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ABB HT592133 manual available for free PDF download: Operation Manual
ABB HT592133 Operation Manual (138 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 26.14 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
24
Product Description
31
Essential Information
33
Introduction
33
Registered Trademarks
33
Related Documents
33
Table 1: Related Documents
33
Fig. 1: Layout and Function
34
Layout and Function of the Turbocharger
34
Fig. 2: Connection of the Compressor Wheel Cooling
35
Fig. 3: Warning Plates on the Turbocharger
36
Warning Plates on the Turbocharger
36
Fig. 4: Locations of the Rating Plates
37
Locations of the Rating Plates
37
Fig. 5: Turbocharger Suspension Points
38
Removal and Installation
38
Table 2: Weight of the Turbocharger
38
Turbocharger Weight
38
Fig. 6: Turbocharger Suspension Points
39
Removing the Turbocharger
39
Fig. 7: Removing the Foot Mounting
40
Fig. 8: Loosening the Clamping Nut
41
Fig. 9: Turbocharger Suspension Points
42
Installing the Turbocharger
42
Fig. 10: Removing Auxiliary Screw
43
Fig. 11: Compressor-End Foot
44
Fig. 12: Turbine-End Foot
44
Table 3: Foot Bolt Dimensions
44
Fig. 13: CE Foot Contact Surface
45
Fig. 14: te Foot: Handling of Cup Spring Contact Surface / Foot Contact Surface
45
Fig. 15: Tightening the Foot Bolts (1)
46
Fig. 16: Tightening the Clamping Nut (2)
47
Table 4: Clamping Screw Tightening Torques
47
Commissioning
48
Oil Supply
48
Inspection Procedures
49
Commissioning after Taking out of Operation
50
Fig. 17: Lubricating Oil Pressure Measuring Point
51
Monitoring During Operation
51
Oil Pressure, Oil Temperature
51
Table 5: Oil Pressure Range
51
Table 6: Oil Temperature at the Inlet
52
Table 7: Oil Temperature at the Outlet
52
Fig. 18: Speed Measurement
53
Turbocharger Speed
53
Noise Emission
56
Operation and Service
56
Fig. 19: Noise Insulation, Bellows
57
Service Work
58
Expected Replacement Intervals
61
Stopping the Engine
62
Table 8: Expected Replacement Intervals
62
Table 9: Recommended Replacement Intervals
62
Foreword to Maintenance
63
Periodic Maintenance
63
Cleaning the Filter Silencer
64
Fig. 20: Cleaning the Filter Silencer
64
Fig. 21: Cleaning the Filter Silencer (2)
66
Table 10: Tightening Torque (81272)
66
Table 11: Tightening Torque (81273)
66
Cleaning the Slotted Diffuser
67
Fig. 22: Cleaning the Slotted Diffuser
67
Cleaning the Compressor During Operation
68
Table 12: Compressor Cleaning Parameters
70
Fig. 23: Operation of Water Pressure Vessel
72
Table 13: Compressor Cleaning Parameters
73
Cleaning Turbine and Nozzle Ring
74
Fig. 24: Turbine and Nozzle Ring Cleaning Cycle
76
Fig. 25: Cleaning Cycle of Turbine and Nozzle Ring with Load Ramp
77
Fig. 26: Procedure Wet Cleaning of Turbine and Nozzle Ring
78
Table 14: Cleaning Parameters Wet Cleaning of Turbine and Nozzle Ring
79
Malfunctions When Starting
80
Table 15: Malfunctions When Starting - Delayed Start-Up
80
Table 16: Malfunctions When Starting - Vibrations
80
Table 17: Malfunctions When Starting - Rubbing of Rotating Parts
80
Troubleshooting
80
Malfunctions During Operation
81
Table 18: Malfunctions During Operation - Lubricating Oil Pressure too Low
81
Table 19: Malfunctions During Operation - Drop in Speed
81
Table 20: Malfunctions During Operation - Speed Increases
81
Table 21: Malfunctions During Operation - Exhaust Gas Temperature too High
82
Table 22: Malfunctions During Operation - Charge Air Pressure too Low
82
Surging of the Turbocharger
83
Table 23: Malfunctions During Operation - Charge Air Pressure too High
83
Table 24: Surging of the Turbocharger
83
Malfunctions When Stopping
84
Table 25: Malfunctions When Stopping - Runout Noises
84
Table 26: Malfunctions When Stopping - Shortened Runout Time
84
Speed Measurement System
85
Table 27: Malfunction, no Speed Measurement Signal or Poor Signal Amplitude
85
Table 28: Malfunction, Measured Speed too High
85
Table 29: Malfunction, Measured Speed too Low
85
Disassembly and Assembly
86
Introduction
86
Fig. 27: Assemblies
88
Table 30: Assembly Weights
88
Weights of Assemblies
88
Fig. 28: Removing / Installing the Filter Silencer
89
Removing / Installing Air-Inlets
89
Table 31: Tightening Torque (27027)
89
Fig. 29: Removing / Installing the Air Suction Branch
90
Table 32: Tightening Torque (27027)
90
Axial Clearance a Prior to Disassembly
91
Fig. 30: Axial Clearance
91
Table 33: Axial Clearance
91
Fig. 31: Removing Wall Insert
92
Removing the Compressor Casing
92
Fig. 32: Transporting and Turning Wall Insert
93
Fig. 33: Removing the Diffuser
94
Fig. 34: Remove Compressor Casing
95
Fig. 35: Safety-Relevant Screws
96
Removing the Cartridge Group
96
Fig. 36: Removing Cartridge Group 1
97
Fig. 37: Removing Cartridge Group 2
98
Fig. 38: Removing Turbine Diffuser 1
99
Fig. 39: Removing Turbine Diffuser 2
99
Removing Nozzle Ring
99
Fig. 40: Removing Cover Ring 1
100
Fig. 41: Removing Cover Ring 2
100
Fig. 42: Removing Nozzle Ring 1
101
Fig. 43: Removing Nozzle Ring 2
101
Fig. 44: Installing Nozzle Ring 1
102
Installing Nozzle Ring
102
Fig. 45: Installing Nozzle Ring 2
103
Table 34: Tightening Torque (56014)
103
Fig. 46: Installing Cover Ring
104
Table 35: Tightening Torque (57005)
104
Fig. 47: Installing Turbine Diffuser 1
105
Fig. 48: Installing Turbine Diffuser 2
105
Table 36: Tightening Torque (61069)
105
Fig. 49: Installing the Cartridge Group 1
106
Installing the Cartridge Group
106
Fig. 50: Installing the Cartridge Group 2
107
Table 37: Tightening Torque (61059 / 42128 / 86505)
107
Fig. 51: Preparing the Threaded Stud (25008)
108
Table 38: Inner Thread Size (25008)
108
Fig. 52: Fitting the Spinner Nose Cone (25012)
109
Table 39: Tightening Torque (25013)
109
Fig. 53: Installing the Cartridge Group 3
110
Fig. 54: Installing the Compressor Casing
111
Installing the Compressor Casing
111
Table 40: Tightening Torque (61037 / 61090)
111
Fig. 55: Installing Diffuser
112
Table 41: Tightening Torque (77015)
112
Fig. 56: Turning and Moving in Wall Insert
113
Fig. 57: Fitting the Wall Insert
114
Table 42: Tightening Torque (72011)
114
Axial Clearance a after Assembly
115
Fig. 58: Axial Clearance
115
Table 43: Axial Clearance
115
Removing and Installing Turbine-End Nozzle Ring
116
Fig. 59: Removing the Nozzle Ring at the Turbine End
117
Fig. 60: Installing the Nozzle Ring at the Turbine End
118
Table 44: Tightening Torque (56014 / 61009)
118
Fig. 61: Tightening Torques 1
120
Fig. 62: Tightening Torques 2
120
Table of Tightening Torques
120
Table 45: Tightening Torques
121
Fig. 63: Flange Tightening Sequence
122
Table 46: Tightening Torques 61009
122
Possible Emergency Repairs
123
Taking a Turbocharger out of Operation
123
Locking the Rotor
124
Fig. 64: Fitting the Locking Device
125
Table 47: Locking Device Tightening Torque
125
Fitting the Cover Plate
127
Table 48: Cover Plate Dimensions 1
127
Table 49: Cover Plate Dimensions 2
127
Table 50: Cover Plate Dimensions 3
127
Blanking off the Inlets and Outlets
129
Engines with Bypass Around the Turbocharger
129
Mothballing the Turbocharger
130
Taking the Engine out of Operation for up to 12 Months
130
Taking the Engine out of Operation for more than 12 Months
131
Disposing of Turbocharger Components
132
Ordering Spare Parts
133
Spare Parts
133
Table 51: Customer Spare Part Set (97070)
133
View of Turbocharger with Part Numbers
134
Table 52: Turbocharger with Part Numbers
135
Figures
136
Tables
138
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