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ABB HT596632 manual available for free PDF download: Operation Manual
ABB HT596632 Operation Manual (144 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 26.07 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 Complete Turbocharger Unit
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
43
Fig. 12: Turbine-End Foot
44
Table 3: Foot Screws, Dimension and Strength Class
44
Table 4: Foot Screws, Dimension CE
44
Table 5: Foot Screws, Dimension te
44
Table 6: Foot Screws, Number of Cup Springs
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 Screws (1)
46
Fig. 16: Tightening Procedure
47
Table 7: Torque-Controlled Tightening of the Pressure Screws
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 8: Oil Pressure Range
51
Table 10: Oil Temperature at the Outlet
52
Table 9: Oil Temperature at the Inlet
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 11: Expected Replacement Intervals
62
Table 12: 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 13: Tightening Torque (81272)
66
Table 14: Tightening Torque (81273)
66
Cleaning the Slotted Diffuser
67
Fig. 22: Cleaning the Slotted Diffuser
67
Cleaning the Compressor During Operation
68
Table 15: Compressor Cleaning Parameters
70
Fig. 23: Operation of Water Pressure Vessel
72
Table 16: 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 17: Cleaning Parameters Wet Cleaning of Turbine and Nozzle Ring
79
Malfunctions When Starting
80
Table 18: Malfunctions When Starting - Delayed Start-Up
80
Table 19: Malfunctions When Starting - Vibrations
80
Table 20: Malfunctions When Starting - Rubbing of Rotating Parts
80
Troubleshooting
80
Malfunctions During Operation
81
Table 21: Malfunctions During Operation - Lubricating Oil Pressure too Low
81
Table 22: Malfunctions During Operation - Drop in Speed
81
Table 23: Malfunctions During Operation - Speed Increases
81
Table 24: Malfunctions During Operation - Exhaust Gas Temperature too High
82
Table 25: Malfunctions During Operation - Charge Air Pressure too Low
82
Surging of the Turbocharger
83
Table 26: Malfunctions During Operation - Charge Air Pressure too High
83
Table 27: Surging of the Turbocharger
83
Malfunctions When Stopping
84
Table 28: Malfunctions When Stopping - Runout Noises
84
Table 29: Malfunctions When Stopping - Shortened Runout Time
84
Speed Measurement System
85
Table 30: Malfunction, no Speed Measurement Signal or Poor Signal Amplitude
85
Table 31: Malfunction, Measured Speed too High
85
Table 32: Malfunction, Measured Speed too Low
85
Disassembly and Assembly
86
Introduction
86
Fig. 27: Weight of Assemblies
88
Table 33: Assembly Weights
88
Weight of Assemblies
88
Fig. 28: Removing the Filter Silencer
89
Removing the Air Inlets
89
Fig. 29: Removing the Air Suction Branch
90
Axial Clearance a Prior to Disassembly
91
Fig. 30: Axial Clearance
91
Table 34: Axial Clearance a
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
93
Fig. 34: Removing the Compressor Casing
94
Fig. 35: Safety-Relevant Screws
95
Removing the Cartridge Group
95
Fig. 36: Removing Cartridge Group 1
96
Fig. 37: Removing Cartridge Group 2
97
Fig. 38: Removing Turbine Diffuser 1
98
Fig. 39: Removing Turbine Diffuser 2
98
Removing the Nozzle Ring
98
Fig. 40: Removing Cover Ring 1
99
Fig. 41: Removing Cover Ring 2
100
Fig. 42: Removing Nozzle Ring 1
100
Fig. 43: Removing Nozzle Ring 2
101
Fig. 44: Installing Nozzle Ring 1
102
Installing the Nozzle Ring
102
Fig. 45: Installing Nozzle Ring 2
103
Table 35: Tightening Torque (56014)
103
Fig. 46: Installing Cover Ring
104
Table 36: Tightening Torque (57005)
104
Fig. 47: Installing Turbine Diffuser 1
105
Fig. 48: Installing Turbine Diffuser 2
106
Table 37: Tightening Torque (61069)
106
Fig. 49: Installing the Cartridge Group 1
107
Installing the Cartridge Group
107
Fig. 50: Installing the Cartridge Group 2
108
Table 38: Tightening Torque (61059 / 42128)
108
Fig. 51: Installing the Cartridge Group 3
109
Table 39: Tightening Torque (86505)
109
Fig. 52: Preparing the Threaded Stud (25008)
110
Fitting the Spinner Nose Cone
110
Table 40: Inner Thread Size (25008)
110
Fig. 53: Fitting the Spinner Nose Cone (25012)
111
Table 41: Tightening Torque (25013)
111
Fig. 54: Installing the Compressor Casing
112
Installing the Compressor Casing
112
Table 42: Tightening Torque (61037)
112
Table 43: Tightening Torque, Nuts that Are Difficult
112
Table 44: Tightening Torque (61090)
112
Fig. 55: Installing Diffuser
113
Table 45: Tightening Torque (77015)
113
Fig. 56: Turning and Moving in Wall Insert
114
Fig. 57: Fitting Wall Insert
115
Table 46: Tightening Torque (72011)
115
Axial Clearance a after Assembly
116
Fig. 58: Axial Clearance
116
Table 47: Axial Clearance a
116
Fig. 59: Installing the Air Suction Branch
117
Installing the Air Inlets
117
Table 48: Tightening Torque (72027)
117
Fig. 60: Installing the Filter Silencer
118
Table 49: Tightening Torque (72027)
118
Removing and Installing Turbine-End Nozzle Ring
119
Fig. 61: Removing the Nozzle Ring at the Turbine End (Radial Gas Inlet Casing)
120
Fig. 62: Removing the Nozzle Ring at the Turbine End (Axial Gas Inlet Casing)
120
Fig. 63: Installing the Nozzle Ring at the Turbine End (Radial Gas Inlet Casing)
121
Fig. 64: Installing the Nozzle Ring at the Turbine End (Axial Gas Inlet Casing)
121
Table 50: Tightening Torque (56014)
122
Table 51: Tightening Torque (61009)
122
Fig. 65: Tightening Torques 1
123
Fig. 66: Tightening Torques 2
123
Table of Tightening Torques
123
Table 52: Tightening Torques
124
Fig. 67: Flange Tightening Sequence
125
Table 53: Tightening Torques 61009
125
Possible Emergency Repairs
126
Taking a Turbocharger out of Operation
126
Locking the Rotor
127
Fig. 68: Fitting the Locking Device
128
Table 54: Locking Device Tightening Torque
128
Fig. 69: Cover Plate (01) / Spacer Sleeves (02) Dimensions
130
Fig. 70: Fitting the Cover Plate
130
Fitting the Cover Plate
130
Table 55: Cover Plate Dimensions 1
130
Table 56: Cover Plate Dimensions 2
130
Table 57: Cover Plate Dimensions 3
130
Blanking off the Inlets and Outlets
132
Engines with Bypass Around the Turbocharger
132
Mothballing the Turbocharger
133
Taking the Engine out of Operation for up to 12 Months
133
Taking the Engine out of Operation for more than 12 Months
134
Disposing of Turbocharger Components
135
Ordering Spare Parts
136
Spare Parts
136
Fig. 71: Turbocharger with Part Numbers
137
Table 58: Customer Spare Part Set (97070)
137
View of Turbocharger with Part Numbers
137
Tools
139
Figures
140
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