
Table 39: Tightening Torque (77015)
99
Fig. 56: Fitting the Diffuser
99
Fitting the Diffuser
99
Fitting Wall Insert
100
Fig. 57: Positioning Wall Insert
100
Fig. 58: Fitting Wall Insert
101
Table 40: Tightening Torque (72011)
101
Fitting the Filter Silencer
102
Fig. 59: Fitting the Filter Silencer
103
Table 41: Tightening Torque (72004)
103
Fig. 60: Fitting the Filter Silencer
104
Table 42: Tightening Torque (72004)
104
Fitting the Filter Silencer with Noise Package
105
Fig. 61: Fitting the Filter Silencer with Noise Package
105
Table 43: Tightening Torque (51087)
105
Table of Tightening Torques
107
Fig. 63: Tightening Torques of Speed Sensor
107
Fig. 62: Overview of Tightening Torques
108
Table 44: Overview of Tightening Torques
108
Table 45: Tightening Torque, Insulation
108
Taking a Turbocharger out of Operation
109
Possible Emergency Repairs
109
Taking Defective Turbochargers out of Operation
110
Table 46: Bypass Procedure
110
Fig. 64: Locking the Rotor
111
Table 47: Tightening Torque
111
Fig. 65: Ensuring Clamping of the Cover Ring
113
Table 48: Required Washers (01)
113
Table 49: Tightening Torque (57005)
113
Fig. 66: Position of Cover Plates
114
Mothballing the Turbocharger
115
Taking the Engine out of Operation for up to 12 Months
115
Taking the Engine out of Operation for more than 12 Months
116
Material and Disposal
117
REACH and Rohs Compliance Declaration for Products
117
Disposing of Turbocharger Components
118
Spare Parts
119
Ordering Spare Parts
119
Table 50: Customer Spare Part Set (97070)
119
Table 51: Customer Spare Part Set (97071)
120
Spare Part - Illustrations
121
Table 52: Spare Parts - Bearing Casing Common Parts
122
Table 53: Spare Parts - Bearing Casing Oil Tank
124
Table 54: Spare Parts - Cartridge
125
Table 55: Spare Parts - Compressor Casing
127
Table 56: Spare Parts - Filter Silencer
128
Table 57: Spare Parts - Gas Inlet Casing Axial
129
Table 58: Spare Parts - Gas Inlet Casing Radial
130
Table 59: Spare Parts - Gas Outlet Casing
131
Table 60: Spare Parts - Rotor and Bearing Parts
133
Table 61: Spare Parts - Sealing Air Supply for Flexible Cut-Out
134
Table 62: Spare Parts - Speed Measurement
135
Table 63: Spare Parts - U-Tube Manometer
136
Table 64: Spare Parts - Turbine Dry Cleaning Radial
138
Tools
139
Table 65: Customer Tool Set 90000
139
Advertisement
ABB A165-L35 Operation Manual (144 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 23.46 MB
Table of Contents
Operation Manual / A100-L
3
Table of Contents
3
Introduction
6
Essential Information
7
Registered Trademarks
7
Layout and Function of the Turbocharger
8
Fig. 1: Layout and Function of the Turbocharger
8
Locations of the Rating Plates
10
Fig. 2: Locations of the Rating Plates
10
Safety
11
Introduction
11
CE Conformity
11
Table 2: Personal Protective Equipment to be Worn Specific to the Respective Task
12
Table 1: Personal Protective Equipment to be Worn at All Times
12
Definition of Safety Instructions
12
Definition of Mandatory Signs
12
Intended Use
13
Deflagration on Gas Engines
14
Warning Plates on the Turbocharger
15
Turbocharger Rating Plate
15
Fig. 3: Warning Plate Locations
15
Fig. 4: Rating Plate
15
Periodic Check of the Pressure Vessels
17
Lifting of Loads
18
Fig. 5: Attachment of Loads on the Crane Hook
18
Fig. 6: Attachment Angle
18
Prerequisites for Operation and Maintenance
19
Hazards During Operation and Maintenance
20
Safe Operation
21
Safe Maintenance
22
Turbocharger Weight
27
Removing the Turbocharger
27
Table 3: Total Weight
27
Removal and Installation
27
Fig. 7: Fitting the Lifting Gear
28
Installing the Turbocharger
29
Fig. 8: Placing the Turbocharger
29
Fig. 9: Compressor-End Foot
30
Fig. 10: Turbine-End Foot
30
Table 4: General Information about Fastening the Turbocharger
30
Table 5: Tightening Torques (Foot Screws)
31
Table 6: Tightening Angle (Foot Screws)
31
Inspection Procedures
32
Commissioning
32
Oil Supply
32
Commissioning after Taking out of Operation
34
Monitoring During Operation
35
Oil Pressure, Oil Temperature
35
Table 7: Lubricating Oil Pressure, Oil Inlet
35
Fig. 11: Oil Temperature at the Outlet
36
Table 8: Lubricating Oil Temperature at the Inlet
36
Table 9: Lubricating Oil Temperature at the Outlet
36
Admissible Air Inlet Temperature
38
Turbocharger Speed
38
Fig. 12: Layout and Overview of the Speed Measurement System
38
Table 10: Tightening Torques (86505)
40
Fig. 13: Replacing the Speed Sensor
40
Low Pressure Measurement at the Filter Silencer
41
Fig. 14: U-Tube Manometer at the Filter Silencer
41
Operation and Service
42
Noise Emission
42
Service Work
43
Fig. 15: Noise Insulation, Bellows
43
Expected Replacement Intervals
47
Table 11: Expected Replacement Intervals for Turbocharger Parts
47
Table 12: Recommended Replacement Intervals for Turbocharger Parts
47
Flexible Turbocharger Cut-Out
48
Stopping the Engine
49
Periodic Maintenance
50
Foreword to Maintenance
50
Cleaning the Filter Silencer
51
Fig. 16: Layout and Overview of Filter Silencer
51
Changing the Filter Strip on the Filter Silencer Casing
53
Fig. 17: Dismantling Filter Ring Circumferential Part
53
Fig. 18: Opening Filter Ring Lock
53
Fig. 19: Attaching New Filter Ring
54
Fig. 20: Fitting New Filter Ring
54
Cleaning the Compressor During Operation
55
Fig. 21: Overview of Wet Cleaning of Compressor
57
Fig. 22: Filter Plug View
58
Table 13: Volume of Water Per Cleaning Process
58
Table 14: Tightening Torques (81125)
58
Cleaning the Turbine During Operation
59
Fig. 23: Dry Cleaning Device
60
Table 15: Amount of Granulate
62
Draining the Gas Outlet Casing
63
Fig. 24: Drain Pipe Diagram
63
Troubleshooting
64
Malfunctions When Starting
64
Table 16: Malfunctions When Starting - Delayed Start-Up
64
Table 17: Malfunctions When Starting - Vibrations
64
Table 18: Malfunctions When Starting - Rubbing of Rotating Parts
64
Malfunctions During Operation
65
Table 19: Malfunctions During Operation - Lubricating Oil Pressure too Low
65
Table 20: Malfunctions During Operation - Drop in Speed
65
Table 21: Malfunctions During Operation - Exhaust Gas Temperature too High
66
Table 22: Malfunctions During Operation - Charge Air Pressure too Low
66
Table 24: Surging of the Turbocharger
67
Table 23: Malfunctions During Operation - Charge Air Pressure too High
67
Surging of the Turbocharger
67
Malfunctions When Stopping
68
Table 25: Malfunctions When Stopping - Runout Noises
68
Table 26: Malfunctions When Stopping - Shortened Runout Time
68
Speed Measurement System
69
Table 27: Malfunctions of the Speed Measurement System
69
Disassembly and Assembly
70
Introduction
70
Material Required
71
Weights of Assemblies
72
Fig. 25: Weights of Assemblies
72
Table 28: Weights of Assemblies [Kg]
72
Table 29: Weight of Wall Insert [Kg]
72
Fig. 26: Dismantling the Filter Silencer Casing
73
Disassembly and Assembly of the Filter Silencer Casing
73
Fig. 27: Fitting the Filter Silencer Casing
74
Fig. 28: Fitting the Filter Silencer Casing
75
Fig. 29: Fitting the Filter Silencer Casing
75
Fig. 30: Fitting the Filter Silencer Casing
76
Fig. 31: Fitting the Filter Silencer Casing
76
Fig. 32: Fitting the Bellows
77
Table 30: Tightening Torques (Filter Silencer Screws)
77
Dismantling the Filter Silencer
78
Fig. 33: Dismantling the Filter Silencer
78
Fig. 34: Dismantling the Filter Silencer
79
Dismantling the Filter Silencer with Noise Package
80
Fig. 35: Dismantling the Filter Silencer with Noise Package
80
Dismantling Wall Insert and Diffuser
81
Fig. 36: Dismantling the Wall Insert
81
Fig. 37: Moving out Wall Insert
82
Fig. 38: Putting down Wall Insert
82
Fig. 39: Putting down Wall Insert
83
Fig. 40: Dismantling the Diffuser
84
Axial Clearance a Prior to Disassembly
85
Fig. 41: Measuring Axial Clearance a
85
Table 31: Axial Clearance a
85
Dismantling the Insulation (≤ A175-L)
86
Fig. 42: Removing the Insulation (A175-L and Smaller)
86
Dismantling the Gas Inlet Casing (≤ A175-L)
87
Fig. 43: Dismantling the Gas Inlet Casing (A175-L and Smaller)
87
Table 32: Maximum Admissible Loosening Torque (51087)
87
Dismantling the Nozzle Ring (≤ A175-L)
88
Fig. 44: Dismantling the Nozzle Ring (A175-L and Smaller)
88
Dismantling the Gas Inlet Casing (≥ A180-L)
89
Fig. 45: Dismantling the Gas Inlet Casing (180-L and Larger)
89
Table 33: Maximum Admissible Loosening Torque (51087)
89
Dismantling the Nozzle Ring (≥ A180-L)
90
Fig. 46: Fitting the Nozzle Ring Holder
90
Fig. 47: Dismantling the Nozzle Ring
91
Fig. 48: Put down the Nozzle Ring
91
Fitting the Nozzle Ring (≤ A175-L)
92
Fig. 49: Fitting the Nozzle Ring (A175-L and Smaller)
92
Table 34: Tightening Torque (56014)
92
Table 35: Tightening Torque (51087)
93
Fig. 50: Fitting the Gas Outlet Casing (A175-L and Smaller)
93
Fitting the Gas Inlet Casing (≤ A175-L)
93
Fitting the Insulation (≤ A175-L)
94
Fig. 51: Fitting the Insulation (A175-L and Smaller)
94
Fitting the Nozzle Ring (≥ A180-L)
95
Fig. 52: Looping Around the Nozzle Ring (A180-L and Larger)
95
Fig. 53: Fitting the Nozzle Ring (A180-L and Larger)
96
Table 36: Tightening Torque (56014)
96
Fitting the Gas Inlet Casing (≥ A180-L)
97
Fig. 54: Fitting the Gas Inlet Casing (A180-L and Larger)
97
Table 37: Tightening Torque (51087)
97
Axial Clearance a after Assembly
98
Fig. 55: Measuring Axial Clearance a
98
Table 38: Axial Clearance a
98
Table 39: Tightening Torque (77015)
99
Fig. 56: Fitting the Diffuser
99
Fitting the Diffuser
99
Fitting Wall Insert
100
Fig. 57: Positioning Wall Insert
100
Fig. 58: Fitting Wall Insert
101
Table 40: Tightening Torque (72011)
101
Fitting the Filter Silencer
102
Fig. 59: Fitting the Filter Silencer
103
Table 41: Tightening Torque (72004)
103
Fig. 60: Fitting the Filter Silencer
104
Table 42: Tightening Torque (72004)
104
Fitting the Filter Silencer with Noise Package
105
Fig. 61: Fitting the Filter Silencer with Noise Package
105
Table 43: Tightening Torque (51087)
105
Table of Tightening Torques
107
Fig. 63: Tightening Torques of Speed Sensor
107
Fig. 62: Overview of Tightening Torques
108
Table 44: Overview of Tightening Torques
108
Table 45: Tightening Torque, Insulation
108
Taking a Turbocharger out of Operation
109
Possible Emergency Repairs
109
Taking Defective Turbochargers out of Operation
110
Table 46: Bypass Procedure
110
Fig. 64: Locking the Rotor
111
Table 47: Tightening Torque
111
Fig. 65: Ensuring Clamping of the Cover Ring
113
Table 48: Required Washers (01)
113
Table 49: Tightening Torque (57005)
113
Fig. 66: Position of Cover Plates
114
Mothballing the Turbocharger
115
Taking the Engine out of Operation for up to 12 Months
115
Taking the Engine out of Operation for more than 12 Months
116
Material and Disposal
117
REACH and Rohs Compliance Declaration for Products
117
Disposing of Turbocharger Components
118
Spare Parts
119
Ordering Spare Parts
119
Table 50: Customer Spare Part Set (97070)
119
Table 51: Customer Spare Part Set (97071)
120
Spare Part - Illustrations
121
Table 52: Spare Parts - Bearing Casing Common Parts
122
Table 53: Spare Parts - Bearing Casing Oil Tank
124
Table 54: Spare Parts - Cartridge
125
Table 55: Spare Parts - Compressor Casing
127
Table 56: Spare Parts - Filter Silencer
128
Table 57: Spare Parts - Gas Inlet Casing Axial
129
Table 58: Spare Parts - Gas Inlet Casing Radial
130
Table 59: Spare Parts - Gas Outlet Casing
131
Table 60: Spare Parts - Rotor and Bearing Parts
133
Table 61: Spare Parts - Sealing Air Supply for Flexible Cut-Out
134
Table 62: Spare Parts - Speed Measurement
135
Table 63: Spare Parts - U-Tube Manometer
136
Table 64: Spare Parts - Turbine Dry Cleaning Radial
138
Tools
139
Table 65: Customer Tool Set 90000
139
ABB A165-L35 Operation Manual (144 pages)
Turbo Systems
Brand:
ABB
| Category:
Industrial Equipment
| Size: 23.46 MB
Table of Contents
Operation Manual / A100-L
3
Table of Contents
3
Introduction
6
Essential Information
7
Registered Trademarks
7
Layout and Function of the Turbocharger
8
Fig. 1: Layout and Function of the Turbocharger
8
Locations of the Rating Plates
10
Fig. 2: Locations of the Rating Plates
10
Safety
11
Introduction
11
CE Conformity
11
Table 2: Personal Protective Equipment to be Worn Specific to the Respective Task
12
Table 1: Personal Protective Equipment to be Worn at All Times
12
Definition of Safety Instructions
12
Definition of Mandatory Signs
12
Intended Use
13
Deflagration on Gas Engines
14
Warning Plates on the Turbocharger
15
Turbocharger Rating Plate
15
Fig. 3: Warning Plate Locations
15
Fig. 4: Rating Plate
15
Periodic Check of the Pressure Vessels
17
Lifting of Loads
18
Fig. 5: Attachment of Loads on the Crane Hook
18
Fig. 6: Attachment Angle
18
Prerequisites for Operation and Maintenance
19
Hazards During Operation and Maintenance
20
Safe Operation
21
Safe Maintenance
22
Turbocharger Weight
27
Removing the Turbocharger
27
Table 3: Total Weight
27
Removal and Installation
27
Fig. 7: Fitting the Lifting Gear
28
Installing the Turbocharger
29
Fig. 8: Placing the Turbocharger
29
Fig. 9: Compressor-End Foot
30
Fig. 10: Turbine-End Foot
30
Table 4: General Information about Fastening the Turbocharger
30
Table 5: Tightening Torques (Foot Screws)
31
Table 6: Tightening Angle (Foot Screws)
31
Inspection Procedures
32
Commissioning
32
Oil Supply
32
Commissioning after Taking out of Operation
34
Monitoring During Operation
35
Oil Pressure, Oil Temperature
35
Table 7: Lubricating Oil Pressure, Oil Inlet
35
Fig. 11: Oil Temperature at the Outlet
36
Table 8: Lubricating Oil Temperature at the Inlet
36
Table 9: Lubricating Oil Temperature at the Outlet
36
Admissible Air Inlet Temperature
38
Turbocharger Speed
38
Fig. 12: Layout and Overview of the Speed Measurement System
38
Table 10: Tightening Torques (86505)
40
Fig. 13: Replacing the Speed Sensor
40
Low Pressure Measurement at the Filter Silencer
41
Fig. 14: U-Tube Manometer at the Filter Silencer
41
Operation and Service
42
Noise Emission
42
Service Work
43
Fig. 15: Noise Insulation, Bellows
43
Expected Replacement Intervals
47
Table 11: Expected Replacement Intervals for Turbocharger Parts
47
Table 12: Recommended Replacement Intervals for Turbocharger Parts
47
Flexible Turbocharger Cut-Out
48
Stopping the Engine
49
Periodic Maintenance
50
Foreword to Maintenance
50
Cleaning the Filter Silencer
51
Fig. 16: Layout and Overview of Filter Silencer
51
Changing the Filter Strip on the Filter Silencer Casing
53
Fig. 17: Dismantling Filter Ring Circumferential Part
53
Fig. 18: Opening Filter Ring Lock
53
Fig. 19: Attaching New Filter Ring
54
Fig. 20: Fitting New Filter Ring
54
Cleaning the Compressor During Operation
55
Fig. 21: Overview of Wet Cleaning of Compressor
57
Fig. 22: Filter Plug View
58
Table 13: Volume of Water Per Cleaning Process
58
Table 14: Tightening Torques (81125)
58
Cleaning the Turbine During Operation
59
Fig. 23: Dry Cleaning Device
60
Table 15: Amount of Granulate
62
Draining the Gas Outlet Casing
63
Fig. 24: Drain Pipe Diagram
63
Troubleshooting
64
Malfunctions When Starting
64
Table 16: Malfunctions When Starting - Delayed Start-Up
64
Table 17: Malfunctions When Starting - Vibrations
64
Table 18: Malfunctions When Starting - Rubbing of Rotating Parts
64
Malfunctions During Operation
65
Table 19: Malfunctions During Operation - Lubricating Oil Pressure too Low
65
Table 20: Malfunctions During Operation - Drop in Speed
65
Table 21: Malfunctions During Operation - Exhaust Gas Temperature too High
66
Table 22: Malfunctions During Operation - Charge Air Pressure too Low
66
Table 24: Surging of the Turbocharger
67
Table 23: Malfunctions During Operation - Charge Air Pressure too High
67
Surging of the Turbocharger
67
Malfunctions When Stopping
68
Table 25: Malfunctions When Stopping - Runout Noises
68
Table 26: Malfunctions When Stopping - Shortened Runout Time
68
Speed Measurement System
69
Table 27: Malfunctions of the Speed Measurement System
69
Disassembly and Assembly
70
Introduction
70
Material Required
71
Weights of Assemblies
72
Fig. 25: Weights of Assemblies
72
Table 28: Weights of Assemblies [Kg]
72
Table 29: Weight of Wall Insert [Kg]
72
Fig. 26: Dismantling the Filter Silencer Casing
73
Disassembly and Assembly of the Filter Silencer Casing
73
Fig. 27: Fitting the Filter Silencer Casing
74
Fig. 28: Fitting the Filter Silencer Casing
75
Fig. 29: Fitting the Filter Silencer Casing
75
Fig. 30: Fitting the Filter Silencer Casing
76
Fig. 31: Fitting the Filter Silencer Casing
76
Fig. 32: Fitting the Bellows
77
Table 30: Tightening Torques (Filter Silencer Screws)
77
Dismantling the Filter Silencer
78
Fig. 33: Dismantling the Filter Silencer
78
Fig. 34: Dismantling the Filter Silencer
79
Dismantling the Filter Silencer with Noise Package
80
Fig. 35: Dismantling the Filter Silencer with Noise Package
80
Dismantling Wall Insert and Diffuser
81
Fig. 36: Dismantling the Wall Insert
81
Fig. 37: Moving out Wall Insert
82
Fig. 38: Putting down Wall Insert
82
Fig. 39: Putting down Wall Insert
83
Fig. 40: Dismantling the Diffuser
84
Axial Clearance a Prior to Disassembly
85
Fig. 41: Measuring Axial Clearance a
85
Table 31: Axial Clearance a
85
Dismantling the Insulation (≤ A175-L)
86
Fig. 42: Removing the Insulation (A175-L and Smaller)
86
Dismantling the Gas Inlet Casing (≤ A175-L)
87
Fig. 43: Dismantling the Gas Inlet Casing (A175-L and Smaller)
87
Table 32: Maximum Admissible Loosening Torque (51087)
87
Dismantling the Nozzle Ring (≤ A175-L)
88
Fig. 44: Dismantling the Nozzle Ring (A175-L and Smaller)
88
Dismantling the Gas Inlet Casing (≥ A180-L)
89
Fig. 45: Dismantling the Gas Inlet Casing (180-L and Larger)
89
Table 33: Maximum Admissible Loosening Torque (51087)
89
Dismantling the Nozzle Ring (≥ A180-L)
90
Fig. 46: Fitting the Nozzle Ring Holder
90
Fig. 47: Dismantling the Nozzle Ring
91
Fig. 48: Put down the Nozzle Ring
91
Fitting the Nozzle Ring (≤ A175-L)
92
Fig. 49: Fitting the Nozzle Ring (A175-L and Smaller)
92
Table 34: Tightening Torque (56014)
92
Table 35: Tightening Torque (51087)
93
Fig. 50: Fitting the Gas Outlet Casing (A175-L and Smaller)
93
Fitting the Gas Inlet Casing (≤ A175-L)
93
Fitting the Insulation (≤ A175-L)
94
Fig. 51: Fitting the Insulation (A175-L and Smaller)
94
Fitting the Nozzle Ring (≥ A180-L)
95
Fig. 52: Looping Around the Nozzle Ring (A180-L and Larger)
95
Fig. 53: Fitting the Nozzle Ring (A180-L and Larger)
96
Table 36: Tightening Torque (56014)
96
Fitting the Gas Inlet Casing (≥ A180-L)
97
Fig. 54: Fitting the Gas Inlet Casing (A180-L and Larger)
97
Table 37: Tightening Torque (51087)
97
Axial Clearance a after Assembly
98
Fig. 55: Measuring Axial Clearance a
98
Table 38: Axial Clearance a
98
Table 39: Tightening Torque (77015)
99
Fig. 56: Fitting the Diffuser
99
Fitting the Diffuser
99
Fitting Wall Insert
100
Fig. 57: Positioning Wall Insert
100
Fig. 58: Fitting Wall Insert
101
Table 40: Tightening Torque (72011)
101
Fitting the Filter Silencer
102
Fig. 59: Fitting the Filter Silencer
103
Table 41: Tightening Torque (72004)
103
Fig. 60: Fitting the Filter Silencer
104
Table 42: Tightening Torque (72004)
104
Fitting the Filter Silencer with Noise Package
105
Fig. 61: Fitting the Filter Silencer with Noise Package
105
Table 43: Tightening Torque (51087)
105
Table of Tightening Torques
107
Fig. 63: Tightening Torques of Speed Sensor
107
Fig. 62: Overview of Tightening Torques
108
Table 44: Overview of Tightening Torques
108
Table 45: Tightening Torque, Insulation
108
Taking a Turbocharger out of Operation
109
Possible Emergency Repairs
109
Taking Defective Turbochargers out of Operation
110
Table 46: Bypass Procedure
110
Fig. 64: Locking the Rotor
111
Table 47: Tightening Torque
111
Fig. 65: Ensuring Clamping of the Cover Ring
113
Table 48: Required Washers (01)
113
Table 49: Tightening Torque (57005)
113
Fig. 66: Position of Cover Plates
114
Mothballing the Turbocharger
115
Taking the Engine out of Operation for up to 12 Months
115
Taking the Engine out of Operation for more than 12 Months
116
Material and Disposal
117
REACH and Rohs Compliance Declaration for Products
117
Disposing of Turbocharger Components
118
Spare Parts
119
Ordering Spare Parts
119
Table 50: Customer Spare Part Set (97070)
119
Table 51: Customer Spare Part Set (97071)
120
Spare Part - Illustrations
121
Table 52: Spare Parts - Bearing Casing Common Parts
122
Table 53: Spare Parts - Bearing Casing Oil Tank
124
Table 54: Spare Parts - Cartridge
125
Table 55: Spare Parts - Compressor Casing
127
Table 56: Spare Parts - Filter Silencer
128
Table 57: Spare Parts - Gas Inlet Casing Axial
129
Table 58: Spare Parts - Gas Inlet Casing Radial
130
Table 59: Spare Parts - Gas Outlet Casing
131
Table 60: Spare Parts - Rotor and Bearing Parts
133
Table 61: Spare Parts - Sealing Air Supply for Flexible Cut-Out
134
Table 62: Spare Parts - Speed Measurement
135
Table 63: Spare Parts - U-Tube Manometer
136
Table 64: Spare Parts - Turbine Dry Cleaning Radial
138
Tools
139
Table 65: Customer Tool Set 90000
139
ABB A165-L35 Operation Manual (144 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 23.46 MB
Table of Contents
Operation Manual / A100-L
3
Table of Contents
3
Introduction
6
Essential Information
7
Registered Trademarks
7
Layout and Function of the Turbocharger
8
Fig. 1: Layout and Function of the Turbocharger
8
Locations of the Rating Plates
10
Fig. 2: Locations of the Rating Plates
10
Safety
11
Introduction
11
CE Conformity
11
Table 2: Personal Protective Equipment to be Worn Specific to the Respective Task
12
Table 1: Personal Protective Equipment to be Worn at All Times
12
Definition of Safety Instructions
12
Definition of Mandatory Signs
12
Intended Use
13
Deflagration on Gas Engines
14
Warning Plates on the Turbocharger
15
Turbocharger Rating Plate
15
Fig. 3: Warning Plate Locations
15
Fig. 4: Rating Plate
15
Periodic Check of the Pressure Vessels
17
Lifting of Loads
18
Fig. 5: Attachment of Loads on the Crane Hook
18
Fig. 6: Attachment Angle
18
Prerequisites for Operation and Maintenance
19
Hazards During Operation and Maintenance
20
Safe Operation
21
Safe Maintenance
22
Turbocharger Weight
27
Removing the Turbocharger
27
Table 3: Total Weight
27
Removal and Installation
27
Fig. 7: Fitting the Lifting Gear
28
Installing the Turbocharger
29
Fig. 8: Placing the Turbocharger
29
Fig. 9: Compressor-End Foot
30
Fig. 10: Turbine-End Foot
30
Table 4: General Information about Fastening the Turbocharger
30
Table 5: Tightening Torques (Foot Screws)
31
Table 6: Tightening Angle (Foot Screws)
31
Inspection Procedures
32
Commissioning
32
Oil Supply
32
Commissioning after Taking out of Operation
34
Monitoring During Operation
35
Oil Pressure, Oil Temperature
35
Table 7: Lubricating Oil Pressure, Oil Inlet
35
Fig. 11: Oil Temperature at the Outlet
36
Table 8: Lubricating Oil Temperature at the Inlet
36
Table 9: Lubricating Oil Temperature at the Outlet
36
Admissible Air Inlet Temperature
38
Turbocharger Speed
38
Fig. 12: Layout and Overview of the Speed Measurement System
38
Table 10: Tightening Torques (86505)
40
Fig. 13: Replacing the Speed Sensor
40
Low Pressure Measurement at the Filter Silencer
41
Fig. 14: U-Tube Manometer at the Filter Silencer
41
Operation and Service
42
Noise Emission
42
Service Work
43
Fig. 15: Noise Insulation, Bellows
43
Expected Replacement Intervals
47
Table 11: Expected Replacement Intervals for Turbocharger Parts
47
Table 12: Recommended Replacement Intervals for Turbocharger Parts
47
Flexible Turbocharger Cut-Out
48
Stopping the Engine
49
Periodic Maintenance
50
Foreword to Maintenance
50
Cleaning the Filter Silencer
51
Fig. 16: Layout and Overview of Filter Silencer
51
Changing the Filter Strip on the Filter Silencer Casing
53
Fig. 17: Dismantling Filter Ring Circumferential Part
53
Fig. 18: Opening Filter Ring Lock
53
Fig. 19: Attaching New Filter Ring
54
Fig. 20: Fitting New Filter Ring
54
Cleaning the Compressor During Operation
55
Fig. 21: Overview of Wet Cleaning of Compressor
57
Fig. 22: Filter Plug View
58
Table 13: Volume of Water Per Cleaning Process
58
Table 14: Tightening Torques (81125)
58
Cleaning the Turbine During Operation
59
Fig. 23: Dry Cleaning Device
60
Table 15: Amount of Granulate
62
Draining the Gas Outlet Casing
63
Fig. 24: Drain Pipe Diagram
63
Troubleshooting
64
Malfunctions When Starting
64
Table 16: Malfunctions When Starting - Delayed Start-Up
64
Table 17: Malfunctions When Starting - Vibrations
64
Table 18: Malfunctions When Starting - Rubbing of Rotating Parts
64
Malfunctions During Operation
65
Table 19: Malfunctions During Operation - Lubricating Oil Pressure too Low
65
Table 20: Malfunctions During Operation - Drop in Speed
65
Table 21: Malfunctions During Operation - Exhaust Gas Temperature too High
66
Table 22: Malfunctions During Operation - Charge Air Pressure too Low
66
Table 24: Surging of the Turbocharger
67
Table 23: Malfunctions During Operation - Charge Air Pressure too High
67
Surging of the Turbocharger
67
Malfunctions When Stopping
68
Table 25: Malfunctions When Stopping - Runout Noises
68
Table 26: Malfunctions When Stopping - Shortened Runout Time
68
Speed Measurement System
69
Table 27: Malfunctions of the Speed Measurement System
69
Disassembly and Assembly
70
Introduction
70
Material Required
71
Weights of Assemblies
72
Fig. 25: Weights of Assemblies
72
Table 28: Weights of Assemblies [Kg]
72
Table 29: Weight of Wall Insert [Kg]
72
Fig. 26: Dismantling the Filter Silencer Casing
73
Disassembly and Assembly of the Filter Silencer Casing
73
Fig. 27: Fitting the Filter Silencer Casing
74
Fig. 28: Fitting the Filter Silencer Casing
75
Fig. 29: Fitting the Filter Silencer Casing
75
Fig. 30: Fitting the Filter Silencer Casing
76
Fig. 31: Fitting the Filter Silencer Casing
76
Fig. 32: Fitting the Bellows
77
Table 30: Tightening Torques (Filter Silencer Screws)
77
Dismantling the Filter Silencer
78
Fig. 33: Dismantling the Filter Silencer
78
Fig. 34: Dismantling the Filter Silencer
79
Dismantling the Filter Silencer with Noise Package
80
Fig. 35: Dismantling the Filter Silencer with Noise Package
80
Dismantling Wall Insert and Diffuser
81
Fig. 36: Dismantling the Wall Insert
81
Fig. 37: Moving out Wall Insert
82
Fig. 38: Putting down Wall Insert
82
Fig. 39: Putting down Wall Insert
83
Fig. 40: Dismantling the Diffuser
84
Axial Clearance a Prior to Disassembly
85
Fig. 41: Measuring Axial Clearance a
85
Table 31: Axial Clearance a
85
Dismantling the Insulation (≤ A175-L)
86
Fig. 42: Removing the Insulation (A175-L and Smaller)
86
Dismantling the Gas Inlet Casing (≤ A175-L)
87
Fig. 43: Dismantling the Gas Inlet Casing (A175-L and Smaller)
87
Table 32: Maximum Admissible Loosening Torque (51087)
87
Dismantling the Nozzle Ring (≤ A175-L)
88
Fig. 44: Dismantling the Nozzle Ring (A175-L and Smaller)
88
Dismantling the Gas Inlet Casing (≥ A180-L)
89
Fig. 45: Dismantling the Gas Inlet Casing (180-L and Larger)
89
Table 33: Maximum Admissible Loosening Torque (51087)
89
Dismantling the Nozzle Ring (≥ A180-L)
90
Fig. 46: Fitting the Nozzle Ring Holder
90
Fig. 47: Dismantling the Nozzle Ring
91
Fig. 48: Put down the Nozzle Ring
91
Fitting the Nozzle Ring (≤ A175-L)
92
Fig. 49: Fitting the Nozzle Ring (A175-L and Smaller)
92
Table 34: Tightening Torque (56014)
92
Table 35: Tightening Torque (51087)
93
Fig. 50: Fitting the Gas Outlet Casing (A175-L and Smaller)
93
Fitting the Gas Inlet Casing (≤ A175-L)
93
Fitting the Insulation (≤ A175-L)
94
Fig. 51: Fitting the Insulation (A175-L and Smaller)
94
Fitting the Nozzle Ring (≥ A180-L)
95
Fig. 52: Looping Around the Nozzle Ring (A180-L and Larger)
95
Fig. 53: Fitting the Nozzle Ring (A180-L and Larger)
96
Table 36: Tightening Torque (56014)
96
Fitting the Gas Inlet Casing (≥ A180-L)
97
Fig. 54: Fitting the Gas Inlet Casing (A180-L and Larger)
97
Table 37: Tightening Torque (51087)
97
Axial Clearance a after Assembly
98
Fig. 55: Measuring Axial Clearance a
98
Table 38: Axial Clearance a
98
Table 39: Tightening Torque (77015)
99
Fig. 56: Fitting the Diffuser
99
Fitting the Diffuser
99
Fitting Wall Insert
100
Fig. 57: Positioning Wall Insert
100
Fig. 58: Fitting Wall Insert
101
Table 40: Tightening Torque (72011)
101
Fitting the Filter Silencer
102
Fig. 59: Fitting the Filter Silencer
103
Table 41: Tightening Torque (72004)
103
Fig. 60: Fitting the Filter Silencer
104
Table 42: Tightening Torque (72004)
104
Fitting the Filter Silencer with Noise Package
105
Fig. 61: Fitting the Filter Silencer with Noise Package
105
Table 43: Tightening Torque (51087)
105
Table of Tightening Torques
107
Fig. 63: Tightening Torques of Speed Sensor
107
Fig. 62: Overview of Tightening Torques
108
Table 44: Overview of Tightening Torques
108
Table 45: Tightening Torque, Insulation
108
Taking a Turbocharger out of Operation
109
Possible Emergency Repairs
109
Taking Defective Turbochargers out of Operation
110
Table 46: Bypass Procedure
110
Fig. 64: Locking the Rotor
111
Table 47: Tightening Torque
111
Fig. 65: Ensuring Clamping of the Cover Ring
113
Table 48: Required Washers (01)
113
Table 49: Tightening Torque (57005)
113
Fig. 66: Position of Cover Plates
114
Mothballing the Turbocharger
115
Taking the Engine out of Operation for up to 12 Months
115
Taking the Engine out of Operation for more than 12 Months
116
Material and Disposal
117
REACH and Rohs Compliance Declaration for Products
117
Disposing of Turbocharger Components
118
Spare Parts
119
Ordering Spare Parts
119
Table 50: Customer Spare Part Set (97070)
119
Table 51: Customer Spare Part Set (97071)
120
Spare Part - Illustrations
121
Table 52: Spare Parts - Bearing Casing Common Parts
122
Table 53: Spare Parts - Bearing Casing Oil Tank
124
Table 54: Spare Parts - Cartridge
125
Table 55: Spare Parts - Compressor Casing
127
Table 56: Spare Parts - Filter Silencer
128
Table 57: Spare Parts - Gas Inlet Casing Axial
129
Table 58: Spare Parts - Gas Inlet Casing Radial
130
Table 59: Spare Parts - Gas Outlet Casing
131
Table 60: Spare Parts - Rotor and Bearing Parts
133
Table 61: Spare Parts - Sealing Air Supply for Flexible Cut-Out
134
Table 62: Spare Parts - Speed Measurement
135
Table 63: Spare Parts - U-Tube Manometer
136
Table 64: Spare Parts - Turbine Dry Cleaning Radial
138
Tools
139
Table 65: Customer Tool Set 90000
139
ABB A165-L35 Operation Manual (144 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 23.46 MB
Table of Contents
Operation Manual / A100-L
3
Table of Contents
3
Introduction
6
Essential Information
7
Registered Trademarks
7
Layout and Function of the Turbocharger
8
Fig. 1: Layout and Function of the Turbocharger
8
Locations of the Rating Plates
10
Fig. 2: Locations of the Rating Plates
10
Safety
11
Introduction
11
CE Conformity
11
Table 2: Personal Protective Equipment to be Worn Specific to the Respective Task
12
Table 1: Personal Protective Equipment to be Worn at All Times
12
Definition of Safety Instructions
12
Definition of Mandatory Signs
12
Intended Use
13
Deflagration on Gas Engines
14
Warning Plates on the Turbocharger
15
Turbocharger Rating Plate
15
Fig. 3: Warning Plate Locations
15
Fig. 4: Rating Plate
15
Periodic Check of the Pressure Vessels
17
Lifting of Loads
18
Fig. 5: Attachment of Loads on the Crane Hook
18
Fig. 6: Attachment Angle
18
Prerequisites for Operation and Maintenance
19
Hazards During Operation and Maintenance
20
Safe Operation
21
Safe Maintenance
22
Turbocharger Weight
27
Removing the Turbocharger
27
Table 3: Total Weight
27
Removal and Installation
27
Fig. 7: Fitting the Lifting Gear
28
Installing the Turbocharger
29
Fig. 8: Placing the Turbocharger
29
Fig. 9: Compressor-End Foot
30
Fig. 10: Turbine-End Foot
30
Table 4: General Information about Fastening the Turbocharger
30
Table 5: Tightening Torques (Foot Screws)
31
Table 6: Tightening Angle (Foot Screws)
31
Inspection Procedures
32
Commissioning
32
Oil Supply
32
Commissioning after Taking out of Operation
34
Monitoring During Operation
35
Oil Pressure, Oil Temperature
35
Table 7: Lubricating Oil Pressure, Oil Inlet
35
Fig. 11: Oil Temperature at the Outlet
36
Table 8: Lubricating Oil Temperature at the Inlet
36
Table 9: Lubricating Oil Temperature at the Outlet
36
Admissible Air Inlet Temperature
38
Turbocharger Speed
38
Fig. 12: Layout and Overview of the Speed Measurement System
38
Table 10: Tightening Torques (86505)
40
Fig. 13: Replacing the Speed Sensor
40
Low Pressure Measurement at the Filter Silencer
41
Fig. 14: U-Tube Manometer at the Filter Silencer
41
Operation and Service
42
Noise Emission
42
Service Work
43
Fig. 15: Noise Insulation, Bellows
43
Expected Replacement Intervals
47
Table 11: Expected Replacement Intervals for Turbocharger Parts
47
Table 12: Recommended Replacement Intervals for Turbocharger Parts
47
Flexible Turbocharger Cut-Out
48
Stopping the Engine
49
Periodic Maintenance
50
Foreword to Maintenance
50
Cleaning the Filter Silencer
51
Fig. 16: Layout and Overview of Filter Silencer
51
Changing the Filter Strip on the Filter Silencer Casing
53
Fig. 17: Dismantling Filter Ring Circumferential Part
53
Fig. 18: Opening Filter Ring Lock
53
Fig. 19: Attaching New Filter Ring
54
Fig. 20: Fitting New Filter Ring
54
Cleaning the Compressor During Operation
55
Fig. 21: Overview of Wet Cleaning of Compressor
57
Fig. 22: Filter Plug View
58
Table 13: Volume of Water Per Cleaning Process
58
Table 14: Tightening Torques (81125)
58
Cleaning the Turbine During Operation
59
Fig. 23: Dry Cleaning Device
60
Table 15: Amount of Granulate
62
Draining the Gas Outlet Casing
63
Fig. 24: Drain Pipe Diagram
63
Troubleshooting
64
Malfunctions When Starting
64
Table 16: Malfunctions When Starting - Delayed Start-Up
64
Table 17: Malfunctions When Starting - Vibrations
64
Table 18: Malfunctions When Starting - Rubbing of Rotating Parts
64
Malfunctions During Operation
65
Table 19: Malfunctions During Operation - Lubricating Oil Pressure too Low
65
Table 20: Malfunctions During Operation - Drop in Speed
65
Table 21: Malfunctions During Operation - Exhaust Gas Temperature too High
66
Table 22: Malfunctions During Operation - Charge Air Pressure too Low
66
Table 24: Surging of the Turbocharger
67
Table 23: Malfunctions During Operation - Charge Air Pressure too High
67
Surging of the Turbocharger
67
Malfunctions When Stopping
68
Table 25: Malfunctions When Stopping - Runout Noises
68
Table 26: Malfunctions When Stopping - Shortened Runout Time
68
Speed Measurement System
69
Table 27: Malfunctions of the Speed Measurement System
69
Disassembly and Assembly
70
Introduction
70
Material Required
71
Weights of Assemblies
72
Fig. 25: Weights of Assemblies
72
Table 28: Weights of Assemblies [Kg]
72
Table 29: Weight of Wall Insert [Kg]
72
Fig. 26: Dismantling the Filter Silencer Casing
73
Disassembly and Assembly of the Filter Silencer Casing
73
Fig. 27: Fitting the Filter Silencer Casing
74
Fig. 28: Fitting the Filter Silencer Casing
75
Fig. 29: Fitting the Filter Silencer Casing
75
Fig. 30: Fitting the Filter Silencer Casing
76
Fig. 31: Fitting the Filter Silencer Casing
76
Fig. 32: Fitting the Bellows
77
Table 30: Tightening Torques (Filter Silencer Screws)
77
Dismantling the Filter Silencer
78
Fig. 33: Dismantling the Filter Silencer
78
Fig. 34: Dismantling the Filter Silencer
79
Dismantling the Filter Silencer with Noise Package
80
Fig. 35: Dismantling the Filter Silencer with Noise Package
80
Dismantling Wall Insert and Diffuser
81
Fig. 36: Dismantling the Wall Insert
81
Fig. 37: Moving out Wall Insert
82
Fig. 38: Putting down Wall Insert
82
Fig. 39: Putting down Wall Insert
83
Fig. 40: Dismantling the Diffuser
84
Axial Clearance a Prior to Disassembly
85
Fig. 41: Measuring Axial Clearance a
85
Table 31: Axial Clearance a
85
Dismantling the Insulation (≤ A175-L)
86
Fig. 42: Removing the Insulation (A175-L and Smaller)
86
Dismantling the Gas Inlet Casing (≤ A175-L)
87
Fig. 43: Dismantling the Gas Inlet Casing (A175-L and Smaller)
87
Table 32: Maximum Admissible Loosening Torque (51087)
87
Dismantling the Nozzle Ring (≤ A175-L)
88
Fig. 44: Dismantling the Nozzle Ring (A175-L and Smaller)
88
Dismantling the Gas Inlet Casing (≥ A180-L)
89
Fig. 45: Dismantling the Gas Inlet Casing (180-L and Larger)
89
Table 33: Maximum Admissible Loosening Torque (51087)
89
Dismantling the Nozzle Ring (≥ A180-L)
90
Fig. 46: Fitting the Nozzle Ring Holder
90
Fig. 47: Dismantling the Nozzle Ring
91
Fig. 48: Put down the Nozzle Ring
91
Fitting the Nozzle Ring (≤ A175-L)
92
Fig. 49: Fitting the Nozzle Ring (A175-L and Smaller)
92
Table 34: Tightening Torque (56014)
92
Table 35: Tightening Torque (51087)
93
Fig. 50: Fitting the Gas Outlet Casing (A175-L and Smaller)
93
Fitting the Gas Inlet Casing (≤ A175-L)
93
Fitting the Insulation (≤ A175-L)
94
Fig. 51: Fitting the Insulation (A175-L and Smaller)
94
Fitting the Nozzle Ring (≥ A180-L)
95
Fig. 52: Looping Around the Nozzle Ring (A180-L and Larger)
95
Fig. 53: Fitting the Nozzle Ring (A180-L and Larger)
96
Table 36: Tightening Torque (56014)
96
Fitting the Gas Inlet Casing (≥ A180-L)
97
Fig. 54: Fitting the Gas Inlet Casing (A180-L and Larger)
97
Table 37: Tightening Torque (51087)
97
Axial Clearance a after Assembly
98
Fig. 55: Measuring Axial Clearance a
98
Table 38: Axial Clearance a
98
Table 39: Tightening Torque (77015)
99
Fig. 56: Fitting the Diffuser
99
Fitting the Diffuser
99
Fitting Wall Insert
100
Fig. 57: Positioning Wall Insert
100
Fig. 58: Fitting Wall Insert
101
Table 40: Tightening Torque (72011)
101
Fitting the Filter Silencer
102
Fig. 59: Fitting the Filter Silencer
103
Table 41: Tightening Torque (72004)
103
Fig. 60: Fitting the Filter Silencer
104
Table 42: Tightening Torque (72004)
104
Fitting the Filter Silencer with Noise Package
105
Fig. 61: Fitting the Filter Silencer with Noise Package
105
Table 43: Tightening Torque (51087)
105
Table of Tightening Torques
107
Fig. 63: Tightening Torques of Speed Sensor
107
Fig. 62: Overview of Tightening Torques
108
Table 44: Overview of Tightening Torques
108
Table 45: Tightening Torque, Insulation
108
Taking a Turbocharger out of Operation
109
Possible Emergency Repairs
109
Taking Defective Turbochargers out of Operation
110
Table 46: Bypass Procedure
110
Fig. 64: Locking the Rotor
111
Table 47: Tightening Torque
111
Fig. 65: Ensuring Clamping of the Cover Ring
113
Table 48: Required Washers (01)
113
Table 49: Tightening Torque (57005)
113
Fig. 66: Position of Cover Plates
114
Mothballing the Turbocharger
115
Taking the Engine out of Operation for up to 12 Months
115
Taking the Engine out of Operation for more than 12 Months
116
Material and Disposal
117
REACH and Rohs Compliance Declaration for Products
117
Disposing of Turbocharger Components
118
Spare Parts
119
Ordering Spare Parts
119
Table 50: Customer Spare Part Set (97070)
119
Table 51: Customer Spare Part Set (97071)
120
Spare Part - Illustrations
121
Table 52: Spare Parts - Bearing Casing Common Parts
122
Table 53: Spare Parts - Bearing Casing Oil Tank
124
Table 54: Spare Parts - Cartridge
125
Table 55: Spare Parts - Compressor Casing
127
Table 56: Spare Parts - Filter Silencer
128
Table 57: Spare Parts - Gas Inlet Casing Axial
129
Table 58: Spare Parts - Gas Inlet Casing Radial
130
Table 59: Spare Parts - Gas Outlet Casing
131
Table 60: Spare Parts - Rotor and Bearing Parts
133
Table 61: Spare Parts - Sealing Air Supply for Flexible Cut-Out
134
Table 62: Spare Parts - Speed Measurement
135
Table 63: Spare Parts - U-Tube Manometer
136
Table 64: Spare Parts - Turbine Dry Cleaning Radial
138
Tools
139
Table 65: Customer Tool Set 90000
139
ABB A165-L35 Operation Manual (144 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 23.46 MB
Table of Contents
Operation Manual / A100-L
3
Table of Contents
3
Introduction
6
Essential Information
7
Registered Trademarks
7
Layout and Function of the Turbocharger
8
Fig. 1: Layout and Function of the Turbocharger
8
Locations of the Rating Plates
10
Fig. 2: Locations of the Rating Plates
10
Safety
11
Introduction
11
CE Conformity
11
Table 2: Personal Protective Equipment to be Worn Specific to the Respective Task
12
Table 1: Personal Protective Equipment to be Worn at All Times
12
Definition of Safety Instructions
12
Definition of Mandatory Signs
12
Intended Use
13
Deflagration on Gas Engines
14
Warning Plates on the Turbocharger
15
Turbocharger Rating Plate
15
Fig. 3: Warning Plate Locations
15
Fig. 4: Rating Plate
15
Periodic Check of the Pressure Vessels
17
Lifting of Loads
18
Fig. 5: Attachment of Loads on the Crane Hook
18
Fig. 6: Attachment Angle
18
Prerequisites for Operation and Maintenance
19
Hazards During Operation and Maintenance
20
Safe Operation
21
Safe Maintenance
22
Turbocharger Weight
27
Removing the Turbocharger
27
Table 3: Total Weight
27
Removal and Installation
27
Fig. 7: Fitting the Lifting Gear
28
Installing the Turbocharger
29
Fig. 8: Placing the Turbocharger
29
Fig. 9: Compressor-End Foot
30
Fig. 10: Turbine-End Foot
30
Table 4: General Information about Fastening the Turbocharger
30
Table 5: Tightening Torques (Foot Screws)
31
Table 6: Tightening Angle (Foot Screws)
31
Inspection Procedures
32
Commissioning
32
Oil Supply
32
Commissioning after Taking out of Operation
34
Monitoring During Operation
35
Oil Pressure, Oil Temperature
35
Table 7: Lubricating Oil Pressure, Oil Inlet
35
Fig. 11: Oil Temperature at the Outlet
36
Table 8: Lubricating Oil Temperature at the Inlet
36
Table 9: Lubricating Oil Temperature at the Outlet
36
Admissible Air Inlet Temperature
38
Turbocharger Speed
38
Fig. 12: Layout and Overview of the Speed Measurement System
38
Table 10: Tightening Torques (86505)
40
Fig. 13: Replacing the Speed Sensor
40
Low Pressure Measurement at the Filter Silencer
41
Fig. 14: U-Tube Manometer at the Filter Silencer
41
Operation and Service
42
Noise Emission
42
Service Work
43
Fig. 15: Noise Insulation, Bellows
43
Expected Replacement Intervals
47
Table 11: Expected Replacement Intervals for Turbocharger Parts
47
Table 12: Recommended Replacement Intervals for Turbocharger Parts
47
Flexible Turbocharger Cut-Out
48
Stopping the Engine
49
Periodic Maintenance
50
Foreword to Maintenance
50
Cleaning the Filter Silencer
51
Fig. 16: Layout and Overview of Filter Silencer
51
Changing the Filter Strip on the Filter Silencer Casing
53
Fig. 17: Dismantling Filter Ring Circumferential Part
53
Fig. 18: Opening Filter Ring Lock
53
Fig. 19: Attaching New Filter Ring
54
Fig. 20: Fitting New Filter Ring
54
Cleaning the Compressor During Operation
55
Fig. 21: Overview of Wet Cleaning of Compressor
57
Fig. 22: Filter Plug View
58
Table 13: Volume of Water Per Cleaning Process
58
Table 14: Tightening Torques (81125)
58
Cleaning the Turbine During Operation
59
Fig. 23: Dry Cleaning Device
60
Table 15: Amount of Granulate
62
Draining the Gas Outlet Casing
63
Fig. 24: Drain Pipe Diagram
63
Troubleshooting
64
Malfunctions When Starting
64
Table 16: Malfunctions When Starting - Delayed Start-Up
64
Table 17: Malfunctions When Starting - Vibrations
64
Table 18: Malfunctions When Starting - Rubbing of Rotating Parts
64
Malfunctions During Operation
65
Table 19: Malfunctions During Operation - Lubricating Oil Pressure too Low
65
Table 20: Malfunctions During Operation - Drop in Speed
65
Table 21: Malfunctions During Operation - Exhaust Gas Temperature too High
66
Table 22: Malfunctions During Operation - Charge Air Pressure too Low
66
Table 24: Surging of the Turbocharger
67
Table 23: Malfunctions During Operation - Charge Air Pressure too High
67
Surging of the Turbocharger
67
Malfunctions When Stopping
68
Table 25: Malfunctions When Stopping - Runout Noises
68
Table 26: Malfunctions When Stopping - Shortened Runout Time
68
Speed Measurement System
69
Table 27: Malfunctions of the Speed Measurement System
69
Disassembly and Assembly
70
Introduction
70
Material Required
71
Weights of Assemblies
72
Fig. 25: Weights of Assemblies
72
Table 28: Weights of Assemblies [Kg]
72
Table 29: Weight of Wall Insert [Kg]
72
Fig. 26: Dismantling the Filter Silencer Casing
73
Disassembly and Assembly of the Filter Silencer Casing
73
Fig. 27: Fitting the Filter Silencer Casing
74
Fig. 28: Fitting the Filter Silencer Casing
75
Fig. 29: Fitting the Filter Silencer Casing
75
Fig. 30: Fitting the Filter Silencer Casing
76
Fig. 31: Fitting the Filter Silencer Casing
76
Fig. 32: Fitting the Bellows
77
Table 30: Tightening Torques (Filter Silencer Screws)
77
Dismantling the Filter Silencer
78
Fig. 33: Dismantling the Filter Silencer
78
Fig. 34: Dismantling the Filter Silencer
79
Dismantling the Filter Silencer with Noise Package
80
Fig. 35: Dismantling the Filter Silencer with Noise Package
80
Dismantling Wall Insert and Diffuser
81
Fig. 36: Dismantling the Wall Insert
81
Fig. 37: Moving out Wall Insert
82
Fig. 38: Putting down Wall Insert
82
Fig. 39: Putting down Wall Insert
83
Fig. 40: Dismantling the Diffuser
84
Axial Clearance a Prior to Disassembly
85
Fig. 41: Measuring Axial Clearance a
85
Table 31: Axial Clearance a
85
Dismantling the Insulation (≤ A175-L)
86
Fig. 42: Removing the Insulation (A175-L and Smaller)
86
Dismantling the Gas Inlet Casing (≤ A175-L)
87
Fig. 43: Dismantling the Gas Inlet Casing (A175-L and Smaller)
87
Table 32: Maximum Admissible Loosening Torque (51087)
87
Dismantling the Nozzle Ring (≤ A175-L)
88
Fig. 44: Dismantling the Nozzle Ring (A175-L and Smaller)
88
Dismantling the Gas Inlet Casing (≥ A180-L)
89
Fig. 45: Dismantling the Gas Inlet Casing (180-L and Larger)
89
Table 33: Maximum Admissible Loosening Torque (51087)
89
Dismantling the Nozzle Ring (≥ A180-L)
90
Fig. 46: Fitting the Nozzle Ring Holder
90
Fig. 47: Dismantling the Nozzle Ring
91
Fig. 48: Put down the Nozzle Ring
91
Fitting the Nozzle Ring (≤ A175-L)
92
Fig. 49: Fitting the Nozzle Ring (A175-L and Smaller)
92
Table 34: Tightening Torque (56014)
92
Table 35: Tightening Torque (51087)
93
Fig. 50: Fitting the Gas Outlet Casing (A175-L and Smaller)
93
Fitting the Gas Inlet Casing (≤ A175-L)
93
Fitting the Insulation (≤ A175-L)
94
Fig. 51: Fitting the Insulation (A175-L and Smaller)
94
Fitting the Nozzle Ring (≥ A180-L)
95
Fig. 52: Looping Around the Nozzle Ring (A180-L and Larger)
95
Fig. 53: Fitting the Nozzle Ring (A180-L and Larger)
96
Table 36: Tightening Torque (56014)
96
Fitting the Gas Inlet Casing (≥ A180-L)
97
Fig. 54: Fitting the Gas Inlet Casing (A180-L and Larger)
97
Table 37: Tightening Torque (51087)
97
Axial Clearance a after Assembly
98
Fig. 55: Measuring Axial Clearance a
98
Table 38: Axial Clearance a
98
Table 39: Tightening Torque (77015)
99
Fig. 56: Fitting the Diffuser
99
Fitting the Diffuser
99
Fitting Wall Insert
100
Fig. 57: Positioning Wall Insert
100
Fig. 58: Fitting Wall Insert
101
Table 40: Tightening Torque (72011)
101
Fitting the Filter Silencer
102
Fig. 59: Fitting the Filter Silencer
103
Table 41: Tightening Torque (72004)
103
Fig. 60: Fitting the Filter Silencer
104
Table 42: Tightening Torque (72004)
104
Fitting the Filter Silencer with Noise Package
105
Fig. 61: Fitting the Filter Silencer with Noise Package
105
Table 43: Tightening Torque (51087)
105
Table of Tightening Torques
107
Fig. 63: Tightening Torques of Speed Sensor
107
Fig. 62: Overview of Tightening Torques
108
Table 44: Overview of Tightening Torques
108
Table 45: Tightening Torque, Insulation
108
Taking a Turbocharger out of Operation
109
Possible Emergency Repairs
109
Taking Defective Turbochargers out of Operation
110
Table 46: Bypass Procedure
110
Fig. 64: Locking the Rotor
111
Table 47: Tightening Torque
111
Fig. 65: Ensuring Clamping of the Cover Ring
113
Table 48: Required Washers (01)
113
Table 49: Tightening Torque (57005)
113
Fig. 66: Position of Cover Plates
114
Mothballing the Turbocharger
115
Taking the Engine out of Operation for up to 12 Months
115
Taking the Engine out of Operation for more than 12 Months
116
Material and Disposal
117
REACH and Rohs Compliance Declaration for Products
117
Disposing of Turbocharger Components
118
Spare Parts
119
Ordering Spare Parts
119
Table 50: Customer Spare Part Set (97070)
119
Table 51: Customer Spare Part Set (97071)
120
Spare Part - Illustrations
121
Table 52: Spare Parts - Bearing Casing Common Parts
122
Table 53: Spare Parts - Bearing Casing Oil Tank
124
Table 54: Spare Parts - Cartridge
125
Table 55: Spare Parts - Compressor Casing
127
Table 56: Spare Parts - Filter Silencer
128
Table 57: Spare Parts - Gas Inlet Casing Axial
129
Table 58: Spare Parts - Gas Inlet Casing Radial
130
Table 59: Spare Parts - Gas Outlet Casing
131
Table 60: Spare Parts - Rotor and Bearing Parts
133
Table 61: Spare Parts - Sealing Air Supply for Flexible Cut-Out
134
Table 62: Spare Parts - Speed Measurement
135
Table 63: Spare Parts - U-Tube Manometer
136
Table 64: Spare Parts - Turbine Dry Cleaning Radial
138
Tools
139
Table 65: Customer Tool Set 90000
139
ABB A165-L35 Operation Manual (140 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 23.57 MB
Table of Contents
Introduction
3
Table of Contents
3
Introduction
4
Purpose of the Manual
4
Symbols, Definitions
5
Storage of New Turbochargers and Spare Parts
7
Contact Information
9
Safety
11
CE Conformity
12
Introduction
12
Safety
12
Definition of Mandatory Signs
13
Definition of Safety Instructions
13
Intended Use
14
Warning Plates on the Turbocharger
15
Turbocharger Rating Plate
16
Periodic Check of the Pressure Vessels
17
Lifting of Loads
18
Prerequisites for Operation and Maintenance
19
Hazards During Operation and Maintenance
20
Safe Operation
22
Safe Maintenance
23
Product Description
29
Essential Information
31
Introduction
31
Registered Trademarks
31
Related Documents
31
Table 1: Related Documents
31
Fig. 1: Layout and Function of the Turbocharger
32
Layout and Function of the Turbocharger
32
Fig. 2: Warning Plate Locations
34
Warning Plates on the Turbocharger
34
Fig. 3: Locations of the Rating Plates
35
Locations of the Rating Plates
35
Removal and Installation
36
Removing the Turbocharger
36
Table 2: Total Weight
36
Turbocharger Weight
36
Fig. 4: Fit the Lifting Gear
37
Fig. 5: Placing the Turbocharger
38
Installing the Turbocharger
38
Fig. 6: Compressor-End Foot
39
Fig. 7: Turbine-End Foot
39
Table 3: General Information about Fastening the Turbocharger
39
Table 4: Tightening Torques (Foot Screws)
40
Table 5: Tightening Angle (Foot Screws)
40
Commissioning
41
Inspection Procedures
41
Oil Supply
41
Commissioning after Taking out of Operation
43
Monitoring During Operation
44
Oil Pressure, Oil Temperature
44
Table 6: Lubricating Oil Pressure, Oil Inlet
44
Fig. 8: Oil Temperature at the Outlet
45
Table 7: Lubricating Oil Temperature at the Inlet
45
Table 8: Lubricating Oil Temperature at the Outlet
45
Admissible Air Inlet Temperature
47
Fig. 9: Layout and Overview of the Speed Measurement System
47
Turbocharger Speed
47
Fig. 10: Replacing the Speed Sensor
49
Table 9: Tightening Torques (86505)
49
Fig. 11: U-Tube Manometer at the Filter Silencer
50
Low Pressure Measurement at the Filter Silencer
50
Noise Emission
51
Operation and Service
51
Fig. 12: Noise Insulation, Bellows
52
Service Work
52
Expected Replacement Intervals
56
Table 10: Expected Replacement Intervals for Turbocharger Parts
56
Table 11: Recommended Replacement Intervals for Turbocharger Parts
56
Flexible Turbocharger Cut-Out
57
Stopping the Engine
58
Foreword to Maintenance
59
Periodic Maintenance
59
Cleaning the Filter Silencer
60
Fig. 13: Layout and Overview of Filter Silencer
60
Changing the Filter Strip on the Filter Silencer Casing
62
Fig. 14: Dismantling Filter Ring Circumferential Part
62
Fig. 15: Opening Filter Ring Lock
62
Fig. 16: Attaching New Filter Ring
63
Fig. 17: Fitting New Filter Ring
63
Cleaning the Compressor During Operation
64
Fig. 18: Overview of Wet Cleaning of Compressor
66
Fig. 19: Filter Plug View
67
Table 12: Volume of Water Per Cleaning Process
67
Table 13: Tightening Torques (81125)
67
Cleaning the Turbine During Operation
68
Fig. 20: Overview of Dry Cleaning Device
69
Table 14: Amount of Granulate
71
Draining the Gas Outlet Casing
72
Fig. 21: Drain Pipe Diagram
72
Malfunctions When Starting
73
Table 15: Malfunctions When Starting - Delayed Start-Up
73
Table 16: Malfunctions When Starting - Vibrations
73
Table 17: Malfunctions When Starting - Rubbing of Rotating Parts
73
Troubleshooting
73
Malfunctions During Operation
74
Table 18: Malfunctions During Operation - Lubricating Oil Pressure too Low
74
Table 19: Malfunctions During Operation - Drop in Speed
74
Table 20: Malfunctions During Operation - Exhaust Gas Temperature too High
75
Table 21: Malfunctions During Operation - Charge Air Pressure too Low
75
Surging of the Turbocharger
76
Table 22: Malfunctions During Operation - Charge Air Pressure too High
76
Table 23: Surging of the Turbocharger
76
Malfunctions When Stopping
77
Table 24: Malfunctions When Stopping - Runout Noises
77
Table 25: Malfunctions When Stopping - Shortened Runout Time
77
Speed Measurement System
78
Table 26: Malfunctions of the Speed Measurement System
78
Disassembly and Assembly
79
Introduction
79
Fig. 22: Weights of Assemblies
81
Table 27: Weights of Assemblies [Kg]
81
Table 28: Weight of Wall Insert [Kg]
81
Weights of Assemblies
81
Disassembly and Assembly of the Filter Silencer Casing
82
Fig. 23: Dismantling the Filter Silencer Casing
82
Fig. 24: Fitting the Filter Silencer Casing
83
Fig. 25: Fitting the Filter Silencer Casing
84
Fig. 26: Fitting the Filter Silencer Casing
84
Fig. 27: Fitting the Filter Silencer Casing
85
Fig. 28: Fitting the Filter Silencer Casing
85
Fig. 29: Fitting the Bellows
86
Table 29: Tightening Torques (Filter Silencer Screws)
86
Dismantling the Filter Silencer
87
Fig. 30: Dismantling the Filter Silencer
87
Fig. 31: Dismantling the Filter Silencer
88
Dismantling the Filter Silencer with Noise Package
89
Fig. 32: Dismantling the Filter Silencer with Noise Package
89
Dismantling Wall Insert and Diffuser
90
Fig. 33: Pressing off Compressor Casing
90
Fig. 34: Moving out Wall Insert
91
Fig. 35: Putting down Wall Insert
91
Fig. 36: Putting down Wall Insert
92
Fig. 37: Dismantling the Diffuser
93
Axial Clearance a Prior to Disassembly
94
Fig. 38: Measuring Axial Clearance a
94
Table 30: Axial Clearance a
94
Dismantling the Insulation (≤ A175-L)
95
Fig. 39: Removing the Insulation (A175-L and Smaller)
95
Dismantling the Gas Inlet Casing (≤ A175-L)
96
Fig. 40: Dismantling the Gas Inlet Casing (A175-L and Smaller) - Screwed Variant
96
Fig. 41: Dismantling the Gas Inlet Casing (A175-L and Smaller) - Threaded Stud Variant
97
Table 31: Maximum Admissible Loosening Torque (51087)
97
Dismantling the Nozzle Ring (≤ A175-L)
98
Fig. 42: Dismantling the Nozzle Ring (A175-L and Smaller)
98
Dismantling the Gas Inlet Casing (≥ A180-L)
99
Fig. 43: Dismantling the Gas Inlet Casing (A180-L and Larger) - Screwed Variant
99
Fig. 44: Dismantling the Gas Inlet Casing (180-L and Larger) - Threaded Stud Variant
100
Table 32: Maximum Admissible Loosening Torque (51087)
100
Dismantling the Nozzle Ring (≥ A180-L)
101
Fig. 45: Fitting the Nozzle Ring Holder
101
Fig. 46: Dismantling the Nozzle Ring
102
Fig. 47: Put down the Nozzle Ring
102
Fig. 48: Fitting the Nozzle Ring (A175-L and Smaller)
103
Fitting the Nozzle Ring (≤ A175-L)
103
Table 33: Tightening Torque (56014)
103
Fig. 49: Fitting the Gas Inlet Casing (A175-L and Smaller) - Screwed Variant
104
Fitting the Gas Inlet Casing (≤ A175-L)
104
Table 34: Tightening Torque (61009)
104
Fig. 50: Fitting the Gas Inlet Casing (A175-L and Smaller) - Threaded Stud Variant
105
Table 35: Tightening Torque (51087)
105
Fig. 51: Fitting the Insulation (A175-L and Smaller)
106
Fitting the Insulation (≤ A175-L)
106
Fig. 52: Looping Around the Nozzle Ring (A180-L and Larger)
107
Fitting the Nozzle Ring (≥ A180-L)
107
Fig. 53: Fitting the Nozzle Ring (A180-L and Larger)
108
Table 36: Tightening Torque (56014)
108
Fig. 54: Fitting the Gas Inlet Casing (A180-L and Larger) - Screwed Variant
109
Fitting the Gas Inlet Casing (≥ A180-L)
109
Table 37: Tightening Torque (61009)
109
Fig. 55: Fitting the Gas Inlet Casing (A180-L and Larger) - Threaded Stud Variant
110
Table 38: Tightening Torque (51087)
110
Axial Clearance a after Assembly
111
Fig. 56: Measuring Axial Clearance a
111
Table 39: Axial Clearance a
111
Fig. 57: Fitting the Diffuser
112
Fitting the Diffuser
112
Table 40: Tightening Torque (77015)
112
Fig. 58: Positioning Wall Insert
113
Fitting Wall Insert
113
Fig. 59: Fitting Wall Insert
114
Table 41: Tightening Torque (72011)
114
Fig. 60: Fitting the Filter Silencer
115
Fitting the Filter Silencer
115
Table 42: Tightening Torque (72004)
115
Fig. 61: Fitting the Filter Silencer
116
Table 43: Tightening Torque (72004)
116
Fig. 62: Fitting the Filter Silencer with Noise Package
117
Fitting the Filter Silencer with Noise Package
117
Table 44: Tightening Torque (51087)
117
Fig. 63: Overview of Tightening Torques
120
Fig. 64: Tightening Torques of Speed Sensor
120
Table of Tightening Torques
120
Table 45: Overview of Tightening Torques
121
Table 46: Tightening Torque, Insulation
121
Possible Emergency Repairs
122
Taking a Turbocharger out of Operation
122
Table 47: Bypass Procedure
123
Taking Defective Turbochargers out of Operation
123
Fig. 65: Locking the Rotor
124
Table 48: Tightening Torque
125
Fig. 66: Ensuring Clamping of the Cover Ring
126
Table 49: Required Washers (01)
126
Table 50: Tightening Torque (57005)
126
Fig. 67: Position of Cover Plates
127
Mothballing the Turbocharger
129
Taking the Engine out of Operation for up to 12 Months
129
Taking the Engine out of Operation for more than 12 Months
130
Disposing of Turbocharger Components
131
Ordering Spare Parts
132
Spare Parts
132
Table 51: Customer Spare Part Set (97070)
132
Table 52: Customer Spare Part Set (97071)
133
Fig. 68: View of Turbocharger with Part Numbers
134
View of Turbocharger with Part Numbers
134
Table 53: Turbocharger with Part Numbers
135
Fig. 69: View of Cartridge Group with Part Numbers
136
View of Cartridge Group with Part Numbers
136
Table 54: Cartridge Group with Part Numbers
137
ABB A165-L35 Operation Manual (138 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 25.3 MB
Table of Contents
Introduction
3
Table of Contents
3
Introduction
4
Purpose of the Manual
4
Symbols, Definitions
5
Storage of New Turbochargers and Spare Parts
7
Contact Information
9
Safety
11
CE Conformity
12
Introduction
12
Safety
12
Definition of Mandatory Signs
13
Definition of Safety Instructions
13
Intended Use
14
Warning Plates on the Turbocharger
15
Turbocharger Rating Plate
16
Periodic Check of the Pressure Vessels
17
Lifting of Loads
18
Prerequisites for Operation and Maintenance
19
Hazards During Operation and Maintenance
20
Safe Operation
22
Safe Maintenance
23
Product Description
29
Essential Information
31
Introduction
31
Registered Trademarks
31
Related Documents
31
Table 1: Related Documents
31
Fig. 1: Layout and Function of the Turbocharger
32
Layout and Function of the Turbocharger
32
Fig. 2: Warning Plate Locations
34
Warning Plates on the Turbocharger
34
Fig. 3: Locations of the Rating Plates
35
Locations of the Rating Plates
35
Removal and Installation
36
Removing the Turbocharger
36
Table 2: A100-L Weights
36
Turbocharger Weight
36
Fig. 4: Fitting Lifting Gear to Turbocharger
37
Fig. 5: Placing the Turbocharger on the Bracket
38
Installing the Turbocharger
38
Fig. 6: Compressor-End Foot
39
Fig. 7: Turbine-End Foot
39
Table 3: General Information about Fastening the Turbocharger
39
Table 4: Tightening Torques (Foot Screws)
40
Table 5: Tightening Angle (Foot Screws)
40
Commissioning
41
Inspection Procedures
41
Oil Supply
41
Commissioning after Taking out of Operation
43
Monitoring During Operation
44
Oil Pressure, Oil Temperature
44
Table 6: Lubricating Oil Pressure, Oil Inlet
44
Table 7: Lubricating Oil Temperature at the Inlet
44
Table 8: Lubricating Oil Temperature at the Outlet
45
Admissible Air Inlet Temperature
46
Fig. 8: Layout and Overview of the Speed Measurement System
46
Turbocharger Speed
46
Fig. 9: Replacing the Speed Sensor
48
Table 9: Tightening Torques (86505)
48
Fig. 10: U-Tube Manometer at the Filter Silencer
49
Low Pressure Measurement at the Filter Silencer
49
Noise Emission
50
Operation and Service
50
Fig. 11: Noise Insulation, Bellows
51
Service Work
51
Expected Replacement Intervals
55
Table 10: Expected Replacement Intervals for Turbocharger Parts
55
Table 11: Recommended Replacement Intervals for Turbocharger Parts
55
Flexible Turbocharger Cut-Out
56
Stopping the Engine
57
Foreword to Maintenance
58
Periodic Maintenance
58
Cleaning the Filter Silencer
59
Fig. 12: Layout and Overview of Filter Silencer
59
Changing the Filter Strip on the Filter Silencer Casing
61
Fig. 13: Dismantling Filter Ring Circumferential Part
61
Fig. 14: Opening Filter Ring Lock
61
Fig. 15: Attaching New Filter Ring
62
Fig. 16: Fitting New Filter Ring
62
Cleaning the Compressor During Operation
63
Fig. 17: Overview of Wet Cleaning of Compressor
65
Fig. 18: Filter Plug View
66
Table 12: Volume of Water Per Cleaning Process
66
Table 13: Tightening Torques (81125)
66
Cleaning the Turbine During Operation
67
Fig. 19: Overview of Dry Cleaning Device
68
Table 14: Amount of Granulate
70
Draining the Gas Outlet Casing
71
Fig. 20: Drain Pipe Diagram
71
Malfunctions When Starting
72
Table 15: Malfunctions When Starting - Delayed Start-Up
72
Table 16: Malfunctions When Starting - Vibrations
72
Table 17: Malfunctions When Starting - Rubbing of Rotating Parts
72
Troubleshooting
72
Malfunctions During Operation
73
Table 18: Malfunctions During Operation - Lubricating Oil Pressure too Low
73
Table 19: Malfunctions During Operation - Drop in Speed
73
Table 20: Malfunctions During Operation - Exhaust Gas Temperature too High
74
Table 21: Malfunctions During Operation - Charge Air Pressure too Low
74
Surging of the Turbocharger
75
Table 22: Malfunctions During Operation - Charge Air Pressure too High
75
Table 23: Surging of the Turbocharger
75
Malfunctions When Stopping
76
Table 24: Malfunctions When Stopping - Runout Noises
76
Table 25: Malfunctions When Stopping - Shortened Runout Time
76
Speed Measurement System
77
Table 26: Malfunctions of the Speed Measurement System
77
Disassembly and Assembly
78
Introduction
78
Fig. 21: Overview of Assembly Weights
80
Table 27: Weights of Assemblies [Kg]
80
Table 28: Weight of Wall Insert [Kg]
80
Weights of Assemblies
80
Disassembly and Assembly of the Filter Silencer Casing
81
Fig. 22: Overview of Filter Silencer Casing Disassembly and Assembly
81
Fig. 23: Fitting Filter Silencer Casing 1
82
Fig. 24: Fitting Filter Silencer Casing 2
83
Fig. 25: Fitting Filter Silencer Casing 3
83
Fig. 26: Fitting Filter Silencer Casing 4
84
Fig. 27: Fitting Filter Silencer Casing 5
84
Fig. 28: Fitting the Bellows
85
Table 29: Tightening Torques (Filter Silencer Screws)
85
Dismantling the Filter Silencer
86
Fig. 29: Dismantling the Filter Silencer
86
Fig. 30: Dismantling the Filter Silencer
87
Dismantling the Filter Silencer with Noise Package
88
Fig. 31: Dismantling the Filter Silencer with Noise Package
88
Dismantling Wall Insert and Diffuser
89
Fig. 32: Pressing off Compressor Casing
89
Fig. 33: Moving out Wall Insert
90
Fig. 34: Putting down Wall Insert
90
Fig. 35: Putting down Wall Insert
91
Fig. 36: Dismantling the Diffuser
92
Axial Clearance a Prior to Disassembly
93
Fig. 37: Measuring Axial Clearance a
93
Table 30: Admissible Axial Clearance a
93
Dismantling the Insulation, the Gas Inlet Casing and the Nozzle Ring (A175-L and Smaller)
94
Fig. 38: Removing the Insulation (A175-L and Smaller)
94
Fig. 39: Dismantling the Gas Inlet Casing (A175-L and Smaller) - Screwed Variant
95
Fig. 40: Dismantling the Gas Inlet Casing (175-L and Smaller) - Threaded Stud Variant
96
Table 31: Maximum Admissible Loosening Torque (51087)
96
Fig. 41: Dismantling the Nozzle Ring (A175-L and Smaller)
97
Dismantling the Gas Inlet Casing, Nozzle Ring (A180-L and Larger)
98
Fig. 42: Dismantling the Gas Inlet Casing (A180-L and Larger) - Screwed Variant
98
Fig. 43: Dismantling the Gas Inlet Casing (180-L and Larger) - Threaded Stud Variant
99
Table 32: Maximum Admissible Loosening Torque (51087)
99
Fig. 44: Fitting the Nozzle Ring Holder
100
Fig. 45: Dismantling the Nozzle Ring (A180-L and Larger)
101
Fig. 46: Putting down the Nozzle Ring (A180-L and Larger)
101
Fig. 47: Fitting the Nozzle Ring (A175-L and Smaller)
102
Fitting the Gas Inlet Casing, the Nozzle Ring and the Insulation (A175-L and Smaller)
102
Table 33: Tightening Torque (56014)
102
Fig. 48: Fitting the Gas Inlet Casing (A175-L and Smaller) - Screwed Variant
103
Table 34: Tightening Torque (61009)
103
Fig. 49: Fitting the Gas Inlet Casing (A175-L and Smaller) - Threaded Stud Variant
104
Table 35: Tightening Torque (51087)
104
Fig. 50: Fit Insulation
105
Fig. 51: Looping Around the Nozzle Ring (A180-L and Larger)
106
Fitting the Gas Inlet Casing, Nozzle Ring (A180-L and Larger)
106
Fig. 52: Fitting the Nozzle Ring (2) (A180-L and Larger)
107
Table 36: Tightening Torque (56014)
107
Fig. 53: Fitting the Gas Inlet Casing (A180-L and Larger) - Screwed Variant
108
Table 37: Tightening Torque (61009)
108
Fig. 54: Fitting the Gas Inlet Casing (A180-L and Larger) - Threaded Stud Variant
109
Table 38: Tightening Torque (51087)
109
Axial Clearance a after Assembly
110
Fig. 55: Measuring Axial Clearance a
110
Table 39: Admissible Axial Clearance a
110
Fig. 56: Fitting the Diffuser
111
Fitting Diffuser, Wall Insert
111
Table 40: Tightening Torque (77015)
111
Fig. 57: Positioning Wall Insert
112
Fig. 58: Fitting the Wall Insert
113
Table 41: Tightening Torque (72011)
113
Fig. 59: Fitting the Filter Silencer
114
Fitting the Filter Silencer
114
Table 42: Tightening Torque (72004)
114
Fig. 60: Fitting the Filter Silencer
115
Table 43: Tightening Torque (72004)
115
Fig. 61: Fitting the Filter Silencer with Noise Package
116
Fitting the Filter Silencer with Noise Package
116
Table 44: Tightening Torques (72004, 74043)
116
Fig. 63: Overview of Speed Sensor Tightening Torque
118
Table of Tightening Torques
118
Fig. 62: Overview of Tightening Torques
119
Table 45: Overview of Tightening Torques
119
Table 46: Tightening Torque, Insulation
119
Possible Emergency Repairs
120
Taking a Turbocharger out of Operation
120
Table 47: Bypass Procedure
121
Taking Defective Turbochargers out of Operation
121
Fig. 64: Locking the Rotor
122
Table 48: Tightening Torque
123
Fig. 65: Ensuring Clamping of the Cover Ring
124
Table 49: Required Washers (01)
124
Table 50: Tightening Torque (57005)
124
Fig. 66: Position of Cover Plates
125
Mothballing the Turbocharger
126
Taking the Engine out of Operation for up to 12 Months
126
Taking the Engine out of Operation for more than 12 Months
127
Disposing of Turbocharger Components
128
Ordering Spare Parts
129
Spare Parts
129
Table 51: Customer Spare Part Set (97070)
129
Table 52: Customer Spare Part Set (97071)
130
Fig. 67: View of Turbocharger with Part Numbers
132
View of Turbocharger with Part Numbers
132
Table 53: Turbocharger with Part Numbers
133
Fig. 68: View of Cartridge Group with Part Numbers
134
View of Cartridge Group with Part Numbers
134
Table 54: Cartridge Group with Part Numbers
135
ABB A165-L35 Operation Manual (138 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 25.3 MB
Table of Contents
Introduction
3
Table of Contents
3
Introduction
4
Purpose of the Manual
4
Symbols, Definitions
5
Storage of New Turbochargers and Spare Parts
7
Contact Information
9
Safety
11
CE Conformity
12
Introduction
12
Safety
12
Definition of Mandatory Signs
13
Definition of Safety Instructions
13
Intended Use
14
Warning Plates on the Turbocharger
15
Turbocharger Rating Plate
16
Periodic Check of the Pressure Vessels
17
Lifting of Loads
18
Prerequisites for Operation and Maintenance
19
Hazards During Operation and Maintenance
20
Safe Operation
22
Safe Maintenance
23
Product Description
29
Essential Information
31
Introduction
31
Registered Trademarks
31
Related Documents
31
Table 1: Related Documents
31
Fig. 1: Layout and Function of the Turbocharger
32
Layout and Function of the Turbocharger
32
Fig. 2: Warning Plate Locations
34
Warning Plates on the Turbocharger
34
Fig. 3: Locations of the Rating Plates
35
Locations of the Rating Plates
35
Removal and Installation
36
Removing the Turbocharger
36
Table 2: A100-L Weights
36
Turbocharger Weight
36
Fig. 4: Fitting Lifting Gear to Turbocharger
37
Fig. 5: Placing the Turbocharger on the Bracket
38
Installing the Turbocharger
38
Fig. 6: Compressor-End Foot
39
Fig. 7: Turbine-End Foot
39
Table 3: General Information about Fastening the Turbocharger
39
Table 4: Tightening Torques (Foot Screws)
40
Table 5: Tightening Angle (Foot Screws)
40
Commissioning
41
Inspection Procedures
41
Oil Supply
41
Commissioning after Taking out of Operation
43
Monitoring During Operation
44
Oil Pressure, Oil Temperature
44
Table 6: Lubricating Oil Pressure, Oil Inlet
44
Table 7: Lubricating Oil Temperature at the Inlet
44
Table 8: Lubricating Oil Temperature at the Outlet
45
Admissible Air Inlet Temperature
46
Fig. 8: Layout and Overview of the Speed Measurement System
46
Turbocharger Speed
46
Fig. 9: Replacing the Speed Sensor
48
Table 9: Tightening Torques (86505)
48
Fig. 10: U-Tube Manometer at the Filter Silencer
49
Low Pressure Measurement at the Filter Silencer
49
Noise Emission
50
Operation and Service
50
Fig. 11: Noise Insulation, Bellows
51
Service Work
51
Expected Replacement Intervals
55
Table 10: Expected Replacement Intervals for Turbocharger Parts
55
Table 11: Recommended Replacement Intervals for Turbocharger Parts
55
Flexible Turbocharger Cut-Out
56
Stopping the Engine
57
Foreword to Maintenance
58
Periodic Maintenance
58
Cleaning the Filter Silencer
59
Fig. 12: Layout and Overview of Filter Silencer
59
Changing the Filter Strip on the Filter Silencer Casing
61
Fig. 13: Dismantling Filter Ring Circumferential Part
61
Fig. 14: Opening Filter Ring Lock
61
Fig. 15: Attaching New Filter Ring
62
Fig. 16: Fitting New Filter Ring
62
Cleaning the Compressor During Operation
63
Fig. 17: Overview of Wet Cleaning of Compressor
65
Fig. 18: Filter Plug View
66
Table 12: Volume of Water Per Cleaning Process
66
Table 13: Tightening Torques (81125)
66
Cleaning the Turbine During Operation
67
Fig. 19: Overview of Dry Cleaning Device
68
Table 14: Amount of Granulate
70
Draining the Gas Outlet Casing
71
Fig. 20: Drain Pipe Diagram
71
Malfunctions When Starting
72
Table 15: Malfunctions When Starting - Delayed Start-Up
72
Table 16: Malfunctions When Starting - Vibrations
72
Table 17: Malfunctions When Starting - Rubbing of Rotating Parts
72
Troubleshooting
72
Malfunctions During Operation
73
Table 18: Malfunctions During Operation - Lubricating Oil Pressure too Low
73
Table 19: Malfunctions During Operation - Drop in Speed
73
Table 20: Malfunctions During Operation - Exhaust Gas Temperature too High
74
Table 21: Malfunctions During Operation - Charge Air Pressure too Low
74
Surging of the Turbocharger
75
Table 22: Malfunctions During Operation - Charge Air Pressure too High
75
Table 23: Surging of the Turbocharger
75
Malfunctions When Stopping
76
Table 24: Malfunctions When Stopping - Runout Noises
76
Table 25: Malfunctions When Stopping - Shortened Runout Time
76
Speed Measurement System
77
Table 26: Malfunctions of the Speed Measurement System
77
Disassembly and Assembly
78
Introduction
78
Fig. 21: Overview of Assembly Weights
80
Table 27: Weights of Assemblies [Kg]
80
Table 28: Weight of Wall Insert [Kg]
80
Weights of Assemblies
80
Disassembly and Assembly of the Filter Silencer Casing
81
Fig. 22: Overview of Filter Silencer Casing Disassembly and Assembly
81
Fig. 23: Fitting Filter Silencer Casing 1
82
Fig. 24: Fitting Filter Silencer Casing 2
83
Fig. 25: Fitting Filter Silencer Casing 3
83
Fig. 26: Fitting Filter Silencer Casing 4
84
Fig. 27: Fitting Filter Silencer Casing 5
84
Fig. 28: Fitting the Bellows
85
Table 29: Tightening Torques (Filter Silencer Screws)
85
Dismantling the Filter Silencer
86
Fig. 29: Dismantling the Filter Silencer
86
Fig. 30: Dismantling the Filter Silencer
87
Dismantling the Filter Silencer with Noise Package
88
Fig. 31: Dismantling the Filter Silencer with Noise Package
88
Dismantling Wall Insert and Diffuser
89
Fig. 32: Pressing off Compressor Casing
89
Fig. 33: Moving out Wall Insert
90
Fig. 34: Putting down Wall Insert
90
Fig. 35: Putting down Wall Insert
91
Fig. 36: Dismantling the Diffuser
92
Axial Clearance a Prior to Disassembly
93
Fig. 37: Measuring Axial Clearance a
93
Table 30: Admissible Axial Clearance a
93
Dismantling the Insulation, the Gas Inlet Casing and the Nozzle Ring (A175-L and Smaller)
94
Fig. 38: Removing the Insulation (A175-L and Smaller)
94
Fig. 39: Dismantling the Gas Inlet Casing (A175-L and Smaller) - Screwed Variant
95
Fig. 40: Dismantling the Gas Inlet Casing (175-L and Smaller) - Threaded Stud Variant
96
Table 31: Maximum Admissible Loosening Torque (51087)
96
Fig. 41: Dismantling the Nozzle Ring (A175-L and Smaller)
97
Dismantling the Gas Inlet Casing, Nozzle Ring (A180-L and Larger)
98
Fig. 42: Dismantling the Gas Inlet Casing (A180-L and Larger) - Screwed Variant
98
Fig. 43: Dismantling the Gas Inlet Casing (180-L and Larger) - Threaded Stud Variant
99
Table 32: Maximum Admissible Loosening Torque (51087)
99
Fig. 44: Fitting the Nozzle Ring Holder
100
Fig. 45: Dismantling the Nozzle Ring (A180-L and Larger)
101
Fig. 46: Putting down the Nozzle Ring (A180-L and Larger)
101
Fig. 47: Fitting the Nozzle Ring (A175-L and Smaller)
102
Fitting the Gas Inlet Casing, the Nozzle Ring and the Insulation (A175-L and Smaller)
102
Table 33: Tightening Torque (56014)
102
Fig. 48: Fitting the Gas Inlet Casing (A175-L and Smaller) - Screwed Variant
103
Table 34: Tightening Torque (61009)
103
Fig. 49: Fitting the Gas Inlet Casing (A175-L and Smaller) - Threaded Stud Variant
104
Table 35: Tightening Torque (51087)
104
Fig. 50: Fit Insulation
105
Fig. 51: Looping Around the Nozzle Ring (A180-L and Larger)
106
Fitting the Gas Inlet Casing, Nozzle Ring (A180-L and Larger)
106
Fig. 52: Fitting the Nozzle Ring (2) (A180-L and Larger)
107
Table 36: Tightening Torque (56014)
107
Fig. 53: Fitting the Gas Inlet Casing (A180-L and Larger) - Screwed Variant
108
Table 37: Tightening Torque (61009)
108
Fig. 54: Fitting the Gas Inlet Casing (A180-L and Larger) - Threaded Stud Variant
109
Table 38: Tightening Torque (51087)
109
Axial Clearance a after Assembly
110
Fig. 55: Measuring Axial Clearance a
110
Table 39: Admissible Axial Clearance a
110
Fig. 56: Fitting the Diffuser
111
Fitting Diffuser, Wall Insert
111
Table 40: Tightening Torque (77015)
111
Fig. 57: Positioning Wall Insert
112
Fig. 58: Fitting the Wall Insert
113
Table 41: Tightening Torque (72011)
113
Fig. 59: Fitting the Filter Silencer
114
Fitting the Filter Silencer
114
Table 42: Tightening Torque (72004)
114
Fig. 60: Fitting the Filter Silencer
115
Table 43: Tightening Torque (72004)
115
Fig. 61: Fitting the Filter Silencer with Noise Package
116
Fitting the Filter Silencer with Noise Package
116
Table 44: Tightening Torques (72004, 74043)
116
Fig. 63: Overview of Speed Sensor Tightening Torque
118
Table of Tightening Torques
118
Fig. 62: Overview of Tightening Torques
119
Table 45: Overview of Tightening Torques
119
Table 46: Tightening Torque, Insulation
119
Possible Emergency Repairs
120
Taking a Turbocharger out of Operation
120
Table 47: Bypass Procedure
121
Taking Defective Turbochargers out of Operation
121
Fig. 64: Locking the Rotor
122
Table 48: Tightening Torque
123
Fig. 65: Ensuring Clamping of the Cover Ring
124
Table 49: Required Washers (01)
124
Table 50: Tightening Torque (57005)
124
Fig. 66: Position of Cover Plates
125
Mothballing the Turbocharger
126
Taking the Engine out of Operation for up to 12 Months
126
Taking the Engine out of Operation for more than 12 Months
127
Disposing of Turbocharger Components
128
Ordering Spare Parts
129
Spare Parts
129
Table 51: Customer Spare Part Set (97070)
129
Table 52: Customer Spare Part Set (97071)
130
Fig. 67: View of Turbocharger with Part Numbers
132
View of Turbocharger with Part Numbers
132
Table 53: Turbocharger with Part Numbers
133
Fig. 68: View of Cartridge Group with Part Numbers
134
View of Cartridge Group with Part Numbers
134
Table 54: Cartridge Group with Part Numbers
135
ABB A165-L35 Operation Manual (134 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 24.92 MB
Table of Contents
Introduction
3
Table of Contents
3
Introduction
4
Purpose of the Manual
4
Symbols, Definitions
5
Storage of New Turbochargers and Spare Parts
7
Contact Information
9
Safety
11
CE Conformity
12
Introduction
12
Safety
12
Definition of Mandatory Signs
13
Definition of Safety Instructions
13
Intended Use
14
Warning Plates on the Turbocharger
15
Turbocharger Rating Plate
16
Periodic Check of the Pressure Vessels
17
Lifting of Loads
18
Prerequisites for Operation and Maintenance
19
Hazards During Operation and Maintenance
20
Safe Operation
22
Safe Maintenance
23
Product Description
29
Essential Information
31
Introduction
31
Registered Trademarks
31
Related Documents
31
Table 1: Related Documents
31
Fig. 1: Layout and Function of the Turbocharger
32
Layout and Function of the Turbocharger
32
Fig. 2: Warning Plate Locations
34
Warning Plates on the Turbocharger
34
Fig. 3: Locations of the Rating Plates
35
Locations of the Rating Plates
35
Removal and Installation
36
Removing the Turbocharger
36
Table 2: A100-L Weights
36
Turbocharger Weight
36
Fig. 4: Fitting Lifting Gear to Turbocharger
37
Fig. 5: Placing the Turbocharger on the Bracket
38
Installing the Turbocharger
38
Fig. 6: Compressor-End Foot
39
Fig. 7: Turbine-End Foot
39
Table 3: General Information about Fastening the Turbocharger
39
Table 4: Tightening Torques (Foot Screws)
40
Table 5: Tightening Angle (Foot Screws)
40
Commissioning
41
Inspection Procedures
41
Oil Supply
41
Commissioning after Taking out of Operation
43
Monitoring During Operation
44
Oil Pressure, Oil Temperature
44
Table 6: Lubricating Oil Pressure, Oil Inlet
44
Table 7: Lubricating Oil Temperature at the Inlet
44
Table 8: Lubricating Oil Temperature at the Outlet
45
Fig. 8: Layout and Overview of the Speed Measurement System
46
Turbocharger Speed
46
Fig. 9: Replacing the Speed Sensor
48
Table 9: Tightening Torques (86505)
48
Fig. 10: U-Tube Manometer at the Filter Silencer
50
Low Pressure Measurement at the Filter Silencer
50
Noise Emission
51
Operation and Service
51
Fig. 11: Noise Insulation, Bellows
52
Service Work
52
Expected Replacement Intervals
56
Table 10: Expected Replacement Intervals for Turbocharger Parts
56
Table 11: Recommended Replacement Intervals for Turbocharger Parts
56
Flexible Turbocharger Cut-Out
57
Stopping the Engine
58
Foreword to Maintenance
59
Periodic Maintenance
59
Cleaning the Filter Silencer
60
Fig. 12: Layout and Overview of Filter Silencer
60
Changing the Filter Strip on the Filter Silencer Casing
62
Fig. 13: Dismantling Filter Ring Circumferential Part
62
Fig. 14: Opening Filter Ring Lock
62
Fig. 15: Attaching New Filter Ring
63
Fig. 16: Fitting New Filter Ring
63
Cleaning the Compressor During Operation
64
Fig. 17: Overview of Wet Cleaning of Compressor
66
Fig. 18: Filter Plug View
67
Table 12: Volume of Water Per Cleaning Process
67
Table 13: Tightening Torques (81125)
67
Cleaning the Turbine During Operation
68
Fig. 19: Overview of Dry Cleaning Device
69
Table 14: Amount of Granulate
71
Draining the Gas Outlet Casing
72
Fig. 20: Drain Pipe Diagram
72
Malfunctions When Starting
73
Table 15: Malfunctions When Starting - Delayed Start-Up
73
Table 16: Malfunctions When Starting - Vibrations
73
Table 17: Malfunctions When Starting - Rubbing of Rotating Parts
73
Troubleshooting
73
Malfunctions During Operation
74
Table 18: Malfunctions During Operation - Lubricating Oil Pressure too Low
74
Table 19: Malfunctions During Operation - Drop in Speed
74
Table 20: Malfunctions During Operation - Exhaust Gas Temperature too High
75
Table 21: Malfunctions During Operation - Charge Air Pressure too Low
75
Surging of the Turbocharger
76
Table 22: Malfunctions During Operation - Charge Air Pressure too High
76
Table 23: Surging of the Turbocharger
76
Malfunctions When Stopping
77
Table 24: Malfunctions When Stopping - Runout Noises
77
Table 25: Malfunctions When Stopping - Shortened Runout Time
77
Speed Measurement System
78
Table 26: Malfunctions of the Speed Measurement System
78
Disassembly and Assembly
79
Introduction
79
Fig. 21: Overview of Assembly Weights
81
Table 27: Weights of Assemblies [Kg]
81
Table 28: Weight of Wall Insert [Kg]
81
Weights of Assemblies
81
Disassembly and Assembly of the Filter Silencer Casing
82
Fig. 22: Overview of Filter Silencer Casing Disassembly and Assembly
82
Fig. 23: Fitting Filter Silencer Casing 1
83
Fig. 24: Fitting Filter Silencer Casing 2
84
Fig. 25: Fitting Filter Silencer Casing 3
84
Fig. 26: Fitting Filter Silencer Casing 4
85
Fig. 27: Fitting Filter Silencer Casing 5
85
Fig. 28: Fitting the Bellows
86
Table 29: Tightening Torques (Filter Silencer Screws)
86
Dismantling the Filter Silencer
87
Fig. 29: Dismantling the Filter Silencer
87
Fig. 30: Dismantling the Filter Silencer
88
Dismantling the Filter Silencer with Noise Package
89
Fig. 31: Dismantling the Filter Silencer with Noise Package
89
Dismantling Wall Insert and Diffuser
90
Fig. 32: Pressing off Compressor Casing
90
Fig. 33: Moving out Wall Insert
91
Fig. 34: Putting down Wall Insert
91
Fig. 35: Putting down Wall Insert
92
Fig. 36: Dismantling the Diffuser
93
Axial Clearance a Prior to Disassembly
94
Fig. 37: Measuring Axial Clearance a
94
Table 30: Admissible Axial Clearance a
94
Dismantling the Insulation, the Gas Inlet Casing and the Nozzle Ring (A175-L and Smaller)
95
Fig. 38: Removing the Insulation (A175-L and Smaller)
95
Fig. 39: Dismantling the Gas Inlet Casing (A175-L and Smaller)
96
Fig. 40: Dismantling the Nozzle Ring (A175-L and Smaller)
96
Dismantling the Gas Inlet Casing, Nozzle Ring (A180-L and Larger)
97
Fig. 41: Dismantling the Gas Inlet Casing (A180-L and Larger)
97
Fig. 42: Fitting the Nozzle Ring Holder
98
Fig. 43: Dismantling the Nozzle Ring (A180-L and Larger)
99
Fig. 44: Putting down the Nozzle Ring (A180-L and Larger)
99
Fig. 45: Fitting the Nozzle Ring (A175-L and Smaller)
100
Fitting the Gas Inlet Casing, the Nozzle Ring and the Insulation (A175-L and Smaller)
100
Table 31: Tightening Torque (56014)
100
Fig. 46: Fitting the Gas Outlet Casing (A175-L and Smaller)
101
Table 32: Tightening Torque (61009)
101
Fig. 47: Fit Insulation
102
Fig. 48: Looping Around the Nozzle Ring (A180-L and Larger)
103
Fitting the Gas Inlet Casing, Nozzle Ring (A180-L and Larger)
103
Fig. 49: Fitting the Nozzle Ring (2) (A180-L and Larger)
104
Table 33: Tightening Torque (56014)
104
Fig. 50: Fitting the Gas Inlet Casing (A180-L and Larger)
105
Table 34: Tightening Torque (61009)
105
Axial Clearance a after Assembly
106
Fig. 51: Measuring Axial Clearance a
106
Table 35: Admissible Axial Clearance a
106
Fig. 52: Fitting the Diffuser
107
Fitting Diffuser, Wall Insert
107
Table 36: Tightening Torque (77015)
107
Fig. 53: Positioning Wall Insert
108
Fig. 54: Fitting the Wall Insert
109
Table 37: Tightening Torque (72011)
109
Fig. 55: Fitting the Filter Silencer
110
Fitting the Filter Silencer
110
Table 38: Tightening Torque (72004)
110
Fig. 56: Fitting the Filter Silencer
111
Table 39: Tightening Torque (72004)
111
Fig. 57: Fitting the Filter Silencer with Noise Package
112
Fitting the Filter Silencer with Noise Package
112
Table 40: Tightening Torques (72004, 74043)
112
Fig. 59: Overview of Speed Sensor Tightening Torque
114
Table of Tightening Torques
114
Fig. 58: Overview of Tightening Torques
115
Table 41: Overview of Tightening Torques
115
Table 42: Tightening Torque, Insulation
115
Possible Emergency Repairs
117
Shutting off Oil Supply to Defective Turbocharger
117
Table 43: Procedure for Taking out of Operation
117
Taking a Turbocharger out of Operation
117
Procedure with One Installed Turbocharger
118
Fig. 60: Locking the Rotor
119
Fig. 61: Ensuring Clamping of the Cover Ring
120
Table 44: Tightening Torque (Locking Device)
120
Table 45: Required Washers (01)
121
Table 46: Tightening Torque (57005)
121
Fig. 62: Position of Cover Plates
122
Procedure with Two or more Installed Turbochargers
122
Mothballing the Turbocharger
123
Taking the Engine out of Operation for up to 12 Months
123
Taking the Engine out of Operation for more than 12 Months
124
Disposing of Turbocharger Components
125
Ordering Spare Parts
127
Spare Parts
127
Table 47: Customer Spare Part Set (97070)
127
Fig. 63: View of Turbocharger with Part Numbers
128
View of Turbocharger with Part Numbers
128
Table 48: Turbocharger with Part Numbers
129
Fig. 64: View of Cartridge Group with Part Numbers
130
View of Cartridge Group with Part Numbers
130
Table 49: Cartridge Group with Part Numbers
131
ABB A165-L35 Operation Manual (134 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 24.92 MB
Table of Contents
Introduction
3
Table of Contents
3
Introduction
4
Purpose of the Manual
4
Symbols, Definitions
5
Storage of New Turbochargers and Spare Parts
7
Contact Information
9
Safety
11
CE Conformity
12
Introduction
12
Safety
12
Definition of Mandatory Signs
13
Definition of Safety Instructions
13
Intended Use
14
Warning Plates on the Turbocharger
15
Turbocharger Rating Plate
16
Periodic Check of the Pressure Vessels
17
Lifting of Loads
18
Prerequisites for Operation and Maintenance
19
Hazards During Operation and Maintenance
20
Safe Operation
22
Safe Maintenance
23
Product Description
29
Essential Information
31
Introduction
31
Registered Trademarks
31
Related Documents
31
Table 1: Related Documents
31
Fig. 1: Layout and Function of the Turbocharger
32
Layout and Function of the Turbocharger
32
Fig. 2: Warning Plate Locations
34
Warning Plates on the Turbocharger
34
Fig. 3: Locations of the Rating Plates
35
Locations of the Rating Plates
35
Removal and Installation
36
Removing the Turbocharger
36
Table 2: A100-L Weights
36
Turbocharger Weight
36
Fig. 4: Fitting Lifting Gear to Turbocharger
37
Fig. 5: Placing the Turbocharger on the Bracket
38
Installing the Turbocharger
38
Fig. 6: Compressor-End Foot
39
Fig. 7: Turbine-End Foot
39
Table 3: General Information about Fastening the Turbocharger
39
Table 4: Tightening Torques (Foot Screws)
40
Table 5: Tightening Angle (Foot Screws)
40
Commissioning
41
Inspection Procedures
41
Oil Supply
41
Commissioning after Taking out of Operation
43
Monitoring During Operation
44
Oil Pressure, Oil Temperature
44
Table 6: Lubricating Oil Pressure, Oil Inlet
44
Table 7: Lubricating Oil Temperature at the Inlet
44
Table 8: Lubricating Oil Temperature at the Outlet
45
Fig. 8: Layout and Overview of the Speed Measurement System
46
Turbocharger Speed
46
Fig. 9: Replacing the Speed Sensor
48
Table 9: Tightening Torques (86505)
48
Fig. 10: U-Tube Manometer at the Filter Silencer
50
Low Pressure Measurement at the Filter Silencer
50
Noise Emission
51
Operation and Service
51
Fig. 11: Noise Insulation, Bellows
52
Service Work
52
Expected Replacement Intervals
56
Table 10: Expected Replacement Intervals for Turbocharger Parts
56
Table 11: Recommended Replacement Intervals for Turbocharger Parts
56
Flexible Turbocharger Cut-Out
57
Stopping the Engine
58
Foreword to Maintenance
59
Periodic Maintenance
59
Cleaning the Filter Silencer
60
Fig. 12: Layout and Overview of Filter Silencer
60
Changing the Filter Strip on the Filter Silencer Casing
62
Fig. 13: Dismantling Filter Ring Circumferential Part
62
Fig. 14: Opening Filter Ring Lock
62
Fig. 15: Attaching New Filter Ring
63
Fig. 16: Fitting New Filter Ring
63
Cleaning the Compressor During Operation
64
Fig. 17: Overview of Wet Cleaning of Compressor
66
Fig. 18: Filter Plug View
67
Table 12: Volume of Water Per Cleaning Process
67
Table 13: Tightening Torques (81125)
67
Cleaning the Turbine During Operation
68
Fig. 19: Overview of Dry Cleaning Device
69
Table 14: Amount of Granulate
71
Draining the Gas Outlet Casing
72
Fig. 20: Drain Pipe Diagram
72
Malfunctions When Starting
73
Table 15: Malfunctions When Starting - Delayed Start-Up
73
Table 16: Malfunctions When Starting - Vibrations
73
Table 17: Malfunctions When Starting - Rubbing of Rotating Parts
73
Troubleshooting
73
Malfunctions During Operation
74
Table 18: Malfunctions During Operation - Lubricating Oil Pressure too Low
74
Table 19: Malfunctions During Operation - Drop in Speed
74
Table 20: Malfunctions During Operation - Exhaust Gas Temperature too High
75
Table 21: Malfunctions During Operation - Charge Air Pressure too Low
75
Surging of the Turbocharger
76
Table 22: Malfunctions During Operation - Charge Air Pressure too High
76
Table 23: Surging of the Turbocharger
76
Malfunctions When Stopping
77
Table 24: Malfunctions When Stopping - Runout Noises
77
Table 25: Malfunctions When Stopping - Shortened Runout Time
77
Speed Measurement System
78
Table 26: Malfunctions of the Speed Measurement System
78
Disassembly and Assembly
79
Introduction
79
Fig. 21: Overview of Assembly Weights
81
Table 27: Weights of Assemblies [Kg]
81
Table 28: Weight of Wall Insert [Kg]
81
Weights of Assemblies
81
Disassembly and Assembly of the Filter Silencer Casing
82
Fig. 22: Overview of Filter Silencer Casing Disassembly and Assembly
82
Fig. 23: Fitting Filter Silencer Casing 1
83
Fig. 24: Fitting Filter Silencer Casing 2
84
Fig. 25: Fitting Filter Silencer Casing 3
84
Fig. 26: Fitting Filter Silencer Casing 4
85
Fig. 27: Fitting Filter Silencer Casing 5
85
Fig. 28: Fitting the Bellows
86
Table 29: Tightening Torques (Filter Silencer Screws)
86
Dismantling the Filter Silencer
87
Fig. 29: Dismantling the Filter Silencer
87
Fig. 30: Dismantling the Filter Silencer
88
Dismantling the Filter Silencer with Noise Package
89
Fig. 31: Dismantling the Filter Silencer with Noise Package
89
Dismantling Wall Insert and Diffuser
90
Fig. 32: Pressing off Compressor Casing
90
Fig. 33: Moving out Wall Insert
91
Fig. 34: Putting down Wall Insert
91
Fig. 35: Putting down Wall Insert
92
Fig. 36: Dismantling the Diffuser
93
Axial Clearance a Prior to Disassembly
94
Fig. 37: Measuring Axial Clearance a
94
Table 30: Admissible Axial Clearance a
94
Dismantling the Insulation, the Gas Inlet Casing and the Nozzle Ring (A175-L and Smaller)
95
Fig. 38: Removing the Insulation (A175-L and Smaller)
95
Fig. 39: Dismantling the Gas Inlet Casing (A175-L and Smaller)
96
Fig. 40: Dismantling the Nozzle Ring (A175-L and Smaller)
96
Dismantling the Gas Inlet Casing, Nozzle Ring (A180-L and Larger)
97
Fig. 41: Dismantling the Gas Inlet Casing (A180-L and Larger)
97
Fig. 42: Fitting the Nozzle Ring Holder
98
Fig. 43: Dismantling the Nozzle Ring (A180-L and Larger)
99
Fig. 44: Putting down the Nozzle Ring (A180-L and Larger)
99
Fig. 45: Fitting the Nozzle Ring (A175-L and Smaller)
100
Fitting the Gas Inlet Casing, the Nozzle Ring and the Insulation (A175-L and Smaller)
100
Table 31: Tightening Torque (56014)
100
Fig. 46: Fitting the Gas Outlet Casing (A175-L and Smaller)
101
Table 32: Tightening Torque (61009)
101
Fig. 47: Fit Insulation
102
Fig. 48: Looping Around the Nozzle Ring (A180-L and Larger)
103
Fitting the Gas Inlet Casing, Nozzle Ring (A180-L and Larger)
103
Fig. 49: Fitting the Nozzle Ring (2) (A180-L and Larger)
104
Table 33: Tightening Torque (56014)
104
Fig. 50: Fitting the Gas Inlet Casing (A180-L and Larger)
105
Table 34: Tightening Torque (61009)
105
Axial Clearance a after Assembly
106
Fig. 51: Measuring Axial Clearance a
106
Table 35: Admissible Axial Clearance a
106
Fig. 52: Fitting the Diffuser
107
Fitting Diffuser, Wall Insert
107
Table 36: Tightening Torque (77015)
107
Fig. 53: Positioning Wall Insert
108
Fig. 54: Fitting the Wall Insert
109
Table 37: Tightening Torque (72011)
109
Fig. 55: Fitting the Filter Silencer
110
Fitting the Filter Silencer
110
Table 38: Tightening Torque (72004)
110
Fig. 56: Fitting the Filter Silencer
111
Table 39: Tightening Torque (72004)
111
Fig. 57: Fitting the Filter Silencer with Noise Package
112
Fitting the Filter Silencer with Noise Package
112
Table 40: Tightening Torques (72004, 74043)
112
Fig. 59: Overview of Speed Sensor Tightening Torque
114
Table of Tightening Torques
114
Fig. 58: Overview of Tightening Torques
115
Table 41: Overview of Tightening Torques
115
Table 42: Tightening Torque, Insulation
115
Possible Emergency Repairs
117
Shutting off Oil Supply to Defective Turbocharger
117
Table 43: Procedure for Taking out of Operation
117
Taking a Turbocharger out of Operation
117
Procedure with One Installed Turbocharger
118
Fig. 60: Locking the Rotor
119
Fig. 61: Ensuring Clamping of the Cover Ring
120
Table 44: Tightening Torque (Locking Device)
120
Table 45: Required Washers (01)
121
Table 46: Tightening Torque (57005)
121
Fig. 62: Position of Cover Plates
122
Procedure with Two or more Installed Turbochargers
122
Mothballing the Turbocharger
123
Taking the Engine out of Operation for up to 12 Months
123
Taking the Engine out of Operation for more than 12 Months
124
Disposing of Turbocharger Components
125
Ordering Spare Parts
127
Spare Parts
127
Table 47: Customer Spare Part Set (97070)
127
Fig. 63: View of Turbocharger with Part Numbers
128
View of Turbocharger with Part Numbers
128
Table 48: Turbocharger with Part Numbers
129
Fig. 64: View of Cartridge Group with Part Numbers
130
View of Cartridge Group with Part Numbers
130
Table 49: Cartridge Group with Part Numbers
131
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