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A175-L37
User Manuals: ABB A175-L37 Turbocharger Equipment
Manuals and User Guides for ABB A175-L37 Turbocharger Equipment. We have
5
ABB A175-L37 Turbocharger Equipment manuals available for free PDF download: Operation Manual
ABB A175-L37 Operation Manual (138 pages)
Brand:
ABB
| Category:
Battery Charger
| 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
Figures
136
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ABB A175-L37 Operation Manual (134 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 24.9 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
Figures
132
ABB A175-L37 Operation Manual (134 pages)
Turbocharging
Brand:
ABB
| Category:
Industrial Equipment
| Size: 24.9 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
Figures
132
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ABB A175-L37 Operation Manual (142 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.28 MB
Table of Contents
Introduction
3
Table of Contents
3
Introduction
5
Purpose of the Manual
5
Symbols, Definitions
6
Storage of New Turbochargers and Spare Parts
8
Contact Information
10
Safety
11
CE Conformity
13
Introduction
13
Safety
13
Definition of Mandatory Signs
14
Definition of Safety Instructions
14
Intended Use
15
Warning Plates on the Turbocharger
16
Turbocharger Rating Plate
17
Periodic Check of the Pressure Vessels
18
Lifting of Loads
19
Prerequisites for Operation and Maintenance
20
Hazards During Operation and Maintenance
21
Safe Operation
23
Safe Maintenance
24
Product Description
31
Essential Information
35
Introduction
35
Registered Trademarks
35
Related Documents
35
Table 1 Related Documents
35
Layout and Function of the Turbocharger
36
Warning Plates on the Turbocharger
38
Locations of the Rating Plates
39
Removal and Installation
41
Removing the Turbocharger
41
Table 2 A100-L Weights
41
Turbocharger Weight
41
Installing the Turbocharger
43
Table 3 General Information about
44
Table 4 Tightening Torques (Foot Screws)
45
Table 43 Tightening Torque
45
Table 5 Tightening Angle (Foot Screws)
45
Commissioning
47
Inspection Procedures
47
Oil Supply
47
Commissioning after Taking out of Operation
49
Monitoring During Operation
51
Oil Pressure, Oil Temperature
51
Table 6 Lubricating Oil Pressure, Oil
51
Table 7 Lubricating Oil Temperature at
51
Table 8 Lubricating Oil Temperature at
52
Turbocharger Speed
53
Table 9 Tightening Torques (86505)
55
Low Pressure Measurement at the Filter Silencer
57
Noise Emission
59
Operation and Service
59
Service Work
60
Expected Replacement Intervals
64
Table 10 Expected Replacement Inter
64
Table 11 Recommended Replacement Intervals for Turbocharger Parts
64
Flexible Turbocharger Cut-Out
65
Stopping the Engine
66
Foreword to Maintenance
67
Periodic Maintenance
67
Cleaning the Filter Silencer
68
Changing the Filter Strip on the Filter Silencer Casing
70
Cleaning the Compressor During Operation
72
Table 12 Volume of Water Per Cleaning
75
Table 13 Tightening Torques (81125)
75
Cleaning the Turbine During Operation
76
Table 14 Amount of Granulate
79
Draining the Gas Outlet Casing
80
Malfunctions When Starting
81
Table 15 Malfunctions When Starting
81
Table 16 Malfunctions When Starting
81
Table 17 Malfunctions When Starting - Rubbing of Rotating Parts
81
Troubleshooting
81
Malfunctions During Operation
82
Table 18 Malfunctions During Operation - Lubricating Oil Pressure too Low
82
Table 19 Malfunctions During Operation - Speed Reductions
82
Table 20 Malfunctions During Operation - Exhaust Gas Temperature too High
83
Table 21 Malfunctions During Operation - Charge Air Pressure too Low
83
Surging of the Turbocharger
84
Table 22 Malfunctions During Operation - Charge Air Pressure too High
84
Table 23 Surging of the Turbocharger
84
Malfunctions When Stopping
85
Table 24 Malfunctions When Stopping - Noises During Run-Down
85
Table 25 Malfunctions When Stopping - Run-Down Time Shortened
85
Speed Measurement System
86
Table 26 Malfunctions of the Speed Measurement System
86
Disassembly and Assembly
87
Introduction
87
Table 27 Weights of Assemblies [Kg]
89
Table 28 Weight of Wall Insert [Kg]
89
Weights of Assemblies
89
Disassembly and Assembly of the Filter Silencer Casing
90
Table 29: Tightening Torques (Filter Silencer Screws)
94
Dismantling the Filter Silencer
95
Dismantling the Filter Silencer with Noise Package
96
Dismantling Wall Insert and Diffuser
97
Axial Clearance a Prior to Disassembly
101
Table 30 Admissible Axial Clearance a
101
Dismantling Insulation, Gas Inlet Casing and Nozzle Ring (A175-L and Smaller)
102
Dismantling the Gas Inlet Casing, Nozzle Ring (A180-L and Larger)
104
Fitting Gas Inlet Casing, Nozzle Ring and Insulation (A175-L and Smaller)
107
Table 31 Tightening Torque
107
Table 32 Tightening Torque
108
Fitting the Gas Inlet Casing, Nozzle Ring (A180-L and Larger)
110
Table 33 Tightening Torque
111
Table 34 Tightening Torque
112
Axial Clearance a after Assembly
113
Table 35 Admissible Axial Clearance a
113
Fitting Diffuser, Wall Insert
114
Table 36 Tightening Torque
114
Table 37 Tightening Torque
116
Fitting the Filter Silencer
117
Table 38 Tightening Torque
117
Fitting the Filter Silencer with Noise Package
118
Table 39 Tightening Torques
118
Table of Tightening Torques
120
Table 40 Overview of Tightening Torques
121
Table 41 Tightening Torque, Insulation
121
Possible Emergency Repairs
123
Shutting off Oil Supply to Defective Turbocharger
123
Table 42 Procedure for Taking out of
123
Taking a Turbocharger out of Operation
123
Procedure with One Installed Turbocharger
124
A165-L 0.32
126
A170-L 0.33
126
A175-L 0.38
126
A180-L 0.41
126
A185-L 0.43
126
A190-L 0.45
126
Table 44 Required Washers
126
Table 45 Tightening Torque
126
Procedure with Two or more Installed Turbochargers
128
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
Spare Parts
133
Table 46 Customer Spare Part Set
133
Table 47 Turbocharger with Part Num
135
Table 48 Cartridge Group with Part
137
ABB A175-L37 Operation Manual (142 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 19.45 MB
Table of Contents
Introduction
3
Table of Contents
3
Introduction
5
Purpose of the Manual
5
Symbols, Definitions
6
Storage of New Turbochargers and Spare Parts
8
Contact Information
10
Safety
11
CE Conformity
13
Introduction
13
Safety
13
Definition of Mandatory Signs
14
Definition of Safety Instructions
14
Intended Use
15
Warning Plates on the Turbocharger
16
Turbocharger Rating Plate
17
Periodic Check of the Pressure Vessels
18
Lifting of Loads
19
Prerequisites for Operation and Maintenance
20
Hazards During Operation and Maintenance
21
Safe Operation
23
Safe Maintenance
24
Product Description
31
Table 15 Malfunctions When Starting
32
Table 20 Malfunctions During Operation
32
Table 23 Surging of the Turbocharger
32
Table 24 Malfunctions When Stopping
32
Essential Information
35
Introduction
35
Registered Trademarks
35
Related Documents
35
Table 1 Related Documents
35
Layout and Function of the Turbocharger
36
Warning Plates on the Turbocharger
38
Locations of the Rating Plates
39
Removal and Installation
41
Removing the Turbocharger
41
Table 2 A100-L Weights
41
Turbocharger Weight
41
Installing the Turbocharger
43
Table 3 General Information about Fastening the Turbocharger
44
Table 4 Tightening Torques
45
Table 43 Tightening Torque
45
Table 5 Tightening Angle (Foot Screws)
45
Commissioning
47
Inspection Procedures
47
Oil Supply
47
Commissioning after Taking out of Operation
49
Monitoring During Operation
51
Oil Pressure, Oil Temperature
51
Table 6 Lubricating Oil Pressure, Oil
51
Table 7 Lubricating Oil Temperature at
51
Table 8 Lubricating Oil Temperature at the Outlet
52
Turbocharger Speed
53
Low Pressure Measurement at the Filter Silencer
57
Noise Emission
59
Operation and Service
59
Service Work
60
Expected Replacement Intervals
64
Table 10: Expected Replacement Intervals for Turbocharger Parts
64
Table 11 Recommended Replacement Intervals for Turbocharger Parts
64
Flexible Turbocharger Cut-Out
65
Stopping the Engine
66
Foreword to Maintenance
67
Periodic Maintenance
67
Cleaning the Filter Silencer
68
Changing the Filter Strip on the Filter Silencer Casing
70
Cleaning the Compressor During Operation
72
Table 12 Volume of Water Per Cleaning
75
Cleaning the Turbine During Operation
76
Table 14 Amount of Granulate
79
Draining the Gas Outlet Casing
80
Malfunctions When Starting
81
Table 16 Malfunctions When Starting
81
Table 17 Malfunctions When Starting - Rubbing of Rotating Parts
81
Troubleshooting
81
Malfunctions During Operation
82
Table 18 Malfunctions During Operation - Lubricating Oil Pressure too Low
82
Table 19 Malfunctions During Operation - Speed Reductions
82
Table 21 Malfunctions During Operation - Charge Air Pressure too Low
83
Surging of the Turbocharger
84
Table 22 Malfunctions During Operation
84
Malfunctions When Stopping
85
Table 25 Malfunctions When Stopping
85
Speed Measurement System
86
Table 26 Malfunctions of the Speed
86
Disassembly and Assembly
87
Introduction
87
Table 27 Weights of Assemblies [Kg]
89
Table 28 Weight of Wall Insert [Kg]
89
Weights of Assemblies
89
Disassembly and Assembly of the Filter Silencer Casing
90
Table 29 Tightening Torques
94
Dismantling the Filter Silencer
95
Dismantling the Filter Silencer with Noise Package
96
Dismantling Wall Insert and Diffuser
97
Axial Clearance a Prior to Disassembly
101
Table 30 Admissible Axial Clearance a
101
Dismantling Insulation, Gas Inlet Casing and Nozzle Ring (A175-L and Smaller)
102
Dismantling the Gas Inlet Casing, Nozzle Ring (A180-L and Larger)
104
Fitting Gas Inlet Casing, Nozzle Ring and Insulation (A175-L and Smaller)
107
Table 31 Tightening Torque (56014)
107
Table 32 Tightening Torque (61009)
108
Fitting the Gas Inlet Casing, Nozzle Ring (A180-L and Larger)
110
Table 33 Tightening Torque (56014)
111
Table 34 Tightening Torque (61009)
112
Axial Clearance a after Assembly
113
Table 35 Admissible Axial Clearance a
113
Fitting Diffuser, Wall Insert
114
Table 36 Tightening Torque (77015)
114
Table 37 Tightening Torque (72011)
116
Fitting the Filter Silencer
117
Table 38 Tightening Torque (72004)
117
Fitting the Filter Silencer with Noise Package
118
Table 39 Tightening Torques (72004, 74043)
118
Table 9 Tightening Torques
118
Table of Tightening Torques
120
Table 13 Tightening Torques
121
Table 40 Overview of Tightening Torques
121
Table 41 Tightening Torque, Insulation
121
Possible Emergency Repairs
123
Shutting off Oil Supply to Defective Turbocharger
123
Table 42 Procedure for Taking out of
123
Taking a Turbocharger out of Operation
123
Procedure with One Installed Turbocharger
124
Table 44 Required Washers (01)
126
Table 45 Tightening Torque (57005)
126
Procedure with Two or more Installed Turbochargers
128
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
Spare Parts
133
Table 46 Customer Spare Part Set
133
Table 47 Turbocharger with Part Num
135
Table 48 Cartridge Group with Part
137
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