ABB HT596782 Manuals

Manuals and User Guides for ABB HT596782. We have 1 ABB HT596782 manual available for free PDF download: Operation Manual

ABB HT596782 Operation Manual (108 pages)

Brand: ABB | Category: Industrial Equipment | Size: 12.37 MB

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
12
Introduction
12
CE Conformity
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
Introduction
33
Essential Information
33
Registered Trademarks
33
Related Documents
33
Table 1: Related Documents
33
Layout and Function of the Turbocharger
34
Fig. 1: Layout and Function of the Turbocharger
34
Position of the Rating Plate
35
Fig. 2: Position of the Rating Plate
35
Warning Plates on the Turbocharger
36
Fig. 3: Warning Plates on the Turbocharger
36
Removing and Installing
37
Turbocharger Weight and Transportation
37
Fig. 4: Turbocharger Transport
37
Table 2: Weight of the Turbocharger
37
Table 3: Swivel Lifting Eye (S) to be Used
37
Table 30: Swivel Lifting Eye (S) to be Used
37
Removing the Turbocharger
38
Fig. 5: Removing the Turbocharger
39
Installing the Turbocharger
40
Fig. 6: Inserting O-Rings into Bracket
40
Fig. 7: Inserting Threaded Rods into the Bracket
41
Fig. 8: Requirements for Threaded Rods
41
Table 4: Requirements for Threaded Rods
41
Fig. 9: Placing the Turbocharger on the Bracket
42
Table 5: Tightening Torque for Turbocharger Fixing Screws
42
Commissioning
43
Oil Supply
43
Inspection Procedures
44
Commissioning after Taking out of Operation
46
Monitoring Operation
47
Oil Pressure, Oil Temperature
47
Table 6: Lubricating Oil Pressure at Oil Inlet before Turbocharger
47
Table 7: Lubricating Oil Temperature at the Inlet
48
Table 8: Lubricating Oil Temperature at the Outlet
48
Exhaust Gas Temperature before Turbine
49
Turbocharger Speed
49
Fig. 10: Layout and Overview of the Speed Measurement System
50
Fig. 11: Fitting the Speed Sensor
52
Table 9: Tightening Torque (86505)
52
Operation and Service
53
Noise Emission
53
Fig. 12: Noise Insulation, Bellows
54
Service Work
55
Expected Replacement Intervals
58
Table 10: Expected Replacement Intervals [H]
58
Stopping the Engine
59
Periodic Maintenance Work
60
Foreword to Maintenance
60
Cleaning Components Mechanically
60
Table 11: Maintenance Table
60
Fig. 13: Cleaning the Filter Silencer
61
Fig. 14: Cleaning the Compressor Casing, Diffuser Mechanically
63
Fig. 15: Cleaning the Nozzle Ring, Turbine Casing Mechanically
64
Fig. 16: Soaking Contamination of the Turbine
66
Table 12: Dimensions of the Cleaning Container
66
Eliminating Malfunctions
69
Malfunctions When Starting
69
Table 13: Malfunctions When Starting - Delayed Start-Up
69
Table 14: Malfunctions When Starting - Vibrations
69
Table 15: Malfunctions When Starting - Rotating Parts Rubbing
69
Malfunctions During Operation
70
Table 16: Malfunctions During Operation - Lubricating Oil Pressure too Low
70
Table 17: Malfunctions During Operation - Speed Reduces
70
Table 18: Malfunctions During Operation - Speed Increases
70
Table 19: Malfunctions During Operation - Exhaust Gas Temperature too High
71
Table 20: Malfunctions During Operation - Charge Air Pressure too Low
71
Table 21: Malfunctions During Operation - Charge Air Pressure too High
72
Table 22: Malfunctions During Operation - Engine Performance Losses
72
Turbocharger Is Surging
73
Table 23: Malfunction - Turbocharger Pumping
73
Table 24: Malfunction - Sporadic Surge Blows
73
Malfunctions When Stopping
74
Table 25: Malfunctions When Stopping - Runout Noises
74
Table 26: Malfunctions When Stopping - Runout Time too Short
74
Speed Measurement System
75
Table 27: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
75
Table 28: Malfunction of the Speed Measurement System - Measured Speed too High
75
Table 29: Malfunction of the Speed Measurement System - Measured Speed too Low
75
Dismantling and Fitting
76
Introduction
76
Table 31: Ring Nuts to be Used
79
Weights of Individual Parts
80
Fig. 17: Overview of Assemblies
80
Table 32: Weights of the Assemblies [Kg]
80
Removing the Gas Outlet Casing
81
Fig. 18: Removing the Gas Outlet Casing
81
Removing Air Inlets
82
Fig. 19: Removing the Air Inlets
82
Removing the Compressor Casing
83
Fig. 20: Removing the Compressor Casing (1/2)
83
Fig. 21: Removing the Compressor Casing (2/2)
84
Removing the Cartridge Group
85
Fig. 22: Do Not Loosen Screw Plugs
85
Fig. 23: Removing the Cartridge Group (1)
86
Fig. 24: Removing Cartridge Group 2
87
Fig. 25: Rotating the Cartridge Group and Fitting the Service Support
87
Removing Nozzle Ring
88
Fig. 26: Removing the Nozzle Ring
88
Axial Clearance a and Radial Clearance B
89
Fig. 27: Measuring Clearance a and B
89
Table 33: Permissible Clearances a and B
89
Nozzle Ring Compression PD
90
Fig. 28: Measuring Nozzle Ring Compression
90
Table 34: Permitted Nozzle Ring Compression PD
90
Fitting the Diffuser
91
Fig. 29: Fitting the Diffuser
91
Table 35: Tightening Torque (72041)
91
Installing the Cartridge Group
92
Fig. 30: Lifting the Cartridge Group and Rotating It
92
Fig. 31: Fitting the Cartridge Group
93
Table 36: Tightening Torque (72011)
93
Installing Nozzle Ring
94
Fig. 32: Installing the Nozzle Ring
94
Fitting the Turbine Casing
95
Fig. 33: Fitting the Turbine Casing
95
Table 37: Tightening Torque (51007)
95
Rotating the Turbocharger
96
Fig. 34: Rotating the Turbocharger
96
Radial Clearances N and R
97
Fig. 35: Measuring Clearances N and R
97
Table 38: Permissible Clearances N and R
97
Installing the Gas Outlet Casing
98
Fig. 36: Fitting the Gas Outlet Casing
98
Table 39: Tightening Torque (51101)
98
Installing Air Inlets
99
Fig. 37: Installing the Air Inlets
99
Table 40: Tightening Torque (72020)
99
Table of Tightening Torques
100
Fig. 38: Overview of Tightening Torques
100
Table 41: Overview of Tightening Torques
100
Taking out of Operation at Short Notice
101
Possible Emergency Repairs
101
Mothballing the Turbocharger
102
Taking the Engine out of Operation for up to 12 Months
102
Taking the Engine out of Operation for more than 12 Months
103
Disposing of Turbocharger Components
104
Spare Parts
105
Spare Part Overview
105
Ordering Spare Parts
105
Figures
106

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