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ABB HT583424 manual available for free PDF download: Operation Manual
ABB HT583424 Operation Manual (144 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 18.52 MB
Table of Contents
Introduction
3
Table of Contents
3
Introduction
4
Purpose of the Manual
4
Symbols, Definitions
5
Storage of New Turbochargers and Spare Parts
7
Contact Information
9
Safety
11
CE Conformity
12
Introduction
12
Safety
12
Definition of Mandatory Signs
13
Definition of Safety Instructions
13
Intended Use
14
Deflagration on Gas Engines
15
Warning Plates on the Turbocharger
16
Turbocharger Rating Plate
17
Periodic Check of the Pressure Vessels
18
Lifting of Loads
19
Prerequisites for Operation and Maintenance
20
Hazards During Operation and Maintenance
21
Safe Operation
23
Safe Maintenance
25
Product Description
31
Essential Information
33
Introduction
33
Registered Trademarks
33
Related Documents
33
Table 1: Related Documents
33
Fig. 1: Layout and Function of the Turbocharger
34
Layout and Function of the Turbocharger
34
Fig. 2: Compressor Wheel Cooling
35
Fig. 3: Warning Plate Locations
36
Warning Plates on the Turbocharger
36
Fig. 4: Locations of the Rating Plates
37
Locations of the Rating Plates
37
Fig. 5: Suspension of Complete Turbocharger Unit
38
Removing and Installing
38
Table 2: Weights of Turbochargers A130-M
38
Turbocharger Weight and Transportation
38
Fig. 6: Turbine Cleaning Nozzle
39
Removing the Turbocharger
39
Fig. 7: Removing the Turbocharger
40
Fig. 8: Loosening the Clamping Nut
42
Fig. 9: Turbocharger Centre of Gravity
43
Fig. 10: Inserting Gaskets into the Bracket
44
Installing the Turbocharger
44
Fig. 11: Inserting the Threaded Rods
45
Fig. 12: Requirements for Threaded Rods
45
Table 3: Requirements for Threaded Rods
45
Fig. 13: Placing the Turbocharger on the Bracket
46
Table 4: Tightening Torques for Standard Nuts
47
Fig. 14: Preparing the Clamping Nut for the Tightening Procedure
48
Fig. 15: Tightening Pressure Screws
49
Table 5: Pressure Screw Tightening Torques
49
Fig. 16: Connecting the Speed Sensor
50
Fig. 17: Connecting the Compressor Cooling Air Intake
50
Fig. 18: Attaching the Support
51
Commissioning
52
Oil Supply
52
Fig. 19: Oil Orifice
53
Inspection Procedures
54
Commissioning after Taking out of Operation
56
Monitoring Operation
57
Oil Pressure, Oil Temperature
57
Table 6: Lubricating Oil Pressure at Oil Inlet before Turbocharger
57
Table 7: Lubricating Oil Temperature at the Inlet
58
Table 8: Lubricating Oil Temperature at the Outlet
58
Exhaust Gas Temperature before Turbine
59
Fig. 20: Layout and Overview of Speed Measurement System
60
Turbocharger Speed
60
Fig. 21: Replacing the Speed Sensor
62
Table 9: Tightening Torque (86505)
62
Noise Emission
63
Operation and Service
63
Fig. 22: Noise Insulation, Bellows
64
Service Work
65
Fig. 23: Replacing the Protective Grid
67
Expected Replacement Intervals
69
Table 10: Expected Replacement Intervals
69
Stopping the Engine
71
Foreword to Maintenance
72
Periodic Maintenance Work
72
Table 11: Maintenance Table
72
Cleaning the Compressor During Operation
73
Fig. 24: Carrying out Wet Cleaning of Compressor
75
Table 12: Parameters for Wet Cleaning of Compressor
75
Cleaning the Turbine During Operation
76
Table 13: Turbine Wet Cleaning, Recommended Operating State
78
Fig. 25: Carrying out Wet Cleaning of Turbine
79
Table 14: Wet Cleaning of Turbine, Parameters
79
Cleaning Components Mechanically
80
Fig. 26: Cleaning the Filter Silencer
81
Fig. 27: Compressor-End, Non-Rotating Parts
83
Fig. 28: Turbine End, Non-Rotating Parts
85
Fig. 29: Soaking the Turbine End
87
Table 15: Value Table for Soaking
87
Eliminating Malfunctions
90
Malfunctions When Starting
90
Table 16: Malfunctions When Starting - Delayed Start-Up
90
Table 17: Malfunctions When Starting - Vibrations
90
Table 18: Malfunctions When Starting - Rubbing of Rotating Parts
90
Malfunctions During Operation
91
Table 19: Malfunctions During Operation - Lubricating Oil Pressure too Low
91
Table 20: Malfunctions During Operation - Speed Reduces
91
Table 21: Malfunctions During Operation - Speed Increases
91
Table 22: Malfunctions During Operation - Exhaust Gas Temperature too High
92
Table 23: Malfunctions During Operation - Charge Air Pressure too Low
92
Table 24: Malfunctions During Operation - Charge Air Pressure too High
93
Table 25: Malfunctions During Operation - Engine Performance Losses
93
Table 26: Malfunction - Turbocharger Pumping
94
Table 27: Malfunction - Sporadic Surge Blows
94
Turbocharger Is Surging
94
Malfunctions When Stopping
95
Table 28: Malfunctions When Stopping - Runout Noises
95
Table 29: Malfunctions When Stopping - Runout Time too Short
95
Speed Measurement System
96
Table 30: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
96
Table 31: Malfunction of the Speed Measurement System - Measured Speed too High
96
Table 32: Malfunction of the Speed Measurement System - Measured Speed too Low
96
Dismantling and Fitting
97
Introduction
97
Table 33: Swivel Lifting Eyes
99
Table 34: Ring Nuts to be Used
100
Fig. 30: Weights of Assemblies
101
Table 35: Weights of Assemblies
101
Weights of Individual Parts
101
Fig. 31: Removing Air Inlets
102
Removing Air Inlets
102
Fig. 32: Removing the Insulation
103
Removing the Gas Outlet Casing
103
Fig. 33: Removing the Gas Outlet Casing
104
Removing the Gas Outlet Flange
105
Fig. 34: Dismantling the Gas Outlet Flange
106
Table 36: 3 Press-Off Screws
106
Fig. 35: Removing the Gas Outlet Flange
107
Table 37: 6 Press-Off Screws
107
Fig. 36: Removing the Compressor Casing
108
Removing the Compressor Casing
108
Fig. 37: Dismantling the Wall Insert
109
Fig. 38: Press off the Casing
110
Pressing off the Casing
110
Fig. 39: Removing Insulation Sheets
111
Fig. 40: Oil Orifice
111
Removing the Cartridge Group
111
Fig. 41: Removing Cartridge Group 1
112
Fig. 42: Removing Cartridge Group 2
112
Fig. 43: Removing the Nozzle Ring
113
Removing the Nozzle Ring
113
Fig. 44: Installing the Cartridge Group on the Service Support
114
Installing the Cartridge Group on the Service Support
114
Axial Clearance a and Radial Clearance B
115
Fig. 45: Measuring Clearance a and B
115
Table 38: Permissible Clearances a and B
115
Fig. 46: Nozzle Ring Compression PD
116
Nozzle Ring Compression PD
116
Table 39: Permitted Nozzle Ring Compression PD
116
Fig. 47: Installing the Nozzle Ring
117
Installing Nozzle Ring
117
Fig. 48: Lifting the Cartridge Group and Rotating It
118
Installing the Cartridge Group
118
Fig. 49: Installing the Cartridge Group
119
Table 40: Tightening Torque (51007)
119
Fig. 50: Turbine Casing Insulation / Burst Protection
120
Installing the Compressor Casing
121
Table 41: Tightening Torque (79041)
121
Fig. 51: Installing the Compressor Casing
122
Table 42: Tightening Torque (72011)
122
Fig. 52: Measuring Clearances N and R
123
Radial Clearances N and R
123
Table 43: Permissible Clearances N and R
123
Fig. 53: Installing the Air Inlets
124
Installing Air Inlets
124
Table 44: Tightening Torque (72020)
124
Fig. 54: Installing the Gas Outlet Flange
125
Installing the Gas Outlet Flange
125
Fig. 55: Fitting the Insulation
126
Fig. 56: Installing the Gas Outlet Casing
127
Installing the Gas Outlet Casing
127
Table 45: Tightening Torque (51009)
127
Fig. 57: Fitting the Insulation
128
Fig. 58: Tightening Torques
129
Table 46: Tightening Torques
129
Table of Tightening Torques
129
Fig. 59: Tightening Torques for Insulation
130
Table 47: Tightening Torques for Insulation
130
Possible Emergency Repairs
131
Taking out of Operation at Short Notice
131
Installing the Replacement Cartridge Group
132
Installing the Replacement Turbocharger
132
Fig. 60: Fitting the Cover Plate
133
Fitting the Cover Plate
133
Cover Plate Drawing
134
Fig. 61: Cover Plate Drawing
134
Table 48: Cover Plate Dimensions [MM]
134
Mothballing the Turbocharger
135
Taking the Engine out of Operation for up to 12 Months
135
Taking the Engine out of Operation for more than 12 Months
136
Disposing of Turbocharger Components
137
Ordering Spare Parts
138
Required Customer Spare Part Set (97070)
138
Spare Parts
138
Table 49: Customer Spare Part Set 97070
138
Fig. 62: Overview of Part Numbers
140
View of Turbocharger with Part Numbers
140
Table 50: Spare Parts List
141
Fig. 63: Overview of Part Numbers
142
Table 51: Spare Parts List
142
View of Turbine Cleaning Device
142
Figures
143
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