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ABB A150-M68 Manuals
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ABB A150-M68 manuals available for free PDF download: Operation Manual
ABB A150-M68 Operation Manual (181 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 30.98 MB
Table of Contents
Table of Contents
1
Fig. 1: Serial Number (01) on the Rating Plate
4
Introduction
4
Purpose of the Manual
4
Contact Information
5
Essential Information
5
Layout and Function of the Turbocharger
6
Fig. 2: Layout and Function of the Turbocharger
6
Fig. 3: Compressor Wheel Cooling
7
Symbols, Definitions
8
Table 1: Definition of Pictograms
9
Storage of New Turbochargers and Spare Parts
10
Fig. 4: Volatile Corrosion Inhibitor (VCI)
10
Fig. 5: Package with Hygrometer
11
Registered Trademarks
12
Safety
13
Introduction
13
CE Conformity
13
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
14
Definition of Mandatory Signs
14
Table 2: Personal Protective Equipment to be Worn at All Times
14
Definition of Safety Instructions
14
Intended Use
15
Warning Plates on the Turbocharger
16
Fig. 6: Warning Plate Locations
16
Turbocharger Rating Plate
17
Fig. 7: Rating Plate
17
Fig. 8: Locations of the Rating Plates
18
Periodic Check of the Pressure Vessels
19
Lifting of Loads
20
Fig. 9: Attachment of Loads on the Crane Hook
20
Fig. 10: Attachment Angle
20
Prerequisites for Operation and Maintenance
21
Hazards During Operation and Maintenance
22
Safe Operation
24
Safe Maintenance
25
Table 4: Weight of Complete Turbocharger Unit
29
Fig. 11: Suspension of Complete Turbocharger Unit
29
Turbocharger Weight and Transportation
29
Removing and Installing
29
Removing the Turbocharger
30
Fig. 12: Turbine Cleaning Nozzle
30
Fig. 13: Removing the Turbocharger
31
Fig. 14: Loosening the Clamping Nut
32
Fig. 15: Turbocharger Centre of Gravity
33
Installing the Turbocharger
34
Fig. 16: Inserting the Gasket
34
Fig. 17: Inserting the Threaded Rods
35
Fig. 18: Placing the Turbocharger on the Bracket
35
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
36
Fig. 20: Tightening Pressure Screws
37
Table 5: Torque-Controlled Tightening of the Pressure Screws
37
Fig. 21: Connecting the Speed Sensor
38
Fig. 22: Connecting the Compressor Cooling Air Intake
38
Fig. 23: Attaching the Support
38
Commissioning
39
Oil Supply
39
Fig. 24: Oil Orifice
40
Inspection Procedures
41
Commissioning after Taking out of Operation
43
Monitoring Operation
44
Oil Pressure, Oil Temperature
44
Table 6: Lubricating Oil Pressure at Oil Inlet before Turbocharger
44
Table 7: Lubricating Oil Temperature at the Inlet
45
Table 8: Maximum Lubricating Oil Temperature at the Outlet
45
Exhaust Gas Temperature before Turbine
46
Fig. 25: Layout and Overview of Speed Measurement System
47
Turbocharger Speed
47
Fig. 26: Replacing the Speed Sensor
49
Table 9: Tightening Torque (86505)
49
Operation and Service
50
Noise Emission
50
Fig. 27: Noise Insulation, Bellows
51
Service Work
52
Expected Replacement Intervals
55
Table 10: Expected Replacement Intervals
55
Stopping the Engine
57
Table 11: Maintenance Table
58
Foreword to Maintenance
58
Periodic Maintenance Work
58
Cleaning the Compressor During Operation
59
Fig. 28: Carrying out Wet Cleaning of Compressor
61
Table 12: Parameters for Wet Cleaning of Compressor
61
Cleaning the Turbine During Operation
62
Fig. 29: Turbine Cleaning Devices
64
Table 13: Turbine Wet Cleaning, Recommended Operating State
64
Fig. 30: Carrying out Wet Cleaning of Turbine
65
Table 14: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
65
Table 15: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
66
Cleaning Components Mechanically
66
Fig. 31: Cleaning the Filter Silencer
67
Fig. 32: Compressor Casing
69
Fig. 33: Diffuser
70
Fig. 34: Turbine End, Non-Rotating Parts
71
Fig. 35: Soaking the Turbine End
74
Table 16: Value Table for Soaking
74
Table 19: Malfunctions When Starting - Rubbing of Rotating Parts
77
Table 18: Malfunctions When Starting - Vibrations
77
Table 17: Malfunctions When Starting - Delayed Start-Up
77
Malfunctions When Starting
77
Eliminating Malfunctions
77
Malfunctions During Operation
78
Table 20: Malfunctions During Operation - Lubricating Oil Pressure too Low
78
Table 21: Malfunctions During Operation - Speed Reduces
78
Table 22: Malfunctions During Operation - Speed Increases
78
Table 23: Malfunctions During Operation - Exhaust Gas Temperature too High
79
Table 24: Malfunctions During Operation - Charge Air Pressure too Low
79
Table 25: Malfunctions During Operation - Charge Air Pressure too High
80
Table 26: Malfunctions During Operation - Engine Performance Losses
80
Turbocharger Is Surging
81
Table 27: Malfunction - Turbocharger Surging
81
Table 28: Malfunction - Sporadic Surge Blows
81
Malfunctions When Stopping
82
Table 29: Malfunctions When Stopping - Runout Noises
82
Table 30: Malfunctions When Stopping - Runout Time too Short
82
Table 32: Malfunction of the Speed Measurement System - Measured Speed too High
83
Table 33: Malfunction of the Speed Measurement System - Measured Speed too Low
83
Table 31: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
83
Speed Measurement System
83
Dismantling and Fitting, General
84
Introduction
84
Material Required
85
Fig. 36: Swivel Lifting Eye (Example)
85
Table 34: Swivel Lifting Eyes
85
Table 36: Dismantling Screw
86
Table 35: Press-Off Screws
86
Fig. 38: Dismantling Screw
86
Fig. 37: Press-Off Screws
86
Disassembly and Assembly Concepts
88
Fig. 39: Removing the Cartridge Group with Compressor and Turbine Casing
88
Fig. 40: Cartridge Concept
89
Fig. 41: Optional Spanner Holder
90
Weights of Individual Parts
91
Fig. 42: Weights of Assemblies
91
Table 37: Weights of Assemblies
91
Table 38: Tightening Torques
92
Fig. 43 Overview of Tightening Torques
92
Table of Tightening Torques
92
Fig. 44: Tightening Torques for Insulation
93
Table 39: Tightening Torques for Insulation
93
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
94
Removing Air Inlets
94
Fig. 45: Removing the Air Inlets
94
Removing the Gas Outlet Casing
95
Fig. 46: Remove Gas Outlet Casing Without Support
95
Fig. 47: Removing Gas Outlet Casing with Support 1
96
Fig. 48: Removing Gas Outlet Casing with Support 1
97
Table 40: Press-Off Screws - Gas Outlet Flange
98
Removing the Gas Outlet Flange
98
Fig. 49: Removing the Gas Outlet Flange
98
Removing the Cartridge Group with Compressor and Turbine Casing
99
Fig. 50: Turbine Cleaning Nozzle
99
Fig. 51: Remove Insulation
99
Fig. 52: Removing the Cartridge Group with Compressor and Turbine Casing
100
Fig. 53: Setting down the Cartridge Group with the Compressor and Turbine Casing
100
Removing the Compressor Casing
101
Fig. 54: Removing the Compressor Casing
101
Table 41: Tightening Torque (90012-01)
102
Fig. 55: Removing Cartridge Group 1
102
Removing the Cartridge Group
102
Fig. 56: Removing Cartridge Group 2
103
Fig. 57: Removing Cartridge Group 3
104
Fig. 58: Installing the Cartridge Group on the Service Support
105
Installing the Cartridge Group on the Service Support
105
Removing the Nozzle Ring
106
Fig. 59: Removing the Nozzle Ring
106
Measuring Clearance a and B
107
Fig. 60: Measuring Clearance a and B
107
Table 42: Permissible Clearances a and B
107
Table 43: Nozzle Ring Compression PD
108
Nozzle Ring Compression PD
108
Fig. 61: Nozzle Ring Compression PD
108
Installing Nozzle Ring
109
Fig. 62: Installing the Nozzle Ring
109
Installing the Cartridge Group
110
Fig. 63: Lifting the Cartridge Group and Rotating It
110
Fig. 64: Turning the Cartridge Group
111
Table 44: Tightening Torque (90012-01)
111
Table 45: Tightening Torque (51007)
112
Fig. 65: Installing the Cartridge Group
112
Installing the Compressor Casing
113
Fig. 66: Fitting the Diffuser
113
Fig. 67: Installing the Compressor Casing
113
Table 46: Tightening Torque (79041)
113
Table 47: Tightening Torque (72011)
114
Turning the Cartridge Group with Compressor and Turbine Casing
115
Fig. 68: Turning the Cartridge Group with Compressor and Turbine Casing
115
Fig. 69: Installing the Gas Outlet Flange
116
Installing the Gas Outlet Flange
116
Radial Clearances N and R
117
Fig. 70: Measuring Clearances N and R
117
Table 48: Permissible Clearances N and R
117
Fitting the Insulation
118
Fig. 71: Fitting the Insulation
118
Installing the Cartridge Group with Compressor and Turbine Casing
119
Fig. 72: Installing the Cartridge Group with Compressor and Turbine Casing
119
Fig. 73: Installing the Cartridge Group with Compressor and Turbine Casing
119
Table 49: Tightening Torque (51009)
120
Fig. 74: Fitting Gas Outlet Casing Without Support
120
Installing the Gas Outlet Casing
120
Fig. 75: Installing Gas Outlet Casing with Support 1
121
Table 50: Tightening Torque (51009)
121
Fig. 76: Installing Gas Outlet Casing with Support 2
122
Installing Air Inlets
123
Fig. 77: Installing the Air Inlets
123
Table 51: Tightening Torque (72051)
123
Dismantling and Fitting, Cartridge Concept
124
Removing Air Inlets
124
Fig. 78: Removing the Air Inlets
124
Removing the Compressor Casing
125
Fig. 79: Removing the Compressor Casing
125
Fig. 80: Pressing off Compressor Casing
126
Fig. 81: Remove the Diffuser
126
Removing the Cartridge Group
127
Fig. 82: Removing Insulation Sheets
127
Fig. 83: Removing Cartridge Group 1
127
Fig. 84: Removing Cartridge Group 2
128
Fig. 85: Removing Cartridge Group 3
129
Removing the Nozzle Ring
130
Fig. 86: S_05180
130
Table 52: Permissible Clearances a and B
131
Measuring Clearance a and B
131
Fig. 87: Measuring Clearance a and B
131
Nozzle Ring Compression PD
132
Fig. 88: Nozzle Ring Compression PD
132
Table 53: Nozzle Ring Compression PD
132
Installing Nozzle Ring
133
Fig. 89: Installing the Nozzle Ring
133
Fig. 90: Installing the Cartridge Group
134
Installing the Cartridge Group
134
Table 54: Tightening Torque (51007)
135
Table 55: Tightening Torque (51007) with Spanner Holder
135
Fig. 91: Installing the Cartridge Group 2
135
Installing the Compressor Casing
136
Fig. 92: Fitting the Diffuser
136
Table 56: Tightening Torque (79041)
136
Fig. 93: Installing the Compressor Casing
137
Table 57: Tightening Torque (72011)
137
Table 58: Permissible Clearances N and R
138
Radial Clearances N and R
138
Fig. 94: Measuring Clearances N and R
138
Fig. 95: Fitting the Insulation
139
Fitting the Insulation
139
Installing Air Inlets
140
Fig. 96: Installing the Air Inlets
140
Table 59: Tightening Torque (72051)
140
Dismantling and Fitting, Special Tools for Fastening Strips
141
Fig. 97: Customer Tool
141
Table 60: Customer Tool
141
Fig. 99: Removing the Fastening Strips
142
Application, Special Tools
142
Fig. 98: Positioning the Collection Tub
142
Fig. 100: Fitting the Upper Fastening Strips
143
Fig. 101: Fitting the Bottom Fastening Strip
143
Table 61: Tightening Torque (51007)
143
Fig. 102: Fitting the Bottom Fastening Strip
144
Table 62: Tightening Torque (51007) with Spanner Holder
144
Fig. 104: Disassembly of the Elbows
145
Fig. 103: Initial Situation
145
Disassembly
145
Removing and Installing 6-Nozzle Turbine Cleaning Component (Optional)
145
Fig. 105: Disassembly of the Elbows
146
Fig. 106: Pipe Disassembly
146
Fig. 107: Disassembly of the Connecting Pieces
147
Fig. 108: Disassembly of the Cleaning Nozzle
147
Table 63: Dismantling Screw
147
Table 64: Dismantling Screw
148
Fig. 110: Assembly of the Connecting Pieces
148
Fig. 109: Assembly of the Cleaning Nozzle
148
Assembly
148
Fig. 111: Pipe Assembly
149
Fig. 112: Elbow 1 Assembly
149
Fig. 113: Elbow 2 Assembly
150
Table 65: Tightening Torque (51314 / 51316)
150
Fitting the Cleaning Nozzles with Multi-Inlet Turbine Casings
151
Fig. 114: Fit the Cleaning Nozzles
151
Taking out of Operation at Short Notice
152
Possible Emergency Repairs
152
Installing the Replacement Turbocharger
153
Installing the Replacement Cartridge Group
153
Fitting the Cover Plate
154
Fig. 115: Fitting the Cover Plate
154
Cover Plate Drawing
155
Fig. 116: Cover Plate Drawing
155
Table 66: Cover Plate Dimensions [MM]
155
Fig. 117: Dimensions for Cover Plate
156
Table 67: Cover Plate Dimensions [MM]
156
Taking the Engine out of Operation for up to 12 Months
157
Mothballing the Turbocharger
157
Taking the Engine out of Operation for more than 12 Months
158
Material and Disposal
159
REACH and Rohs Compliance Declaration for Products
159
Disposing of Turbocharger Components
160
Spare Parts
161
Ordering Spare Parts
161
Required Customer Spare Part Set (97070)
161
Table 68: Customer Spare Part Set 97070
161
Spare Part - Illustrations
162
Table 69: Spare Parts - Cartridge, Oil Cooled
163
Table 70: Spare Parts - Bearing, Casing Oil Cooled
164
Table 71: Spare Parts - Rotor and Bearing Parts
165
Table 72: Spare Parts - Turbine Casing, 1 Inlet
166
Table 73: Spare Parts - Turbine Casing, 2 Inlets
167
Table 74: Spare Parts - Turbine Casing, 3 Inlets
168
Table 75: Spare Parts - Cleaning Device
169
Table 76: Spare Parts - Gas Outlet Casing, Radial
170
Table 77: Spare Parts - Compressor Casing
171
Table 79: Spare Parts - Air Suction Branch Axial
173
Table 78: Spare Parts - Filter Silencer
173
Table 80: Spare Parts - Air Suction Branch Radial
174
Table 81: Spare Parts - Speed Measurement System
175
Tools
176
Fig. 118: Special Tool
176
Table 82: Customer Tool Set 90000
176
Table 83: Special Tool (90160)
176
Advertisement
ABB A150-M68 Operation Manual (184 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 31.04 MB
Table of Contents
Operation Manual / A150-M58/68
3
Table of Contents
3
Fig. 1: Serial Number (01) on the Rating Plate
6
Introduction
6
Purpose of the Manual
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
Safety
15
Introduction
15
CE Conformity
15
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Definition of Mandatory Signs
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Definition of Safety Instructions
16
Intended Use
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 7: Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Periodic Check of the Pressure Vessels
21
Lifting of Loads
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Fig. 10: Attachment Angle
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
Table 4: Weight of Complete Turbocharger Unit
31
Turbocharger Weight and Transportation
31
Fig. 11: Suspension of Complete Turbocharger Unit
31
Removing and Installing
31
Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Fig. 13: Removing the Turbocharger
33
Fig. 14: Loosening the Clamping Nut
34
Fig. 15: Turbocharger Centre of Gravity
35
Fig. 16: Inserting the Gasket
36
Installing the Turbocharger
36
Fig. 17: Inserting the Threaded Rods
37
Fig. 18: Placing the Turbocharger on the Bracket
37
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
38
Fig. 20: Tightening Pressure Screws
39
Table 5: Torque-Controlled Tightening of the Pressure Screws
39
Fig. 21: Connecting the Speed Sensor
40
Fig. 22: Connecting the Compressor Cooling Air Intake
40
Fig. 23: Attaching the Support
40
Oil Supply
41
Commissioning
41
Fig. 24: Oil Orifice
42
Inspection Procedures
43
Commissioning after Taking out of Operation
45
Monitoring Operation
46
Oil Pressure, Oil Temperature
46
Table 6: Lubricating Oil Pressure at Oil Inlet before Turbocharger
46
Table 7: Lubricating Oil Temperature at the Inlet
47
Table 8: Maximum Lubricating Oil Temperature at the Outlet
47
Exhaust Gas Temperature before Turbine
48
Turbocharger Speed
49
Fig. 25: Layout and Overview of Speed Measurement System
49
Fig. 26: Replacing the Speed Sensor
51
Table 9: Tightening Torque (86505)
51
Operation and Service
52
Noise Emission
52
Fig. 27: Noise Insulation, Bellows
53
Service Work
54
Table 10: Expected Replacement Intervals
57
Expected Replacement Intervals
57
Stopping the Engine
59
Periodic Maintenance Work
60
Foreword to Maintenance
60
Table 11: Maintenance Table
60
Cleaning the Compressor During Operation
61
Fig. 28: Carrying out Wet Cleaning of Compressor
63
Table 12: Parameters for Wet Cleaning of Compressor
63
Cleaning the Turbine During Operation
64
Table 13: Turbine Wet Cleaning, Recommended Operating State
66
Fig. 29: Turbine Cleaning Devices
66
Fig. 30: Carrying out Wet Cleaning of Turbine
67
Table 14: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
67
Cleaning Components Mechanically
68
Table 15: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
68
Fig. 31: Cleaning the Filter Silencer
69
Fig. 32: Compressor Casing
71
Fig. 33: Diffuser
72
Fig. 34: Turbine End, Non-Rotating Parts
73
Table 16: Value Table for Soaking
76
Fig. 35: Soaking the Turbine End
76
Malfunctions When Starting
79
Table 17: Malfunctions When Starting - Delayed Start-Up
79
Table 18: Malfunctions When Starting - Vibrations
79
Table 19: Malfunctions When Starting - Rubbing of Rotating Parts
79
Eliminating Malfunctions
79
Table 21: Malfunctions During Operation - Speed Reduces
80
Table 22: Malfunctions During Operation - Speed Increases
80
Table 20: Malfunctions During Operation - Lubricating Oil Pressure too Low
80
Malfunctions During Operation
80
Table 23: Malfunctions During Operation - Exhaust Gas Temperature too High
81
Table 24: Malfunctions During Operation - Charge Air Pressure too Low
81
Table 25: Malfunctions During Operation - Charge Air Pressure too High
82
Table 26: Malfunctions During Operation - Engine Performance Losses
82
Turbocharger Is Surging
83
Table 27: Malfunction - Turbocharger Surging
83
Table 28: Malfunction - Sporadic Surge Blows
83
Table 30: Malfunctions When Stopping - Runout Time too Short
84
Malfunctions When Stopping
84
Table 29: Malfunctions When Stopping - Runout Noises
84
Table 33: Malfunction of the Speed Measurement System - Measured Speed too Low
85
Speed Measurement System
85
Table 32: Malfunction of the Speed Measurement System - Measured Speed too High
85
Table 31: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
85
Dismantling and Fitting, General
86
Introduction
86
Material Required
87
Fig. 36: Swivel Lifting Eye (Example)
87
Table 34: Swivel Lifting Eyes
87
Fig. 37: Press-Off Screws
88
Fig. 38: Dismantling Screw
88
Table 35: Press-Off Screws
88
Table 36: Dismantling Screw
88
Disassembly and Assembly Concepts
90
Fig. 39: Removing the Cartridge Group with Compressor and Turbine Casing
90
Fig. 40: Cartridge Concept
91
Fig. 41: Optional Spanner Holder
92
Table 37: Weights of Assemblies
93
Weights of Individual Parts
93
Fig. 42: Weights of Assemblies
93
Table of Tightening Torques
94
Fig. 43 Overview of Tightening Torques
94
Table 38: Tightening Torques
94
Fig. 44: Tightening Torques for Insulation
95
Table 39: Tightening Torques for Insulation
95
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
96
Removing Air Inlets
96
Fig. 45: Removing the Air Inlets
96
Removing the Gas Outlet Casing
97
Fig. 46: Remove Gas Outlet Casing Without Support
97
Fig. 47: Removing Gas Outlet Casing with Support 1
98
Fig. 48: Removing Gas Outlet Casing with Support 1
99
Removing the Gas Outlet Flange
100
Fig. 49: Removing the Gas Outlet Flange
100
Table 40: Press-Off Screws - Gas Outlet Flange
100
Fig. 51: Remove Insulation
101
Fig. 50: Turbine Cleaning Nozzle
101
Removing the Cartridge Group with Compressor and Turbine Casing
101
Fig. 52: Removing the Cartridge Group with Compressor and Turbine Casing
102
Fig. 53: Setting down the Cartridge Group with the Compressor and Turbine Casing
102
Removing the Compressor Casing
103
Fig. 54: Removing the Compressor Casing
103
Removing the Cartridge Group
104
Fig. 55: Removing Cartridge Group 1
104
Table 41: Tightening Torque (90012-01)
104
Fig. 56: Removing Cartridge Group 2
105
Fig. 57: Removing Cartridge Group 3
106
Installing the Cartridge Group on the Service Support
107
Fig. 58: Installing the Cartridge Group on the Service Support
107
Removing the Nozzle Ring
108
Fig. 59: Removing the Nozzle Ring
108
Measuring Clearance a and B
109
Fig. 60: Measuring Clearance a and B
109
Table 42: Permissible Clearances a and B
109
Table 43: Nozzle Ring Compression PD
110
Nozzle Ring Compression PD
110
Fig. 61: Nozzle Ring Compression PD
110
Installing Nozzle Ring
111
Fig. 62: Installing the Nozzle Ring
111
Installing the Cartridge Group
112
Fig. 63: Lifting the Cartridge Group and Rotating It
112
Fig. 64: Turning the Cartridge Group
113
Table 44: Tightening Torque (90012-01)
113
Fig. 65: Installing the Cartridge Group
114
Table 45: Tightening Torque (51007)
114
Table 46: Tightening Torque (79041)
115
Installing the Compressor Casing
115
Fig. 67: Installing the Compressor Casing
115
Fig. 66: Fitting the Diffuser
115
Table 47: Tightening Torque (72011)
116
Turning the Cartridge Group with Compressor and Turbine Casing
117
Fig. 68: Turning the Cartridge Group with Compressor and Turbine Casing
117
Installing the Gas Outlet Flange
118
Fig. 69: Installing the Gas Outlet Flange
118
Table 48: Permissible Clearances N and R
119
Radial Clearances N and R
119
Fig. 70: Measuring Clearances N and R
119
Fitting the Insulation
120
Fig. 71: Fitting the Insulation
120
Installing the Cartridge Group with Compressor and Turbine Casing
121
Fig. 72: Installing the Cartridge Group with Compressor and Turbine Casing
121
Fig. 73: Installing the Cartridge Group with Compressor and Turbine Casing
121
Installing the Gas Outlet Casing
122
Fig. 74: Fitting Gas Outlet Casing Without Support
122
Table 49: Tightening Torque (51009)
122
Fig. 75: Installing Gas Outlet Casing with Support 1
123
Table 50: Tightening Torque (51009)
123
Fig. 76: Installing Gas Outlet Casing with Support 2
124
Installing Air Inlets
125
Fig. 77: Installing the Air Inlets
125
Table 51: Tightening Torque (72051)
125
Dismantling and Fitting, Cartridge Concept
126
Removing Air Inlets
126
Fig. 78: Removing the Air Inlets
126
Removing the Compressor Casing
127
Fig. 79: Removing the Compressor Casing
127
Fig. 80: Pressing off Compressor Casing
128
Fig. 81: Remove the Diffuser
128
Removing the Cartridge Group
129
Fig. 82: Removing Insulation Sheets
129
Fig. 83: Removing Cartridge Group 1
129
Fig. 84: Removing Cartridge Group 2
130
Fig. 85: Removing Cartridge Group 3
131
Fig. 86: S_05180
132
Fig. 87: Measuring Clearance a and B
133
Table 52: Permissible Clearances a and B
133
Fig. 88: Nozzle Ring Compression PD
134
Table 53: Nozzle Ring Compression PD
134
Fig. 89: Installing the Nozzle Ring
135
Fig. 90: Installing the Cartridge Group
136
Fig. 91: Installing the Cartridge Group 2
137
Table 54: Tightening Torque (51007)
137
Table 55: Tightening Torque (51007) with Spanner Holder
137
Fig. 92: Fitting the Diffuser
138
Table 56: Tightening Torque (79041)
138
Fig. 93: Installing the Compressor Casing
139
Table 57: Tightening Torque (72011)
139
Fig. 94: Measuring Clearances N and R
140
Table 58: Permissible Clearances N and R
140
Fig. 95: Fitting the Insulation
141
Fig. 96: Installing the Air Inlets
142
Table 59: Tightening Torque (72051)
142
Table 60: Customer Tool
143
Fig. 97: Customer Tool
143
Dismantling and Fitting, Special Tools for Fastening Strips
143
Fig. 98: Positioning the Collection Tub
144
Fig. 99: Removing the Fastening Strips
144
Application, Special Tools
144
Fig. 100: Fitting the Upper Fastening Strips
145
Fig. 101: Fitting the Bottom Fastening Strip
145
Table 61: Tightening Torque (51007)
145
Fig. 102: Fitting the Bottom Fastening Strip
146
Table 62: Tightening Torque (51007) with Spanner Holder
146
Fig. 104: Disassembly of the Elbows
147
Removing and Installing 6-Nozzle Turbine Cleaning Component (Optional)
147
Fig. 103: Initial Situation
147
Disassembly
147
Fig. 105: Disassembly of the Elbows
148
Fig. 106: Pipe Disassembly
148
Fig. 107: Disassembly of the Connecting Pieces
149
Fig. 108: Disassembly of the Cleaning Nozzle
149
Table 63: Dismantling Screw
149
Table 64: Dismantling Screw
150
Fig. 109: Assembly of the Cleaning Nozzle
150
Fig. 110: Assembly of the Connecting Pieces
150
Assembly
150
Fig. 111: Pipe Assembly
151
Fig. 112: Elbow 1 Assembly
151
Fig. 113: Elbow 2 Assembly
152
Table 65: Tightening Torque (51314 / 51316)
152
Fitting the Cleaning Nozzles with Multi-Inlet Turbine Casings
153
Fig. 114: Fit the Cleaning Nozzles
153
Taking out of Operation at Short Notice
154
Possible Emergency Repairs
154
Installing the Replacement Cartridge Group
155
Installing the Replacement Turbocharger
155
Fitting the Cover Plate
156
Fig. 115: Fitting the Cover Plate
156
Cover Plate Drawing
157
Fig. 116: Cover Plate Drawing
157
Table 66: Cover Plate Dimensions [MM]
157
Fig. 117: Dimensions for Cover Plate
158
Table 67: Cover Plate Dimensions [MM]
158
Mothballing the Turbocharger
159
Taking the Engine out of Operation for more than 12 Months
160
Material and Disposal
161
REACH and Rohs Compliance Declaration for Products
161
Disposing of Turbocharger Components
162
Required Customer Spare Part Set (97070)
163
Table 68: Customer Spare Part Set 97070
163
Ordering Spare Parts
163
Spare Parts
163
Spare Part - Illustrations
164
Table 69: Spare Parts - Cartridge, Oil Cooled
165
Table 70: Spare Parts - Bearing, Casing Oil Cooled
166
Table 71: Spare Parts - Rotor and Bearing Parts
167
Table 72: Spare Parts - Turbine Casing, 1 Inlet
168
Table 73: Spare Parts - Turbine Casing, 2 Inlets
169
Table 74: Spare Parts - Turbine Casing, 3 Inlets
170
Table 75: Spare Parts - Cleaning Device
171
Table 76: Spare Parts - Gas Outlet Casing, Radial
172
Table 77: Spare Parts - Compressor Casing
173
Table 78: Spare Parts - Filter Silencer
175
Table 79: Spare Parts - Air Suction Branch Axial
175
Table 80: Spare Parts - Air Suction Branch Radial
176
Table 81: Spare Parts - Speed Measurement System
177
Tools
178
Fig. 118: Special Tool
178
Table 82: Customer Tool Set 90000
178
Table 83: Special Tool (90160)
178
ABB A150-M68 Operation Manual (184 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 31.04 MB
Table of Contents
Operation Manual / A150-M58/68
3
Table of Contents
3
Fig. 1: Serial Number (01) on the Rating Plate
6
Introduction
6
Purpose of the Manual
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
Safety
15
Introduction
15
CE Conformity
15
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Definition of Mandatory Signs
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Definition of Safety Instructions
16
Intended Use
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 7: Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Periodic Check of the Pressure Vessels
21
Lifting of Loads
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Fig. 10: Attachment Angle
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
Table 4: Weight of Complete Turbocharger Unit
31
Turbocharger Weight and Transportation
31
Fig. 11: Suspension of Complete Turbocharger Unit
31
Removing and Installing
31
Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Fig. 13: Removing the Turbocharger
33
Fig. 14: Loosening the Clamping Nut
34
Fig. 15: Turbocharger Centre of Gravity
35
Fig. 16: Inserting the Gasket
36
Installing the Turbocharger
36
Fig. 17: Inserting the Threaded Rods
37
Fig. 18: Placing the Turbocharger on the Bracket
37
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
38
Fig. 20: Tightening Pressure Screws
39
Table 5: Torque-Controlled Tightening of the Pressure Screws
39
Fig. 21: Connecting the Speed Sensor
40
Fig. 22: Connecting the Compressor Cooling Air Intake
40
Fig. 23: Attaching the Support
40
Oil Supply
41
Commissioning
41
Fig. 24: Oil Orifice
42
Inspection Procedures
43
Commissioning after Taking out of Operation
45
Monitoring Operation
46
Oil Pressure, Oil Temperature
46
Table 6: Lubricating Oil Pressure at Oil Inlet before Turbocharger
46
Table 7: Lubricating Oil Temperature at the Inlet
47
Table 8: Maximum Lubricating Oil Temperature at the Outlet
47
Exhaust Gas Temperature before Turbine
48
Turbocharger Speed
49
Fig. 25: Layout and Overview of Speed Measurement System
49
Fig. 26: Replacing the Speed Sensor
51
Table 9: Tightening Torque (86505)
51
Operation and Service
52
Noise Emission
52
Fig. 27: Noise Insulation, Bellows
53
Service Work
54
Table 10: Expected Replacement Intervals
57
Expected Replacement Intervals
57
Stopping the Engine
59
Periodic Maintenance Work
60
Foreword to Maintenance
60
Table 11: Maintenance Table
60
Cleaning the Compressor During Operation
61
Fig. 28: Carrying out Wet Cleaning of Compressor
63
Table 12: Parameters for Wet Cleaning of Compressor
63
Cleaning the Turbine During Operation
64
Table 13: Turbine Wet Cleaning, Recommended Operating State
66
Fig. 29: Turbine Cleaning Devices
66
Fig. 30: Carrying out Wet Cleaning of Turbine
67
Table 14: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
67
Cleaning Components Mechanically
68
Table 15: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
68
Fig. 31: Cleaning the Filter Silencer
69
Fig. 32: Compressor Casing
71
Fig. 33: Diffuser
72
Fig. 34: Turbine End, Non-Rotating Parts
73
Table 16: Value Table for Soaking
76
Fig. 35: Soaking the Turbine End
76
Malfunctions When Starting
79
Table 17: Malfunctions When Starting - Delayed Start-Up
79
Table 18: Malfunctions When Starting - Vibrations
79
Table 19: Malfunctions When Starting - Rubbing of Rotating Parts
79
Eliminating Malfunctions
79
Table 21: Malfunctions During Operation - Speed Reduces
80
Table 22: Malfunctions During Operation - Speed Increases
80
Table 20: Malfunctions During Operation - Lubricating Oil Pressure too Low
80
Malfunctions During Operation
80
Table 23: Malfunctions During Operation - Exhaust Gas Temperature too High
81
Table 24: Malfunctions During Operation - Charge Air Pressure too Low
81
Table 25: Malfunctions During Operation - Charge Air Pressure too High
82
Table 26: Malfunctions During Operation - Engine Performance Losses
82
Turbocharger Is Surging
83
Table 27: Malfunction - Turbocharger Surging
83
Table 28: Malfunction - Sporadic Surge Blows
83
Table 30: Malfunctions When Stopping - Runout Time too Short
84
Malfunctions When Stopping
84
Table 29: Malfunctions When Stopping - Runout Noises
84
Table 33: Malfunction of the Speed Measurement System - Measured Speed too Low
85
Speed Measurement System
85
Table 32: Malfunction of the Speed Measurement System - Measured Speed too High
85
Table 31: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
85
Dismantling and Fitting, General
86
Introduction
86
Material Required
87
Fig. 36: Swivel Lifting Eye (Example)
87
Table 34: Swivel Lifting Eyes
87
Fig. 37: Press-Off Screws
88
Fig. 38: Dismantling Screw
88
Table 35: Press-Off Screws
88
Table 36: Dismantling Screw
88
Disassembly and Assembly Concepts
90
Fig. 39: Removing the Cartridge Group with Compressor and Turbine Casing
90
Fig. 40: Cartridge Concept
91
Fig. 41: Optional Spanner Holder
92
Table 37: Weights of Assemblies
93
Weights of Individual Parts
93
Fig. 42: Weights of Assemblies
93
Table of Tightening Torques
94
Fig. 43 Overview of Tightening Torques
94
Table 38: Tightening Torques
94
Fig. 44: Tightening Torques for Insulation
95
Table 39: Tightening Torques for Insulation
95
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
96
Removing Air Inlets
96
Fig. 45: Removing the Air Inlets
96
Removing the Gas Outlet Casing
97
Fig. 46: Remove Gas Outlet Casing Without Support
97
Fig. 47: Removing Gas Outlet Casing with Support 1
98
Fig. 48: Removing Gas Outlet Casing with Support 1
99
Removing the Gas Outlet Flange
100
Fig. 49: Removing the Gas Outlet Flange
100
Table 40: Press-Off Screws - Gas Outlet Flange
100
Fig. 51: Remove Insulation
101
Fig. 50: Turbine Cleaning Nozzle
101
Removing the Cartridge Group with Compressor and Turbine Casing
101
Fig. 52: Removing the Cartridge Group with Compressor and Turbine Casing
102
Fig. 53: Setting down the Cartridge Group with the Compressor and Turbine Casing
102
Removing the Compressor Casing
103
Fig. 54: Removing the Compressor Casing
103
Removing the Cartridge Group
104
Fig. 55: Removing Cartridge Group 1
104
Table 41: Tightening Torque (90012-01)
104
Fig. 56: Removing Cartridge Group 2
105
Fig. 57: Removing Cartridge Group 3
106
Installing the Cartridge Group on the Service Support
107
Fig. 58: Installing the Cartridge Group on the Service Support
107
Removing the Nozzle Ring
108
Fig. 59: Removing the Nozzle Ring
108
Measuring Clearance a and B
109
Fig. 60: Measuring Clearance a and B
109
Table 42: Permissible Clearances a and B
109
Table 43: Nozzle Ring Compression PD
110
Nozzle Ring Compression PD
110
Fig. 61: Nozzle Ring Compression PD
110
Installing Nozzle Ring
111
Fig. 62: Installing the Nozzle Ring
111
Installing the Cartridge Group
112
Fig. 63: Lifting the Cartridge Group and Rotating It
112
Fig. 64: Turning the Cartridge Group
113
Table 44: Tightening Torque (90012-01)
113
Fig. 65: Installing the Cartridge Group
114
Table 45: Tightening Torque (51007)
114
Table 46: Tightening Torque (79041)
115
Installing the Compressor Casing
115
Fig. 67: Installing the Compressor Casing
115
Fig. 66: Fitting the Diffuser
115
Table 47: Tightening Torque (72011)
116
Turning the Cartridge Group with Compressor and Turbine Casing
117
Fig. 68: Turning the Cartridge Group with Compressor and Turbine Casing
117
Installing the Gas Outlet Flange
118
Fig. 69: Installing the Gas Outlet Flange
118
Table 48: Permissible Clearances N and R
119
Radial Clearances N and R
119
Fig. 70: Measuring Clearances N and R
119
Fitting the Insulation
120
Fig. 71: Fitting the Insulation
120
Installing the Cartridge Group with Compressor and Turbine Casing
121
Fig. 72: Installing the Cartridge Group with Compressor and Turbine Casing
121
Fig. 73: Installing the Cartridge Group with Compressor and Turbine Casing
121
Installing the Gas Outlet Casing
122
Fig. 74: Fitting Gas Outlet Casing Without Support
122
Table 49: Tightening Torque (51009)
122
Fig. 75: Installing Gas Outlet Casing with Support 1
123
Table 50: Tightening Torque (51009)
123
Fig. 76: Installing Gas Outlet Casing with Support 2
124
Installing Air Inlets
125
Fig. 77: Installing the Air Inlets
125
Table 51: Tightening Torque (72051)
125
Dismantling and Fitting, Cartridge Concept
126
Removing Air Inlets
126
Fig. 78: Removing the Air Inlets
126
Removing the Compressor Casing
127
Fig. 79: Removing the Compressor Casing
127
Fig. 80: Pressing off Compressor Casing
128
Fig. 81: Remove the Diffuser
128
Removing the Cartridge Group
129
Fig. 82: Removing Insulation Sheets
129
Fig. 83: Removing Cartridge Group 1
129
Fig. 84: Removing Cartridge Group 2
130
Fig. 85: Removing Cartridge Group 3
131
Fig. 86: S_05180
132
Fig. 87: Measuring Clearance a and B
133
Table 52: Permissible Clearances a and B
133
Fig. 88: Nozzle Ring Compression PD
134
Table 53: Nozzle Ring Compression PD
134
Fig. 89: Installing the Nozzle Ring
135
Fig. 90: Installing the Cartridge Group
136
Fig. 91: Installing the Cartridge Group 2
137
Table 54: Tightening Torque (51007)
137
Table 55: Tightening Torque (51007) with Spanner Holder
137
Fig. 92: Fitting the Diffuser
138
Table 56: Tightening Torque (79041)
138
Fig. 93: Installing the Compressor Casing
139
Table 57: Tightening Torque (72011)
139
Fig. 94: Measuring Clearances N and R
140
Table 58: Permissible Clearances N and R
140
Fig. 95: Fitting the Insulation
141
Fig. 96: Installing the Air Inlets
142
Table 59: Tightening Torque (72051)
142
Table 60: Customer Tool
143
Fig. 97: Customer Tool
143
Dismantling and Fitting, Special Tools for Fastening Strips
143
Fig. 98: Positioning the Collection Tub
144
Fig. 99: Removing the Fastening Strips
144
Application, Special Tools
144
Fig. 100: Fitting the Upper Fastening Strips
145
Fig. 101: Fitting the Bottom Fastening Strip
145
Table 61: Tightening Torque (51007)
145
Fig. 102: Fitting the Bottom Fastening Strip
146
Table 62: Tightening Torque (51007) with Spanner Holder
146
Fig. 104: Disassembly of the Elbows
147
Removing and Installing 6-Nozzle Turbine Cleaning Component (Optional)
147
Fig. 103: Initial Situation
147
Disassembly
147
Fig. 105: Disassembly of the Elbows
148
Fig. 106: Pipe Disassembly
148
Fig. 107: Disassembly of the Connecting Pieces
149
Fig. 108: Disassembly of the Cleaning Nozzle
149
Table 63: Dismantling Screw
149
Table 64: Dismantling Screw
150
Fig. 109: Assembly of the Cleaning Nozzle
150
Fig. 110: Assembly of the Connecting Pieces
150
Assembly
150
Fig. 111: Pipe Assembly
151
Fig. 112: Elbow 1 Assembly
151
Fig. 113: Elbow 2 Assembly
152
Table 65: Tightening Torque (51314 / 51316)
152
Fitting the Cleaning Nozzles with Multi-Inlet Turbine Casings
153
Fig. 114: Fit the Cleaning Nozzles
153
Taking out of Operation at Short Notice
154
Possible Emergency Repairs
154
Installing the Replacement Cartridge Group
155
Installing the Replacement Turbocharger
155
Fitting the Cover Plate
156
Fig. 115: Fitting the Cover Plate
156
Cover Plate Drawing
157
Fig. 116: Cover Plate Drawing
157
Table 66: Cover Plate Dimensions [MM]
157
Fig. 117: Dimensions for Cover Plate
158
Table 67: Cover Plate Dimensions [MM]
158
Mothballing the Turbocharger
159
Taking the Engine out of Operation for more than 12 Months
160
Material and Disposal
161
REACH and Rohs Compliance Declaration for Products
161
Disposing of Turbocharger Components
162
Required Customer Spare Part Set (97070)
163
Table 68: Customer Spare Part Set 97070
163
Ordering Spare Parts
163
Spare Parts
163
Spare Part - Illustrations
164
Table 69: Spare Parts - Cartridge, Oil Cooled
165
Table 70: Spare Parts - Bearing, Casing Oil Cooled
166
Table 71: Spare Parts - Rotor and Bearing Parts
167
Table 72: Spare Parts - Turbine Casing, 1 Inlet
168
Table 73: Spare Parts - Turbine Casing, 2 Inlets
169
Table 74: Spare Parts - Turbine Casing, 3 Inlets
170
Table 75: Spare Parts - Cleaning Device
171
Table 76: Spare Parts - Gas Outlet Casing, Radial
172
Table 77: Spare Parts - Compressor Casing
173
Table 78: Spare Parts - Filter Silencer
175
Table 79: Spare Parts - Air Suction Branch Axial
175
Table 80: Spare Parts - Air Suction Branch Radial
176
Table 81: Spare Parts - Speed Measurement System
177
Tools
178
Fig. 118: Special Tool
178
Table 82: Customer Tool Set 90000
178
Table 83: Special Tool (90160)
178
Advertisement
ABB A150-M68 Operation Manual (182 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 31.02 MB
Table of Contents
Introduction
3
Table of Contents
3
Purpose of the Manual
4
Symbols, Definitions
5
Storage of New Turbochargers and Spare Parts
7
Contact Information
9
Safety
11
CE Conformity
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
Introduction
32
Essential Information
34
Introduction
34
Registered Trademarks
34
Related Documents
35
Table 1: Related Documents
35
Fig. 1: Layout and Function of the Turbocharger
36
Layout and Function of the Turbocharger
36
Fig. 2: Compressor Wheel Cooling
37
Fig. 3: Warning Plate Locations
38
Warning Plates on the Turbocharger
38
Fig. 4: Locations of the Rating Plates
39
Locations of the Rating Plates
39
Fig. 5: Suspension of Complete Turbocharger Unit
40
Removing and Installing
40
Table 2: Weight of Complete Turbocharger Unit
40
Turbocharger Weight and Transportation
40
Fig. 6: Turbine Cleaning Nozzle
41
Fig. 7: Removing the Turbocharger
41
Removing the Turbocharger
41
Fig. 8: Loosening the Clamping Nut
42
Fig. 9: Turbocharger Centre of Gravity
43
Fig. 10: Inserting the Gasket
44
Installing the Turbocharger
44
Fig. 11: Inserting the Threaded Rods
45
Fig. 12: Placing the Turbocharger on the Bracket
45
Fig. 13: Preparing the Clamping Nut for the Tightening Procedure
46
Fig. 14: Tightening Pressure Screws
47
Table 3: Torque-Controlled Tightening of the Pressure Screws
47
Fig. 15: Connecting the Speed Sensor
48
Fig. 16: Connecting the Compressor Cooling Air Intake
48
Fig. 17: Attaching the Support
48
Commissioning
49
Oil Supply
49
Fig. 18: Oil Orifice
50
Inspection Procedures
51
Commissioning after Taking out of Operation
53
Monitoring Operation
54
Oil Pressure, Oil Temperature
54
Table 4: Lubricating Oil Pressure at Oil Inlet before Turbocharger
54
Table 5: Lubricating Oil Temperature at the Inlet
55
Table 6: Maximum Lubricating Oil Temperature at the Outlet
55
Exhaust Gas Temperature before Turbine
56
Fig. 19: Layout and Overview of Speed Measurement System
57
Turbocharger Speed
57
Fig. 20: Replacing the Speed Sensor
59
Table 7: Tightening Torque (86505)
59
Noise Emission
60
Operation and Service
60
Fig. 21: Noise Insulation, Bellows
61
Service Work
62
Expected Replacement Intervals
65
Table 8: Expected Replacement Intervals
65
Stopping the Engine
67
Foreword to Maintenance
68
Periodic Maintenance Work
68
Table 9: Maintenance Table
68
Cleaning the Compressor During Operation
69
Fig. 22: Carrying out Wet Cleaning of Compressor
71
Table 10: Parameters for Wet Cleaning of Compressor
71
Cleaning the Turbine During Operation
72
Fig. 23: Turbine Cleaning Devices
74
Table 11: Turbine Wet Cleaning, Recommended Operating State
74
Fig. 24: Carrying out Wet Cleaning of Turbines
75
Table 12: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
75
Cleaning Components Mechanically
76
Table 13: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
76
Fig. 25: Cleaning the Filter Silencer
77
Fig. 26: Compressor Casing
79
Fig. 27: Diffuser
80
Fig. 28: Turbine End, Non-Rotating Parts
82
Fig. 29: Soaking the Turbine End
84
Table 14: Value Table for Soaking
84
Eliminating Malfunctions
87
Malfunctions When Starting
87
Table 15: Malfunctions When Starting - Delayed Start-Up
87
Table 16: Malfunctions When Starting - Vibrations
87
Table 17: Malfunctions When Starting - Rubbing of Rotating Parts
87
Malfunctions During Operation
88
Table 18: Malfunctions During Operation - Lubricating Oil Pressure too Low
88
Table 19: Malfunctions During Operation - Speed Reduces
88
Table 20: Malfunctions During Operation - Speed Increases
88
Table 21: Malfunctions During Operation - Exhaust Gas Temperature too High
89
Table 22: Malfunctions During Operation - Charge Air Pressure too Low
89
Table 23: Malfunctions During Operation - Charge Air Pressure too High
90
Table 24: Malfunctions During Operation - Engine Performance Losses
90
Table 25: Malfunction - Turbocharger Pumping
91
Table 26: Malfunction - Sporadic Surge Blows
91
Turbocharger Is Surging
91
Malfunctions When Stopping
92
Table 27: Malfunctions When Stopping - Runout Noises
92
Table 28: Malfunctions When Stopping - Runout Time too Short
92
Speed Measurement System
93
Table 29: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
93
Table 30: Malfunction of the Speed Measurement System - Measured Speed too High
93
Table 31: Malfunction of the Speed Measurement System - Measured Speed too Low
93
Dismantling and Fitting, General
94
Introduction
94
Fig. 30: Swivel Lifting Eyes
95
Material Required
95
Table 32: Swivel Lifting Eyes
95
Fig. 31: Press-Off Screws
96
Fig. 32: Dismantling Screw
96
Table 33: Press-Off Screws
96
Table 34: Dismantling Screw
96
Disassembly and Assembly Concepts
98
Fig. 33: Removing the Cartridge Group with Compressor and Turbine Casing
98
Fig. 34: Cartridge Concept
99
Fig. 35: Optional Spanner Holder
100
Fig. 36: Weights of Assemblies
101
Table 35: Weights of Assemblies
101
Weights of Individual Parts
101
Fig. 37 Overview of Tightening Torques
102
Table 36: Tightening Torques
102
Table of Tightening Torques
102
Fig. 38: Tightening Torques for Insulation
103
Table 37: Tightening Torques for Insulation
103
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
104
Fig. 39: Removing the Air Inlets
104
Removing Air Inlets
104
Fig. 40: Remove Gas Outlet Casing Without Support
105
Removing the Gas Outlet Casing
105
Fig. 41: Removing Gas Outlet Casing with Support 1
106
Fig. 42: Removing Gas Outlet Casing with Support 1
107
Fig. 43: Removing the Gas Outlet Flange
108
Removing the Gas Outlet Flange
108
Table 38: Press-Off Screws - Gas Outlet Flange
108
Fig. 44: Turbine Cleaning Nozzle
109
Fig. 45: Remove Insulation
109
Removing the Cartridge Group with Compressor and Turbine Casing
109
Fig. 46: Removing the Cartridge Group with Compressor and Turbine Casing
110
Fig. 47: Set down the Cartridge Group with the Compressor and Turbine Casing
110
Fig. 48: Removing the Compressor Casing
111
Removing the Compressor Casing
111
Fig. 49: Removing Cartridge Group 1
112
Removing the Cartridge Group
112
Table 39: Tightening Torque (90012-01)
112
Fig. 50: Removing Cartridge Group 2
113
Fig. 51: Removing Cartridge Group 3
114
Fig. 52: Installing the Cartridge Group on the Service Support
115
Installing the Cartridge Group on the Service Support
115
Fig. 53: Removing the Nozzle Ring
116
Removing the Nozzle Ring
116
Fig. 54: Measuring Clearance a and B
117
Measuring Clearance a and B
117
Table 40: Permissible Clearances a and B
117
Fig. 55: Nozzle Ring Compression PD
118
Nozzle Ring Compression PD
118
Table 41: Nozzle Ring Compression PD
118
Fig. 56: Installing the Nozzle Ring
119
Installing Nozzle Ring
119
Fig. 57: Lifting the Cartridge Group and Rotating It by 90
120
Fig. 59: Installing the Cartridge Group
120
Installing the Cartridge Group
120
Fig. 58: Turning the Cartridge Group
121
Table 42: Tightening Torque (90012-01)
121
Table 43: Tightening Torque (51007)
122
Fig. 60: Fitting the Diffuser
123
Fig. 61: Installing the Compressor Casing
123
Installing the Compressor Casing
123
Table 44: Tightening Torque (79041)
123
Table 45: Tightening Torque (72011)
124
Fig. 62: Turning the Cartridge Group with Compressor and Turbine Casing
125
Turning the Cartridge Group with Compressor and Turbine Casing
125
Fig. 63: Installing the Gas Outlet Flange
126
Installing the Gas Outlet Flange
126
Fig. 64: Measuring Clearances N and R
127
Radial Clearances N and R
127
Table 46: Permissible Clearances N and R
127
Fig. 65: Fitting the Insulation
128
Fitting the Insulation
128
Fig. 66: Installing the Cartridge Group with Compressor and Turbine Casing
129
Fig. 67: Installing the Cartridge Group with Compressor and Turbine Casing
129
Installing the Cartridge Group with Compressor and Turbine Casing
129
Fig. 68: Fitting Gas Outlet Casing Without Support
130
Installing the Gas Outlet Casing
130
Table 47: Tightening Torque (51009)
130
Fig. 69: Installing Gas Outlet Casing with Support 1
131
Table 48: Tightening Torque (51009)
131
Fig. 70: Installing Gas Outlet Casing with Support 2
132
Fig. 71: Installing the Air Inlets
133
Installing Air Inlets
133
Table 49: Tightening Torque (72051)
133
Dismantling and Fitting, Cartridge Concept
134
Fig. 72: Removing the Air Inlets
134
Removing Air Inlets
134
Fig. 73: Removing the Compressor Casing
135
Removing the Compressor Casing
135
Fig. 74: Pressing off Compressor Casing
136
Fig. 75: Remove the Diffuser
136
Fig. 76: Removing Insulation Sheets
137
Removing the Cartridge Group
137
Fig. 77: Removing Cartridge Group 1
138
Fig. 78: Removing Cartridge Group 2
139
Fig. 79: Removing Cartridge Group 3
140
Fig. 80: S_05180
141
Removing the Nozzle Ring
141
Fig. 81: Measuring Clearance a and B
142
Measuring Clearance a and B
142
Table 50: Permissible Clearances a and B
142
Fig. 82: Nozzle Ring Compression PD
143
Nozzle Ring Compression PD
143
Table 51: Nozzle Ring Compression PD
143
Fig. 83: Installing the Nozzle Ring
144
Installing Nozzle Ring
144
Fig. 84: Installing the Cartridge Group
145
Installing the Cartridge Group
145
Fig. 85: Installing the Cartridge Group 2
146
Table 52: Tightening Torque (51007)
146
Table 53: Tightening Torque (51007) with Spanner Holder
146
Fig. 86: Fitting the Diffuser
147
Installing the Compressor Casing
147
Table 54: Tightening Torque (79041)
147
Fig. 87: Installing the Compressor Casing
148
Table 55: Tightening Torque (72011)
148
Fig. 88: Measuring Clearances N and R
149
Radial Clearances N and R
149
Table 56: Permissible Clearances N and R
149
Fig. 89: Fitting the Insulation
150
Fitting the Insulation
150
Fig. 90: Installing the Air Inlets
151
Installing Air Inlets
151
Table 57: Tightening Torque (72051)
151
Dismantling and Fitting, Special Tools for Fastening Strips
152
Fig. 91: Customer Tool
152
Table 58: Customer Tool
152
Application, Special Tools
153
Fig. 92: Positioning the Collection Tub
153
Fig. 93: Removing the Fastening Strips
153
Fig. 94: Fitting the Upper Fastening Strips
154
Fig. 95: Fitting the Bottom Fastening Strip
154
Table 59: Tightening Torque (51007)
154
Fig. 96: Fitting the Bottom Fastening Strip
155
Table 60: Tightening Torque (51007) with Spanner Holder
155
Disassembly
156
Fig. 97: Initial Situation
156
Fig. 98: Disassembly of the Elbows
156
Removing and Installing 6-Nozzle Turbine Cleaning Component (Optional)
156
Fig. 100: Pipe Disassembly
157
Fig. 99: Disassembly of the Elbows
157
Fig. 101: Disassembly of the Connecting Pieces
158
Fig. 102: Disassembly of the Cleaning Nozzle
158
Table 61: Dismantling Screw
158
Assembly
159
Fig. 103: Assembly of the Cleaning Nozzle
159
Fig. 104: Assembly of the Connecting Pieces
159
Table 62: Dismantling Screw
159
Fig. 105: Pipe Assembly
160
Fig. 106: Elbow 1 Assembly
160
Fig. 107: Elbow 2 Assembly
161
Table 63: Tightening Torque (51314 / 51316)
161
Fig. 108: Fit the Cleaning Nozzles
162
Fitting the Cleaning Nozzles with Multi-Inlet Turbine Casings
162
Possible Emergency Repairs
163
Taking out of Operation at Short Notice
163
Installing the Replacement Cartridge Group
164
Installing the Replacement Turbocharger
164
Fig. 109: Fitting the Cover Plate
165
Fitting the Cover Plate
165
Cover Plate Drawing
166
Fig. 110: Cover Plate Drawing
166
Table 64: Cover Plate Dimensions [MM]
166
Fig. 111: Dimensions for Cover Plate
167
Table 65: Cover Plate Dimensions [MM]
167
Mothballing the Turbocharger
168
Taking the Engine out of Operation for up to 12 Months
168
Taking the Engine out of Operation for more than 12 Months
169
Disposing of Turbocharger Components
170
Ordering Spare Parts
171
Required Customer Spare Part Set (97070)
171
Spare Parts
171
Table 66: Customer Spare Part Set 97070
171
Fig. 112: Overview of Part Numbers
172
View of Turbocharger with Part Numbers
172
Table 67: Spare Parts List
173
Fig. 113: Overview of Part Numbers
174
Table 68: Spare Parts List
174
View of Turbine Cleaning Device
174
Fig. 114: Overview of Part Numbers
175
Table 69: Spare Parts List
175
Fig. 115: Special Tool
176
Table 70: Customer Tool Set 90000
176
Table 71: Special Tool (90160)
176
Tools
176
ABB A150-M68 Operation Manual (182 pages)
Turbocharging
Brand:
ABB
| Category:
Industrial Equipment
| Size: 31.03 MB
Table of Contents
Operation Manual / A150-M58/68
3
Table of Contents
3
1 Introduction
6
Purpose of the Manual
6
Fig. 1: Serial Number (01) on the Rating Plate
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
2 Safety
15
Introduction
15
CE Conformity
15
Definition of Mandatory Signs
16
Definition of Safety Instructions
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Intended Use
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 7: Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Periodic Check of the Pressure Vessels
21
Lifting of Loads
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Fig. 10: Attachment Angle
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
3 Removing and Installing
31
Turbocharger Weight and Transportation
31
Fig. 11: Suspension of Complete Turbocharger Unit
31
Table 4: Weight of Complete Turbocharger Unit
31
Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Fig. 13: Removing the Turbocharger
32
Fig. 14: Loosening the Clamping Nut
33
Fig. 15: Turbocharger Centre of Gravity
34
Installing the Turbocharger
35
Fig. 16: Inserting the Gasket
35
Fig. 17: Inserting the Threaded Rods
36
Fig. 18: Placing the Turbocharger on the Bracket
36
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
37
Fig. 20: Tightening Pressure Screws
38
Table 5: Torque-Controlled Tightening of the Pressure Screws
38
Fig. 21: Connecting the Speed Sensor
39
Fig. 22: Connecting the Compressor Cooling Air Intake
39
Fig. 23: Attaching the Support
39
4 Commissioning
40
Oil Supply
40
Fig. 24: Oil Orifice
41
Inspection Procedures
42
Commissioning after Taking out of Operation
44
5 Monitoring Operation
45
Oil Pressure, Oil Temperature
45
Table 6: Lubricating Oil Pressure at Oil Inlet before Turbocharger
45
Table 7: Lubricating Oil Temperature at the Inlet
46
Table 8: Maximum Lubricating Oil Temperature at the Outlet
46
Exhaust Gas Temperature before Turbine
47
Turbocharger Speed
48
Fig. 25: Layout and Overview of Speed Measurement System
48
Fig. 26: Replacing the Speed Sensor
50
Table 9: Tightening Torque (86505)
50
6 Operation and Service
51
Noise Emission
51
Fig. 27: Noise Insulation, Bellows
52
Service Work
53
Expected Replacement Intervals
56
Table 10: Expected Replacement Intervals
56
Stopping the Engine
58
7 Periodic Maintenance Work
59
Foreword to Maintenance
59
Table 11: Maintenance Table
59
Cleaning the Compressor During Operation
60
Fig. 28: Carrying out Wet Cleaning of Compressor
62
Table 12: Parameters for Wet Cleaning of Compressor
62
Cleaning the Turbine During Operation
63
Fig. 29: Turbine Cleaning Devices
65
Table 13: Turbine Wet Cleaning, Recommended Operating State
65
Fig. 30: Carrying out Wet Cleaning of Turbines
66
Table 14: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
66
Cleaning Components Mechanically
67
Table 15: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
67
Fig. 31: Cleaning the Filter Silencer
68
Fig. 32: Compressor Casing
70
Fig. 33: Diffuser
71
Fig. 34: Turbine End, Non-Rotating Parts
73
Fig. 35: Soaking the Turbine End
75
Table 16: Value Table for Soaking
75
8 Eliminating Malfunctions
78
Malfunctions When Starting
78
Table 17: Malfunctions When Starting - Delayed Start-Up
78
Table 18: Malfunctions When Starting - Vibrations
78
Table 19: Malfunctions When Starting - Rubbing of Rotating Parts
78
Malfunctions During Operation
79
Table 20: Malfunctions During Operation - Lubricating Oil Pressure too Low
79
Table 21: Malfunctions During Operation - Speed Reduces
79
Table 22: Malfunctions During Operation - Speed Increases
79
Table 23: Malfunctions During Operation - Exhaust Gas Temperature too High
80
Table 24: Malfunctions During Operation - Charge Air Pressure too Low
80
Table 25: Malfunctions During Operation - Charge Air Pressure too High
81
Table 26: Malfunctions During Operation - Engine Performance Losses
81
Turbocharger Is Surging
82
Table 27: Malfunction - Turbocharger Pumping
82
Table 28: Malfunction - Sporadic Surge Blows
82
Malfunctions When Stopping
83
Table 29: Malfunctions When Stopping - Runout Noises
83
Table 30: Malfunctions When Stopping - Runout Time too Short
83
Speed Measurement System
84
Table 31: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
84
Table 32: Malfunction of the Speed Measurement System - Measured Speed too High
84
Table 33: Malfunction of the Speed Measurement System - Measured Speed too Low
84
9 Dismantling and Fitting, General
85
Introduction
85
Material Required
86
Fig. 36: Swivel Lifting Eyes
86
Table 34: Swivel Lifting Eyes
86
Fig. 37: Press-Off Screws
87
Fig. 38: Dismantling Screw
87
Table 35: Press-Off Screws
87
Table 36: Dismantling Screw
87
Disassembly and Assembly Concepts
89
Fig. 39: Removing the Cartridge Group with Compressor and Turbine Casing
89
Fig. 40: Cartridge Concept
90
Fig. 41: Optional Spanner Holder
91
Weights of Individual Parts
92
Fig. 42: Weights of Assemblies
92
Table 37: Weights of Assemblies
92
Table of Tightening Torques
93
Fig. 43 Overview of Tightening Torques
93
Table 38: Tightening Torques
93
Fig. 44: Tightening Torques for Insulation
94
Table 39: Tightening Torques for Insulation
94
10 Dismantling and Fitting with Removed Air Inlet and Gas Outlet
95
Removing Air Inlets
95
Fig. 45: Removing the Air Inlets
95
Removing the Gas Outlet Casing
96
Fig. 46: Remove Gas Outlet Casing Without Support
96
Fig. 47: Removing Gas Outlet Casing with Support 1
97
Fig. 48: Removing Gas Outlet Casing with Support 1
98
Removing the Gas Outlet Flange
99
Fig. 49: Removing the Gas Outlet Flange
99
Table 40: Press-Off Screws - Gas Outlet Flange
99
Removing the Cartridge Group with Compressor and Turbine Casing
100
Fig. 50: Turbine Cleaning Nozzle
100
Fig. 51: Remove Insulation
100
Fig. 52: Removing the Cartridge Group with Compressor and Turbine Casing
101
Fig. 53: Set down the Cartridge Group with the Compressor and Turbine Casing
101
Removing the Compressor Casing
102
Fig. 54: Removing the Compressor Casing
102
Removing the Cartridge Group
103
Fig. 55: Removing Cartridge Group 1
103
Table 41: Tightening Torque (90012-01)
103
Fig. 56: Removing Cartridge Group 2
104
Fig. 57: Removing Cartridge Group 3
105
Installing the Cartridge Group on the Service Support
106
Fig. 58: Installing the Cartridge Group on the Service Support
106
Removing the Nozzle Ring
107
Fig. 59: Removing the Nozzle Ring
107
Measuring Clearance a and B
108
Fig. 60: Measuring Clearance a and B
108
Table 42: Permissible Clearances a and B
108
Nozzle Ring Compression PD
109
Fig. 61: Nozzle Ring Compression PD
109
Table 43: Nozzle Ring Compression PD
109
Installing Nozzle Ring
110
Fig. 62: Installing the Nozzle Ring
110
Installing the Cartridge Group
111
Fig. 63: Lifting the Cartridge Group and Rotating It
111
Fig. 64: Turning the Cartridge Group
112
Table 44: Tightening Torque (90012-01)
112
Fig. 65: Installing the Cartridge Group
113
Table 45: Tightening Torque (51007)
113
Installing the Compressor Casing
114
Fig. 66: Fitting the Diffuser
114
Table 46: Tightening Torque (79041)
114
Fig. 67: Installing the Compressor Casing
115
Table 47: Tightening Torque (72011)
115
Turning the Cartridge Group with Compressor and Turbine Casing
116
Fig. 68: Turning the Cartridge Group with Compressor and Turbine Casing
116
Installing the Gas Outlet Flange
117
Fig. 69: Installing the Gas Outlet Flange
117
Radial Clearances N and R
118
Fig. 70: Measuring Clearances N and R
118
Table 48: Permissible Clearances N and R
118
Fitting the Insulation
119
Fig. 71: Fitting the Insulation
119
Installing the Cartridge Group with Compressor and Turbine Casing
120
Fig. 72: Installing the Cartridge Group with Compressor and Turbine Casing
120
Fig. 73: Installing the Cartridge Group with Compressor and Turbine Casing
120
Installing the Gas Outlet Casing
121
Fig. 74: Fitting Gas Outlet Casing Without Support
121
Table 49: Tightening Torque (51009)
121
Fig. 75: Installing Gas Outlet Casing with Support 1
122
Table 50: Tightening Torque (51009)
122
Fig. 76: Installing Gas Outlet Casing with Support 2
123
Installing Air Inlets
124
Fig. 77: Installing the Air Inlets
124
Table 51: Tightening Torque (72051)
124
11 Dismantling and Fitting, Cartridge Concept
125
Fig. 78: Removing the Air Inlets
125
Fig. 79: Removing the Compressor Casing
126
Fig. 80: Pressing off Compressor Casing
127
Fig. 81: Remove the Diffuser
127
Fig. 82: Removing Insulation Sheets
128
Fig. 83: Removing Cartridge Group 1
128
Fig. 84: Removing Cartridge Group 2
129
Fig. 85: Removing Cartridge Group 3
130
Fig. 86: S_05180
131
Fig. 87: Measuring Clearance a and B
132
Table 52: Permissible Clearances a and B
132
Fig. 88: Nozzle Ring Compression PD
133
Table 53: Nozzle Ring Compression PD
133
Fig. 89: Installing the Nozzle Ring
134
Fig. 90: Installing the Cartridge Group
135
Fig. 91: Installing the Cartridge Group 2
136
Table 54: Tightening Torque (51007)
136
Table 55: Tightening Torque (51007) with Spanner Holder
136
Fig. 92: Fitting the Diffuser
137
Table 56: Tightening Torque (79041)
137
Fig. 93: Installing the Compressor Casing
138
Table 57: Tightening Torque (72011)
138
Fig. 94: Measuring Clearances N and R
139
Table 58: Permissible Clearances N and R
139
Fig. 95: Fitting the Insulation
140
Fig. 96: Installing the Air Inlets
141
Table 59: Tightening Torque (72051)
141
12 Dismantling and Fitting, Special Tools for Fastening Strips
142
Fig. 97: Customer Tool
142
Table 60: Customer Tool
142
Application, Special Tools
143
Fig. 98: Positioning the Collection Tub
143
Fig. 99: Removing the Fastening Strips
143
Fig. 100: Fitting the Upper Fastening Strips
144
Fig. 101: Fitting the Bottom Fastening Strip
144
Table 61: Tightening Torque (51007)
144
Fig. 102: Fitting the Bottom Fastening Strip
145
Table 62: Tightening Torque (51007) with Spanner Holder
145
13 Removing and Installing 6-Nozzle Turbine Cleaning Component (Optional)
146
Disassembly
146
Fig. 103: Initial Situation
146
Fig. 104: Disassembly of the Elbows
146
Fig. 105: Disassembly of the Elbows
147
Fig. 106: Pipe Disassembly
147
Fig. 107: Disassembly of the Connecting Pieces
148
Fig. 108: Disassembly of the Cleaning Nozzle
148
Table 63: Dismantling Screw
148
Assembly
149
Fig. 109: Assembly of the Cleaning Nozzle
149
Fig. 110: Assembly of the Connecting Pieces
149
Table 64: Dismantling Screw
149
Fig. 111: Pipe Assembly
150
Fig. 112: Elbow 1 Assembly
150
Fig. 113: Elbow 2 Assembly
151
Table 65: Tightening Torque (51314 / 51316)
151
14 Fitting the Cleaning Nozzles with Multi-Inlet Turbine Casings
152
Fig. 114: Fit the Cleaning Nozzles
152
15 Taking out of Operation at Short Notice
153
Possible Emergency Repairs
153
Installing the Replacement Turbocharger
154
Installing the Replacement Cartridge Group
154
Fitting the Cover Plate
155
Fig. 115: Fitting the Cover Plate
155
Cover Plate Drawing
156
Fig. 116: Cover Plate Drawing
156
Table 66: Cover Plate Dimensions [MM]
156
Fig. 117: Dimensions for Cover Plate
157
Table 67: Cover Plate Dimensions [MM]
157
16 Mothballing the Turbocharger
158
Taking the Engine out of Operation for up to 12 Months
158
Taking the Engine out of Operation for more than 12 Months
159
17 Disposing of Turbocharger Components
160
18 Spare Parts
161
Ordering Spare Parts
161
Required Customer Spare Part Set (97070)
161
Table 68: Customer Spare Part Set 97070
161
Spare Part - Illustrations
162
Table 69: Spare Parts - Cartridge, Oil Cooled
163
Table 70: Spare Parts - Bearing, Casing Oil Cooled
164
Table 71: Spare Parts - Rotor and Bearing Parts
165
Table 72: Spare Parts - Turbine Casing, 1 Inlet
166
Table 73: Spare Parts - Turbine Casing, 2 Inlets
167
Table 74: Spare Parts - Turbine Casing, 3 Inlets
168
Table 75: Spare Parts - Cleaning Device
169
Table 76: Spare Parts - Gas Outlet Casing, Radial
170
Table 77: Spare Parts - Compressor Casing
171
Table 78: Spare Parts - Filter Silencer
173
Table 79: Spare Parts - Air Suction Branch Axial
173
Table 80: Spare Parts - Air Suction Branch Radial
174
Table 81: Spare Parts - Speed Measurement System
175
19 Tools
176
Fig. 118: Special Tool
176
Table 82: Customer Tool Set 90000
176
Table 83: Special Tool (90160)
176
ABB A150-M68 Operation Manual (182 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 31.03 MB
Table of Contents
Operation Manual / A150-M58/68
3
Table of Contents
3
Fig. 1: Serial Number (01) on the Rating Plate
6
Introduction
6
Purpose of the Manual
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
Safety
15
Introduction
15
CE Conformity
15
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Definition of Safety Instructions
16
Definition of Mandatory Signs
16
Intended Use
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 7: Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Periodic Check of the Pressure Vessels
21
Lifting of Loads
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Fig. 10: Attachment Angle
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
Table 4: Weight of Complete Turbocharger Unit
31
Fig. 11: Suspension of Complete Turbocharger Unit
31
Turbocharger Weight and Transportation
31
Removing and Installing
31
Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Fig. 13: Removing the Turbocharger
32
Fig. 14: Loosening the Clamping Nut
33
Fig. 15: Turbocharger Centre of Gravity
34
Fig. 16: Inserting the Gasket
35
Installing the Turbocharger
35
Fig. 17: Inserting the Threaded Rods
36
Fig. 18: Placing the Turbocharger on the Bracket
36
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
37
Fig. 20: Tightening Pressure Screws
38
Table 5: Torque-Controlled Tightening of the Pressure Screws
38
Fig. 21: Connecting the Speed Sensor
39
Fig. 22: Connecting the Compressor Cooling Air Intake
39
Fig. 23: Attaching the Support
39
Oil Supply
40
Commissioning
40
Fig. 24: Oil Orifice
41
Inspection Procedures
42
Commissioning after Taking out of Operation
44
Monitoring Operation
45
Oil Pressure, Oil Temperature
45
Table 6: Lubricating Oil Pressure at Oil Inlet before Turbocharger
45
Table 7: Lubricating Oil Temperature at the Inlet
46
Table 8: Maximum Lubricating Oil Temperature at the Outlet
46
Exhaust Gas Temperature before Turbine
47
Turbocharger Speed
48
Fig. 25: Layout and Overview of Speed Measurement System
48
Fig. 26: Replacing the Speed Sensor
50
Table 9: Tightening Torque (86505)
50
Operation and Service
51
Noise Emission
51
Fig. 27: Noise Insulation, Bellows
52
Service Work
53
Table 10: Expected Replacement Intervals
56
Expected Replacement Intervals
56
Stopping the Engine
58
Periodic Maintenance Work
59
Foreword to Maintenance
59
Table 11: Maintenance Table
59
Cleaning the Compressor During Operation
60
Fig. 28: Carrying out Wet Cleaning of Compressor
62
Table 12: Parameters for Wet Cleaning of Compressor
62
Cleaning the Turbine During Operation
63
Fig. 29: Turbine Cleaning Devices
65
Table 13: Turbine Wet Cleaning, Recommended Operating State
65
Fig. 30: Carrying out Wet Cleaning of Turbines
66
Table 14: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
66
Cleaning Components Mechanically
67
Table 15: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
67
Fig. 31: Cleaning the Filter Silencer
68
Fig. 32: Compressor Casing
70
Fig. 33: Diffuser
71
Fig. 34: Turbine End, Non-Rotating Parts
73
Fig. 35: Soaking the Turbine End
75
Table 16: Value Table for Soaking
75
Malfunctions When Starting
78
Table 17: Malfunctions When Starting - Delayed Start-Up
78
Table 18: Malfunctions When Starting - Vibrations
78
Table 19: Malfunctions When Starting - Rubbing of Rotating Parts
78
Eliminating Malfunctions
78
Table 21: Malfunctions During Operation - Speed Reduces
79
Table 22: Malfunctions During Operation - Speed Increases
79
Table 20: Malfunctions During Operation - Lubricating Oil Pressure too Low
79
Malfunctions During Operation
79
Table 23: Malfunctions During Operation - Exhaust Gas Temperature too High
80
Table 24: Malfunctions During Operation - Charge Air Pressure too Low
80
Table 25: Malfunctions During Operation - Charge Air Pressure too High
81
Table 26: Malfunctions During Operation - Engine Performance Losses
81
Turbocharger Is Surging
82
Table 27: Malfunction - Turbocharger Pumping
82
Table 28: Malfunction - Sporadic Surge Blows
82
Table 30: Malfunctions When Stopping - Runout Time too Short
83
Table 29: Malfunctions When Stopping - Runout Noises
83
Malfunctions When Stopping
83
Table 33: Malfunction of the Speed Measurement System - Measured Speed too Low
84
Speed Measurement System
84
Table 32: Malfunction of the Speed Measurement System - Measured Speed too High
84
Table 31: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
84
Dismantling and Fitting, General
85
Introduction
85
Material Required
86
Fig. 36: Swivel Lifting Eyes
86
Table 34: Swivel Lifting Eyes
86
Fig. 37: Press-Off Screws
87
Fig. 38: Dismantling Screw
87
Table 35: Press-Off Screws
87
Table 36: Dismantling Screw
87
Disassembly and Assembly Concepts
89
Fig. 39: Removing the Cartridge Group with Compressor and Turbine Casing
89
Fig. 40: Cartridge Concept
90
Fig. 41: Optional Spanner Holder
91
Table 37: Weights of Assemblies
92
Weights of Individual Parts
92
Fig. 42: Weights of Assemblies
92
Table of Tightening Torques
93
Fig. 43 Overview of Tightening Torques
93
Table 38: Tightening Torques
93
Fig. 44: Tightening Torques for Insulation
94
Table 39: Tightening Torques for Insulation
94
Fig. 45: Removing the Air Inlets
95
Removing Air Inlets
95
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
95
Removing the Gas Outlet Casing
96
Fig. 46: Remove Gas Outlet Casing Without Support
96
Fig. 47: Removing Gas Outlet Casing with Support 1
97
Fig. 48: Removing Gas Outlet Casing with Support 1
98
Removing the Gas Outlet Flange
99
Fig. 49: Removing the Gas Outlet Flange
99
Table 40: Press-Off Screws - Gas Outlet Flange
99
Fig. 51: Remove Insulation
100
Removing the Cartridge Group with Compressor and Turbine Casing
100
Fig. 50: Turbine Cleaning Nozzle
100
Fig. 52: Removing the Cartridge Group with Compressor and Turbine Casing
101
Fig. 53: Set down the Cartridge Group with the Compressor and Turbine Casing
101
Removing the Compressor Casing
102
Fig. 54: Removing the Compressor Casing
102
Removing the Cartridge Group
103
Fig. 55: Removing Cartridge Group 1
103
Table 41: Tightening Torque (90012-01)
103
Fig. 56: Removing Cartridge Group 2
104
Fig. 57: Removing Cartridge Group 3
105
Installing the Cartridge Group on the Service Support
106
Fig. 58: Installing the Cartridge Group on the Service Support
106
Removing the Nozzle Ring
107
Fig. 59: Removing the Nozzle Ring
107
Measuring Clearance a and B
108
Fig. 60: Measuring Clearance a and B
108
Table 42: Permissible Clearances a and B
108
Table 43: Nozzle Ring Compression PD
109
Nozzle Ring Compression PD
109
Fig. 61: Nozzle Ring Compression PD
109
Installing Nozzle Ring
110
Fig. 62: Installing the Nozzle Ring
110
Installing the Cartridge Group
111
Fig. 63: Lifting the Cartridge Group and Rotating It
111
Fig. 64: Turning the Cartridge Group
112
Table 44: Tightening Torque (90012-01)
112
Fig. 65: Installing the Cartridge Group
113
Table 45: Tightening Torque (51007)
113
Installing the Compressor Casing
114
Fig. 66: Fitting the Diffuser
114
Table 46: Tightening Torque (79041)
114
Fig. 67: Installing the Compressor Casing
115
Table 47: Tightening Torque (72011)
115
Turning the Cartridge Group with Compressor and Turbine Casing
116
Fig. 68: Turning the Cartridge Group with Compressor and Turbine Casing
116
Fig. 69: Installing the Gas Outlet Flange
117
Installing the Gas Outlet Flange
117
Fig. 70: Measuring Clearances N and R
118
Table 48: Permissible Clearances N and R
118
Radial Clearances N and R
118
Fitting the Insulation
119
Fig. 71: Fitting the Insulation
119
Installing the Cartridge Group with Compressor and Turbine Casing
120
Fig. 72: Installing the Cartridge Group with Compressor and Turbine Casing
120
Fig. 73: Installing the Cartridge Group with Compressor and Turbine Casing
120
Table 49: Tightening Torque (51009)
121
Installing the Gas Outlet Casing
121
Fig. 74: Fitting Gas Outlet Casing Without Support
121
Fig. 75: Installing Gas Outlet Casing with Support 1
122
Table 50: Tightening Torque (51009)
122
Fig. 76: Installing Gas Outlet Casing with Support 2
123
Installing Air Inlets
124
Fig. 77: Installing the Air Inlets
124
Table 51: Tightening Torque (72051)
124
Dismantling and Fitting, Cartridge Concept
125
Fig. 78: Removing the Air Inlets
125
Fig. 79: Removing the Compressor Casing
126
Fig. 80: Pressing off Compressor Casing
127
Fig. 81: Remove the Diffuser
127
Fig. 82: Removing Insulation Sheets
128
Fig. 83: Removing Cartridge Group 1
128
Fig. 84: Removing Cartridge Group 2
129
Fig. 85: Removing Cartridge Group 3
130
Fig. 86: S_05180
131
Fig. 87: Measuring Clearance a and B
132
Table 52: Permissible Clearances a and B
132
Fig. 88: Nozzle Ring Compression PD
133
Table 53: Nozzle Ring Compression PD
133
Fig. 89: Installing the Nozzle Ring
134
Fig. 90: Installing the Cartridge Group
135
Fig. 91: Installing the Cartridge Group 2
136
Table 54: Tightening Torque (51007)
136
Table 55: Tightening Torque (51007) with Spanner Holder
136
Table 56: Tightening Torque (79041)
137
Fig. 92: Fitting the Diffuser
137
Table 57: Tightening Torque (72011)
138
Fig. 93: Installing the Compressor Casing
138
Fig. 94: Measuring Clearances N and R
139
Table 58: Permissible Clearances N and R
139
Fig. 95: Fitting the Insulation
140
Fig. 96: Installing the Air Inlets
141
Table 59: Tightening Torque (72051)
141
Table 60: Customer Tool
142
Dismantling and Fitting, Special Tools for Fastening Strips
142
Fig. 97: Customer Tool
142
Application, Special Tools
143
Fig. 98: Positioning the Collection Tub
143
Fig. 99: Removing the Fastening Strips
143
Fig. 100: Fitting the Upper Fastening Strips
144
Fig. 101: Fitting the Bottom Fastening Strip
144
Table 61: Tightening Torque (51007)
144
Table 62: Tightening Torque (51007) with Spanner Holder
145
Fig. 102: Fitting the Bottom Fastening Strip
145
Removing and Installing 6-Nozzle Turbine Cleaning Component (Optional)
146
Disassembly
146
Fig. 103: Initial Situation
146
Fig. 104: Disassembly of the Elbows
146
Fig. 105: Disassembly of the Elbows
147
Fig. 106: Pipe Disassembly
147
Table 63: Dismantling Screw
148
Fig. 108: Disassembly of the Cleaning Nozzle
148
Fig. 107: Disassembly of the Connecting Pieces
148
Assembly
149
Fig. 109: Assembly of the Cleaning Nozzle
149
Fig. 110: Assembly of the Connecting Pieces
149
Table 64: Dismantling Screw
149
Fig. 111: Pipe Assembly
150
Fig. 112: Elbow 1 Assembly
150
Fig. 113: Elbow 2 Assembly
151
Table 65: Tightening Torque (51314 / 51316)
151
Fig. 114: Fit the Cleaning Nozzles
152
Fitting the Cleaning Nozzles with Multi-Inlet Turbine Casings
152
Taking out of Operation at Short Notice
153
Possible Emergency Repairs
153
Installing the Replacement Turbocharger
154
Installing the Replacement Cartridge Group
154
Fitting the Cover Plate
155
Fig. 115: Fitting the Cover Plate
155
Cover Plate Drawing
156
Table 66: Cover Plate Dimensions [MM]
156
Fig. 116: Cover Plate Drawing
156
Fig. 117: Dimensions for Cover Plate
157
Table 67: Cover Plate Dimensions [MM]
157
Mothballing the Turbocharger
158
Taking the Engine out of Operation for up to 12 Months
158
Taking the Engine out of Operation for more than 12 Months
159
Disposing of Turbocharger Components
160
Required Customer Spare Part Set (97070)
161
Table 68: Customer Spare Part Set 97070
161
Ordering Spare Parts
161
Spare Parts
161
Spare Part - Illustrations
162
Table 69: Spare Parts - Cartridge, Oil Cooled
163
Table 70: Spare Parts - Bearing, Casing Oil Cooled
164
Table 71: Spare Parts - Rotor and Bearing Parts
165
Table 72: Spare Parts - Turbine Casing, 1 Inlet
166
Table 73: Spare Parts - Turbine Casing, 2 Inlets
167
Table 74: Spare Parts - Turbine Casing, 3 Inlets
168
Table 75: Spare Parts - Cleaning Device
169
Table 76: Spare Parts - Gas Outlet Casing, Radial
170
Table 77: Spare Parts - Compressor Casing
171
Table 78: Spare Parts - Filter Silencer
173
Table 79: Spare Parts - Air Suction Branch Axial
173
Table 80: Spare Parts - Air Suction Branch Radial
174
Table 81: Spare Parts - Speed Measurement System
175
Tools
176
Fig. 118: Special Tool
176
Table 82: Customer Tool Set 90000
176
Table 83: Special Tool (90160)
176
ABB A150-M68 Operation Manual (182 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 31.03 MB
Table of Contents
Operation Manual / A150-M58/68
3
Table of Contents
3
Fig. 1: Serial Number (01) on the Rating Plate
6
Introduction
6
Purpose of the Manual
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
Safety
15
Introduction
15
CE Conformity
15
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Definition of Safety Instructions
16
Definition of Mandatory Signs
16
Intended Use
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 7: Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Periodic Check of the Pressure Vessels
21
Lifting of Loads
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Fig. 10: Attachment Angle
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
Table 4: Weight of Complete Turbocharger Unit
31
Fig. 11: Suspension of Complete Turbocharger Unit
31
Turbocharger Weight and Transportation
31
Removing and Installing
31
Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Fig. 13: Removing the Turbocharger
32
Fig. 14: Loosening the Clamping Nut
33
Fig. 15: Turbocharger Centre of Gravity
34
Fig. 16: Inserting the Gasket
35
Installing the Turbocharger
35
Fig. 17: Inserting the Threaded Rods
36
Fig. 18: Placing the Turbocharger on the Bracket
36
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
37
Fig. 20: Tightening Pressure Screws
38
Table 5: Torque-Controlled Tightening of the Pressure Screws
38
Fig. 21: Connecting the Speed Sensor
39
Fig. 22: Connecting the Compressor Cooling Air Intake
39
Fig. 23: Attaching the Support
39
Oil Supply
40
Commissioning
40
Fig. 24: Oil Orifice
41
Inspection Procedures
42
Commissioning after Taking out of Operation
44
Monitoring Operation
45
Oil Pressure, Oil Temperature
45
Table 6: Lubricating Oil Pressure at Oil Inlet before Turbocharger
45
Table 7: Lubricating Oil Temperature at the Inlet
46
Table 8: Maximum Lubricating Oil Temperature at the Outlet
46
Exhaust Gas Temperature before Turbine
47
Turbocharger Speed
48
Fig. 25: Layout and Overview of Speed Measurement System
48
Fig. 26: Replacing the Speed Sensor
50
Table 9: Tightening Torque (86505)
50
Operation and Service
51
Noise Emission
51
Fig. 27: Noise Insulation, Bellows
52
Service Work
53
Table 10: Expected Replacement Intervals
56
Expected Replacement Intervals
56
Stopping the Engine
58
Periodic Maintenance Work
59
Foreword to Maintenance
59
Table 11: Maintenance Table
59
Cleaning the Compressor During Operation
60
Fig. 28: Carrying out Wet Cleaning of Compressor
62
Table 12: Parameters for Wet Cleaning of Compressor
62
Cleaning the Turbine During Operation
63
Fig. 29: Turbine Cleaning Devices
65
Table 13: Turbine Wet Cleaning, Recommended Operating State
65
Fig. 30: Carrying out Wet Cleaning of Turbines
66
Table 14: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
66
Cleaning Components Mechanically
67
Table 15: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
67
Fig. 31: Cleaning the Filter Silencer
68
Fig. 32: Compressor Casing
70
Fig. 33: Diffuser
71
Fig. 34: Turbine End, Non-Rotating Parts
73
Fig. 35: Soaking the Turbine End
75
Table 16: Value Table for Soaking
75
Malfunctions When Starting
78
Table 17: Malfunctions When Starting - Delayed Start-Up
78
Table 18: Malfunctions When Starting - Vibrations
78
Table 19: Malfunctions When Starting - Rubbing of Rotating Parts
78
Eliminating Malfunctions
78
Table 21: Malfunctions During Operation - Speed Reduces
79
Table 22: Malfunctions During Operation - Speed Increases
79
Table 20: Malfunctions During Operation - Lubricating Oil Pressure too Low
79
Malfunctions During Operation
79
Table 23: Malfunctions During Operation - Exhaust Gas Temperature too High
80
Table 24: Malfunctions During Operation - Charge Air Pressure too Low
80
Table 25: Malfunctions During Operation - Charge Air Pressure too High
81
Table 26: Malfunctions During Operation - Engine Performance Losses
81
Turbocharger Is Surging
82
Table 27: Malfunction - Turbocharger Pumping
82
Table 28: Malfunction - Sporadic Surge Blows
82
Table 30: Malfunctions When Stopping - Runout Time too Short
83
Table 29: Malfunctions When Stopping - Runout Noises
83
Malfunctions When Stopping
83
Table 33: Malfunction of the Speed Measurement System - Measured Speed too Low
84
Speed Measurement System
84
Table 32: Malfunction of the Speed Measurement System - Measured Speed too High
84
Table 31: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
84
Dismantling and Fitting, General
85
Introduction
85
Material Required
86
Fig. 36: Swivel Lifting Eyes
86
Table 34: Swivel Lifting Eyes
86
Fig. 37: Press-Off Screws
87
Fig. 38: Dismantling Screw
87
Table 35: Press-Off Screws
87
Table 36: Dismantling Screw
87
Disassembly and Assembly Concepts
89
Fig. 39: Removing the Cartridge Group with Compressor and Turbine Casing
89
Fig. 40: Cartridge Concept
90
Fig. 41: Optional Spanner Holder
91
Table 37: Weights of Assemblies
92
Weights of Individual Parts
92
Fig. 42: Weights of Assemblies
92
Table of Tightening Torques
93
Fig. 43 Overview of Tightening Torques
93
Table 38: Tightening Torques
93
Fig. 44: Tightening Torques for Insulation
94
Table 39: Tightening Torques for Insulation
94
Fig. 45: Removing the Air Inlets
95
Removing Air Inlets
95
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
95
Removing the Gas Outlet Casing
96
Fig. 46: Remove Gas Outlet Casing Without Support
96
Fig. 47: Removing Gas Outlet Casing with Support 1
97
Fig. 48: Removing Gas Outlet Casing with Support 1
98
Removing the Gas Outlet Flange
99
Fig. 49: Removing the Gas Outlet Flange
99
Table 40: Press-Off Screws - Gas Outlet Flange
99
Fig. 51: Remove Insulation
100
Removing the Cartridge Group with Compressor and Turbine Casing
100
Fig. 50: Turbine Cleaning Nozzle
100
Fig. 52: Removing the Cartridge Group with Compressor and Turbine Casing
101
Fig. 53: Set down the Cartridge Group with the Compressor and Turbine Casing
101
Removing the Compressor Casing
102
Fig. 54: Removing the Compressor Casing
102
Removing the Cartridge Group
103
Fig. 55: Removing Cartridge Group 1
103
Table 41: Tightening Torque (90012-01)
103
Fig. 56: Removing Cartridge Group 2
104
Fig. 57: Removing Cartridge Group 3
105
Installing the Cartridge Group on the Service Support
106
Fig. 58: Installing the Cartridge Group on the Service Support
106
Removing the Nozzle Ring
107
Fig. 59: Removing the Nozzle Ring
107
Measuring Clearance a and B
108
Fig. 60: Measuring Clearance a and B
108
Table 42: Permissible Clearances a and B
108
Table 43: Nozzle Ring Compression PD
109
Nozzle Ring Compression PD
109
Fig. 61: Nozzle Ring Compression PD
109
Installing Nozzle Ring
110
Fig. 62: Installing the Nozzle Ring
110
Installing the Cartridge Group
111
Fig. 63: Lifting the Cartridge Group and Rotating It
111
Fig. 64: Turning the Cartridge Group
112
Table 44: Tightening Torque (90012-01)
112
Fig. 65: Installing the Cartridge Group
113
Table 45: Tightening Torque (51007)
113
Installing the Compressor Casing
114
Fig. 66: Fitting the Diffuser
114
Table 46: Tightening Torque (79041)
114
Fig. 67: Installing the Compressor Casing
115
Table 47: Tightening Torque (72011)
115
Turning the Cartridge Group with Compressor and Turbine Casing
116
Fig. 68: Turning the Cartridge Group with Compressor and Turbine Casing
116
Fig. 69: Installing the Gas Outlet Flange
117
Installing the Gas Outlet Flange
117
Fig. 70: Measuring Clearances N and R
118
Table 48: Permissible Clearances N and R
118
Radial Clearances N and R
118
Fitting the Insulation
119
Fig. 71: Fitting the Insulation
119
Installing the Cartridge Group with Compressor and Turbine Casing
120
Fig. 72: Installing the Cartridge Group with Compressor and Turbine Casing
120
Fig. 73: Installing the Cartridge Group with Compressor and Turbine Casing
120
Table 49: Tightening Torque (51009)
121
Installing the Gas Outlet Casing
121
Fig. 74: Fitting Gas Outlet Casing Without Support
121
Fig. 75: Installing Gas Outlet Casing with Support 1
122
Table 50: Tightening Torque (51009)
122
Fig. 76: Installing Gas Outlet Casing with Support 2
123
Installing Air Inlets
124
Fig. 77: Installing the Air Inlets
124
Table 51: Tightening Torque (72051)
124
Dismantling and Fitting, Cartridge Concept
125
Fig. 78: Removing the Air Inlets
125
Fig. 79: Removing the Compressor Casing
126
Fig. 80: Pressing off Compressor Casing
127
Fig. 81: Remove the Diffuser
127
Fig. 82: Removing Insulation Sheets
128
Fig. 83: Removing Cartridge Group 1
128
Fig. 84: Removing Cartridge Group 2
129
Fig. 85: Removing Cartridge Group 3
130
Fig. 86: S_05180
131
Fig. 87: Measuring Clearance a and B
132
Table 52: Permissible Clearances a and B
132
Fig. 88: Nozzle Ring Compression PD
133
Table 53: Nozzle Ring Compression PD
133
Fig. 89: Installing the Nozzle Ring
134
Fig. 90: Installing the Cartridge Group
135
Fig. 91: Installing the Cartridge Group 2
136
Table 54: Tightening Torque (51007)
136
Table 55: Tightening Torque (51007) with Spanner Holder
136
Table 56: Tightening Torque (79041)
137
Fig. 92: Fitting the Diffuser
137
Table 57: Tightening Torque (72011)
138
Fig. 93: Installing the Compressor Casing
138
Fig. 94: Measuring Clearances N and R
139
Table 58: Permissible Clearances N and R
139
Fig. 95: Fitting the Insulation
140
Fig. 96: Installing the Air Inlets
141
Table 59: Tightening Torque (72051)
141
Table 60: Customer Tool
142
Dismantling and Fitting, Special Tools for Fastening Strips
142
Fig. 97: Customer Tool
142
Application, Special Tools
143
Fig. 98: Positioning the Collection Tub
143
Fig. 99: Removing the Fastening Strips
143
Fig. 100: Fitting the Upper Fastening Strips
144
Fig. 101: Fitting the Bottom Fastening Strip
144
Table 61: Tightening Torque (51007)
144
Table 62: Tightening Torque (51007) with Spanner Holder
145
Fig. 102: Fitting the Bottom Fastening Strip
145
Removing and Installing 6-Nozzle Turbine Cleaning Component (Optional)
146
Disassembly
146
Fig. 103: Initial Situation
146
Fig. 104: Disassembly of the Elbows
146
Fig. 105: Disassembly of the Elbows
147
Fig. 106: Pipe Disassembly
147
Table 63: Dismantling Screw
148
Fig. 108: Disassembly of the Cleaning Nozzle
148
Fig. 107: Disassembly of the Connecting Pieces
148
Assembly
149
Fig. 109: Assembly of the Cleaning Nozzle
149
Fig. 110: Assembly of the Connecting Pieces
149
Table 64: Dismantling Screw
149
Fig. 111: Pipe Assembly
150
Fig. 112: Elbow 1 Assembly
150
Fig. 113: Elbow 2 Assembly
151
Table 65: Tightening Torque (51314 / 51316)
151
Fig. 114: Fit the Cleaning Nozzles
152
Fitting the Cleaning Nozzles with Multi-Inlet Turbine Casings
152
Taking out of Operation at Short Notice
153
Possible Emergency Repairs
153
Installing the Replacement Turbocharger
154
Installing the Replacement Cartridge Group
154
Fitting the Cover Plate
155
Fig. 115: Fitting the Cover Plate
155
Cover Plate Drawing
156
Table 66: Cover Plate Dimensions [MM]
156
Fig. 116: Cover Plate Drawing
156
Fig. 117: Dimensions for Cover Plate
157
Table 67: Cover Plate Dimensions [MM]
157
Mothballing the Turbocharger
158
Taking the Engine out of Operation for up to 12 Months
158
Taking the Engine out of Operation for more than 12 Months
159
Disposing of Turbocharger Components
160
Required Customer Spare Part Set (97070)
161
Table 68: Customer Spare Part Set 97070
161
Ordering Spare Parts
161
Spare Parts
161
Spare Part - Illustrations
162
Table 69: Spare Parts - Cartridge, Oil Cooled
163
Table 70: Spare Parts - Bearing, Casing Oil Cooled
164
Table 71: Spare Parts - Rotor and Bearing Parts
165
Table 72: Spare Parts - Turbine Casing, 1 Inlet
166
Table 73: Spare Parts - Turbine Casing, 2 Inlets
167
Table 74: Spare Parts - Turbine Casing, 3 Inlets
168
Table 75: Spare Parts - Cleaning Device
169
Table 76: Spare Parts - Gas Outlet Casing, Radial
170
Table 77: Spare Parts - Compressor Casing
171
Table 78: Spare Parts - Filter Silencer
173
Table 79: Spare Parts - Air Suction Branch Axial
173
Table 80: Spare Parts - Air Suction Branch Radial
174
Table 81: Spare Parts - Speed Measurement System
175
Tools
176
Fig. 118: Special Tool
176
Table 82: Customer Tool Set 90000
176
Table 83: Special Tool (90160)
176
ABB A150-M68 Operation Manual (182 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 31.03 MB
Table of Contents
Operation Manual / A150-M58/68
3
Table of Contents
3
Fig. 1: Serial Number (01) on the Rating Plate
6
Introduction
6
Purpose of the Manual
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
Safety
15
Introduction
15
CE Conformity
15
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Definition of Safety Instructions
16
Definition of Mandatory Signs
16
Intended Use
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 7: Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Periodic Check of the Pressure Vessels
21
Lifting of Loads
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Fig. 10: Attachment Angle
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
Table 4: Weight of Complete Turbocharger Unit
31
Fig. 11: Suspension of Complete Turbocharger Unit
31
Turbocharger Weight and Transportation
31
Removing and Installing
31
Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Fig. 13: Removing the Turbocharger
32
Fig. 14: Loosening the Clamping Nut
33
Fig. 15: Turbocharger Centre of Gravity
34
Fig. 16: Inserting the Gasket
35
Installing the Turbocharger
35
Fig. 17: Inserting the Threaded Rods
36
Fig. 18: Placing the Turbocharger on the Bracket
36
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
37
Fig. 20: Tightening Pressure Screws
38
Table 5: Torque-Controlled Tightening of the Pressure Screws
38
Fig. 21: Connecting the Speed Sensor
39
Fig. 22: Connecting the Compressor Cooling Air Intake
39
Fig. 23: Attaching the Support
39
Oil Supply
40
Commissioning
40
Fig. 24: Oil Orifice
41
Inspection Procedures
42
Commissioning after Taking out of Operation
44
Monitoring Operation
45
Oil Pressure, Oil Temperature
45
Table 6: Lubricating Oil Pressure at Oil Inlet before Turbocharger
45
Table 7: Lubricating Oil Temperature at the Inlet
46
Table 8: Maximum Lubricating Oil Temperature at the Outlet
46
Exhaust Gas Temperature before Turbine
47
Turbocharger Speed
48
Fig. 25: Layout and Overview of Speed Measurement System
48
Fig. 26: Replacing the Speed Sensor
50
Table 9: Tightening Torque (86505)
50
Operation and Service
51
Noise Emission
51
Fig. 27: Noise Insulation, Bellows
52
Service Work
53
Table 10: Expected Replacement Intervals
56
Expected Replacement Intervals
56
Stopping the Engine
58
Periodic Maintenance Work
59
Foreword to Maintenance
59
Table 11: Maintenance Table
59
Cleaning the Compressor During Operation
60
Fig. 28: Carrying out Wet Cleaning of Compressor
62
Table 12: Parameters for Wet Cleaning of Compressor
62
Cleaning the Turbine During Operation
63
Fig. 29: Turbine Cleaning Devices
65
Table 13: Turbine Wet Cleaning, Recommended Operating State
65
Fig. 30: Carrying out Wet Cleaning of Turbines
66
Table 14: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
66
Cleaning Components Mechanically
67
Table 15: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
67
Fig. 31: Cleaning the Filter Silencer
68
Fig. 32: Compressor Casing
70
Fig. 33: Diffuser
71
Fig. 34: Turbine End, Non-Rotating Parts
73
Fig. 35: Soaking the Turbine End
75
Table 16: Value Table for Soaking
75
Malfunctions When Starting
78
Table 17: Malfunctions When Starting - Delayed Start-Up
78
Table 18: Malfunctions When Starting - Vibrations
78
Table 19: Malfunctions When Starting - Rubbing of Rotating Parts
78
Eliminating Malfunctions
78
Table 21: Malfunctions During Operation - Speed Reduces
79
Table 22: Malfunctions During Operation - Speed Increases
79
Table 20: Malfunctions During Operation - Lubricating Oil Pressure too Low
79
Malfunctions During Operation
79
Table 23: Malfunctions During Operation - Exhaust Gas Temperature too High
80
Table 24: Malfunctions During Operation - Charge Air Pressure too Low
80
Table 25: Malfunctions During Operation - Charge Air Pressure too High
81
Table 26: Malfunctions During Operation - Engine Performance Losses
81
Turbocharger Is Surging
82
Table 27: Malfunction - Turbocharger Pumping
82
Table 28: Malfunction - Sporadic Surge Blows
82
Table 30: Malfunctions When Stopping - Runout Time too Short
83
Table 29: Malfunctions When Stopping - Runout Noises
83
Malfunctions When Stopping
83
Table 33: Malfunction of the Speed Measurement System - Measured Speed too Low
84
Speed Measurement System
84
Table 32: Malfunction of the Speed Measurement System - Measured Speed too High
84
Table 31: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
84
Dismantling and Fitting, General
85
Introduction
85
Material Required
86
Fig. 36: Swivel Lifting Eyes
86
Table 34: Swivel Lifting Eyes
86
Fig. 37: Press-Off Screws
87
Fig. 38: Dismantling Screw
87
Table 35: Press-Off Screws
87
Table 36: Dismantling Screw
87
Disassembly and Assembly Concepts
89
Fig. 39: Removing the Cartridge Group with Compressor and Turbine Casing
89
Fig. 40: Cartridge Concept
90
Fig. 41: Optional Spanner Holder
91
Table 37: Weights of Assemblies
92
Weights of Individual Parts
92
Fig. 42: Weights of Assemblies
92
Table of Tightening Torques
93
Fig. 43 Overview of Tightening Torques
93
Table 38: Tightening Torques
93
Fig. 44: Tightening Torques for Insulation
94
Table 39: Tightening Torques for Insulation
94
Fig. 45: Removing the Air Inlets
95
Removing Air Inlets
95
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
95
Removing the Gas Outlet Casing
96
Fig. 46: Remove Gas Outlet Casing Without Support
96
Fig. 47: Removing Gas Outlet Casing with Support 1
97
Fig. 48: Removing Gas Outlet Casing with Support 1
98
Removing the Gas Outlet Flange
99
Fig. 49: Removing the Gas Outlet Flange
99
Table 40: Press-Off Screws - Gas Outlet Flange
99
Fig. 51: Remove Insulation
100
Removing the Cartridge Group with Compressor and Turbine Casing
100
Fig. 50: Turbine Cleaning Nozzle
100
Fig. 52: Removing the Cartridge Group with Compressor and Turbine Casing
101
Fig. 53: Set down the Cartridge Group with the Compressor and Turbine Casing
101
Removing the Compressor Casing
102
Fig. 54: Removing the Compressor Casing
102
Removing the Cartridge Group
103
Fig. 55: Removing Cartridge Group 1
103
Table 41: Tightening Torque (90012-01)
103
Fig. 56: Removing Cartridge Group 2
104
Fig. 57: Removing Cartridge Group 3
105
Installing the Cartridge Group on the Service Support
106
Fig. 58: Installing the Cartridge Group on the Service Support
106
Removing the Nozzle Ring
107
Fig. 59: Removing the Nozzle Ring
107
Measuring Clearance a and B
108
Fig. 60: Measuring Clearance a and B
108
Table 42: Permissible Clearances a and B
108
Table 43: Nozzle Ring Compression PD
109
Nozzle Ring Compression PD
109
Fig. 61: Nozzle Ring Compression PD
109
Installing Nozzle Ring
110
Fig. 62: Installing the Nozzle Ring
110
Installing the Cartridge Group
111
Fig. 63: Lifting the Cartridge Group and Rotating It
111
Fig. 64: Turning the Cartridge Group
112
Table 44: Tightening Torque (90012-01)
112
Fig. 65: Installing the Cartridge Group
113
Table 45: Tightening Torque (51007)
113
Installing the Compressor Casing
114
Fig. 66: Fitting the Diffuser
114
Table 46: Tightening Torque (79041)
114
Fig. 67: Installing the Compressor Casing
115
Table 47: Tightening Torque (72011)
115
Turning the Cartridge Group with Compressor and Turbine Casing
116
Fig. 68: Turning the Cartridge Group with Compressor and Turbine Casing
116
Fig. 69: Installing the Gas Outlet Flange
117
Installing the Gas Outlet Flange
117
Fig. 70: Measuring Clearances N and R
118
Table 48: Permissible Clearances N and R
118
Radial Clearances N and R
118
Fitting the Insulation
119
Fig. 71: Fitting the Insulation
119
Installing the Cartridge Group with Compressor and Turbine Casing
120
Fig. 72: Installing the Cartridge Group with Compressor and Turbine Casing
120
Fig. 73: Installing the Cartridge Group with Compressor and Turbine Casing
120
Table 49: Tightening Torque (51009)
121
Installing the Gas Outlet Casing
121
Fig. 74: Fitting Gas Outlet Casing Without Support
121
Fig. 75: Installing Gas Outlet Casing with Support 1
122
Table 50: Tightening Torque (51009)
122
Fig. 76: Installing Gas Outlet Casing with Support 2
123
Installing Air Inlets
124
Fig. 77: Installing the Air Inlets
124
Table 51: Tightening Torque (72051)
124
Dismantling and Fitting, Cartridge Concept
125
Fig. 78: Removing the Air Inlets
125
Fig. 79: Removing the Compressor Casing
126
Fig. 80: Pressing off Compressor Casing
127
Fig. 81: Remove the Diffuser
127
Fig. 82: Removing Insulation Sheets
128
Fig. 83: Removing Cartridge Group 1
128
Fig. 84: Removing Cartridge Group 2
129
Fig. 85: Removing Cartridge Group 3
130
Fig. 86: S_05180
131
Fig. 87: Measuring Clearance a and B
132
Table 52: Permissible Clearances a and B
132
Fig. 88: Nozzle Ring Compression PD
133
Table 53: Nozzle Ring Compression PD
133
Fig. 89: Installing the Nozzle Ring
134
Fig. 90: Installing the Cartridge Group
135
Fig. 91: Installing the Cartridge Group 2
136
Table 54: Tightening Torque (51007)
136
Table 55: Tightening Torque (51007) with Spanner Holder
136
Table 56: Tightening Torque (79041)
137
Fig. 92: Fitting the Diffuser
137
Table 57: Tightening Torque (72011)
138
Fig. 93: Installing the Compressor Casing
138
Fig. 94: Measuring Clearances N and R
139
Table 58: Permissible Clearances N and R
139
Fig. 95: Fitting the Insulation
140
Fig. 96: Installing the Air Inlets
141
Table 59: Tightening Torque (72051)
141
Table 60: Customer Tool
142
Dismantling and Fitting, Special Tools for Fastening Strips
142
Fig. 97: Customer Tool
142
Application, Special Tools
143
Fig. 98: Positioning the Collection Tub
143
Fig. 99: Removing the Fastening Strips
143
Fig. 100: Fitting the Upper Fastening Strips
144
Fig. 101: Fitting the Bottom Fastening Strip
144
Table 61: Tightening Torque (51007)
144
Table 62: Tightening Torque (51007) with Spanner Holder
145
Fig. 102: Fitting the Bottom Fastening Strip
145
Removing and Installing 6-Nozzle Turbine Cleaning Component (Optional)
146
Disassembly
146
Fig. 103: Initial Situation
146
Fig. 104: Disassembly of the Elbows
146
Fig. 105: Disassembly of the Elbows
147
Fig. 106: Pipe Disassembly
147
Table 63: Dismantling Screw
148
Fig. 108: Disassembly of the Cleaning Nozzle
148
Fig. 107: Disassembly of the Connecting Pieces
148
Assembly
149
Fig. 109: Assembly of the Cleaning Nozzle
149
Fig. 110: Assembly of the Connecting Pieces
149
Table 64: Dismantling Screw
149
Fig. 111: Pipe Assembly
150
Fig. 112: Elbow 1 Assembly
150
Fig. 113: Elbow 2 Assembly
151
Table 65: Tightening Torque (51314 / 51316)
151
Fig. 114: Fit the Cleaning Nozzles
152
Fitting the Cleaning Nozzles with Multi-Inlet Turbine Casings
152
Taking out of Operation at Short Notice
153
Possible Emergency Repairs
153
Installing the Replacement Turbocharger
154
Installing the Replacement Cartridge Group
154
Fitting the Cover Plate
155
Fig. 115: Fitting the Cover Plate
155
Cover Plate Drawing
156
Table 66: Cover Plate Dimensions [MM]
156
Fig. 116: Cover Plate Drawing
156
Fig. 117: Dimensions for Cover Plate
157
Table 67: Cover Plate Dimensions [MM]
157
Mothballing the Turbocharger
158
Taking the Engine out of Operation for up to 12 Months
158
Taking the Engine out of Operation for more than 12 Months
159
Disposing of Turbocharger Components
160
Required Customer Spare Part Set (97070)
161
Table 68: Customer Spare Part Set 97070
161
Ordering Spare Parts
161
Spare Parts
161
Spare Part - Illustrations
162
Table 69: Spare Parts - Cartridge, Oil Cooled
163
Table 70: Spare Parts - Bearing, Casing Oil Cooled
164
Table 71: Spare Parts - Rotor and Bearing Parts
165
Table 72: Spare Parts - Turbine Casing, 1 Inlet
166
Table 73: Spare Parts - Turbine Casing, 2 Inlets
167
Table 74: Spare Parts - Turbine Casing, 3 Inlets
168
Table 75: Spare Parts - Cleaning Device
169
Table 76: Spare Parts - Gas Outlet Casing, Radial
170
Table 77: Spare Parts - Compressor Casing
171
Table 78: Spare Parts - Filter Silencer
173
Table 79: Spare Parts - Air Suction Branch Axial
173
Table 80: Spare Parts - Air Suction Branch Radial
174
Table 81: Spare Parts - Speed Measurement System
175
Tools
176
Fig. 118: Special Tool
176
Table 82: Customer Tool Set 90000
176
Table 83: Special Tool (90160)
176
ABB A150-M68 Operation Manual (182 pages)
Turbocharging
Brand:
ABB
| Category:
Industrial Equipment
| Size: 31.03 MB
Table of Contents
Operation Manual / A150-M58/68
3
Table of Contents
3
Fig. 1: Serial Number (01) on the Rating Plate
6
Introduction
6
Purpose of the Manual
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
Safety
15
Introduction
15
CE Conformity
15
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Definition of Safety Instructions
16
Definition of Mandatory Signs
16
Intended Use
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 7: Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Periodic Check of the Pressure Vessels
21
Lifting of Loads
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Fig. 10: Attachment Angle
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
Table 4: Weight of Complete Turbocharger Unit
31
Fig. 11: Suspension of Complete Turbocharger Unit
31
Turbocharger Weight and Transportation
31
Removing and Installing
31
Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Fig. 13: Removing the Turbocharger
32
Fig. 14: Loosening the Clamping Nut
33
Fig. 15: Turbocharger Centre of Gravity
34
Fig. 16: Inserting the Gasket
35
Installing the Turbocharger
35
Fig. 17: Inserting the Threaded Rods
36
Fig. 18: Placing the Turbocharger on the Bracket
36
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
37
Fig. 20: Tightening Pressure Screws
38
Table 5: Torque-Controlled Tightening of the Pressure Screws
38
Fig. 21: Connecting the Speed Sensor
39
Fig. 22: Connecting the Compressor Cooling Air Intake
39
Fig. 23: Attaching the Support
39
Oil Supply
40
Commissioning
40
Fig. 24: Oil Orifice
41
Inspection Procedures
42
Commissioning after Taking out of Operation
44
Monitoring Operation
45
Oil Pressure, Oil Temperature
45
Table 6: Lubricating Oil Pressure at Oil Inlet before Turbocharger
45
Table 7: Lubricating Oil Temperature at the Inlet
46
Table 8: Maximum Lubricating Oil Temperature at the Outlet
46
Exhaust Gas Temperature before Turbine
47
Turbocharger Speed
48
Fig. 25: Layout and Overview of Speed Measurement System
48
Fig. 26: Replacing the Speed Sensor
50
Table 9: Tightening Torque (86505)
50
Operation and Service
51
Noise Emission
51
Fig. 27: Noise Insulation, Bellows
52
Service Work
53
Table 10: Expected Replacement Intervals
56
Expected Replacement Intervals
56
Stopping the Engine
58
Periodic Maintenance Work
59
Foreword to Maintenance
59
Table 11: Maintenance Table
59
Cleaning the Compressor During Operation
60
Fig. 28: Carrying out Wet Cleaning of Compressor
62
Table 12: Parameters for Wet Cleaning of Compressor
62
Cleaning the Turbine During Operation
63
Fig. 29: Turbine Cleaning Devices
65
Table 13: Turbine Wet Cleaning, Recommended Operating State
65
Fig. 30: Carrying out Wet Cleaning of Turbines
66
Table 14: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
66
Cleaning Components Mechanically
67
Table 15: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
67
Fig. 31: Cleaning the Filter Silencer
68
Fig. 32: Compressor Casing
70
Fig. 33: Diffuser
71
Fig. 34: Turbine End, Non-Rotating Parts
73
Fig. 35: Soaking the Turbine End
75
Table 16: Value Table for Soaking
75
Malfunctions When Starting
78
Table 17: Malfunctions When Starting - Delayed Start-Up
78
Table 18: Malfunctions When Starting - Vibrations
78
Table 19: Malfunctions When Starting - Rubbing of Rotating Parts
78
Eliminating Malfunctions
78
Table 21: Malfunctions During Operation - Speed Reduces
79
Table 22: Malfunctions During Operation - Speed Increases
79
Table 20: Malfunctions During Operation - Lubricating Oil Pressure too Low
79
Malfunctions During Operation
79
Table 23: Malfunctions During Operation - Exhaust Gas Temperature too High
80
Table 24: Malfunctions During Operation - Charge Air Pressure too Low
80
Table 25: Malfunctions During Operation - Charge Air Pressure too High
81
Table 26: Malfunctions During Operation - Engine Performance Losses
81
Turbocharger Is Surging
82
Table 27: Malfunction - Turbocharger Pumping
82
Table 28: Malfunction - Sporadic Surge Blows
82
Table 30: Malfunctions When Stopping - Runout Time too Short
83
Table 29: Malfunctions When Stopping - Runout Noises
83
Malfunctions When Stopping
83
Table 33: Malfunction of the Speed Measurement System - Measured Speed too Low
84
Speed Measurement System
84
Table 32: Malfunction of the Speed Measurement System - Measured Speed too High
84
Table 31: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
84
Dismantling and Fitting, General
85
Introduction
85
Material Required
86
Fig. 36: Swivel Lifting Eyes
86
Table 34: Swivel Lifting Eyes
86
Fig. 37: Press-Off Screws
87
Fig. 38: Dismantling Screw
87
Table 35: Press-Off Screws
87
Table 36: Dismantling Screw
87
Disassembly and Assembly Concepts
89
Fig. 39: Removing the Cartridge Group with Compressor and Turbine Casing
89
Fig. 40: Cartridge Concept
90
Fig. 41: Optional Spanner Holder
91
Table 37: Weights of Assemblies
92
Weights of Individual Parts
92
Fig. 42: Weights of Assemblies
92
Table of Tightening Torques
93
Fig. 43 Overview of Tightening Torques
93
Table 38: Tightening Torques
93
Fig. 44: Tightening Torques for Insulation
94
Table 39: Tightening Torques for Insulation
94
Fig. 45: Removing the Air Inlets
95
Removing Air Inlets
95
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
95
Removing the Gas Outlet Casing
96
Fig. 46: Remove Gas Outlet Casing Without Support
96
Fig. 47: Removing Gas Outlet Casing with Support 1
97
Fig. 48: Removing Gas Outlet Casing with Support 1
98
Removing the Gas Outlet Flange
99
Fig. 49: Removing the Gas Outlet Flange
99
Table 40: Press-Off Screws - Gas Outlet Flange
99
Fig. 51: Remove Insulation
100
Removing the Cartridge Group with Compressor and Turbine Casing
100
Fig. 50: Turbine Cleaning Nozzle
100
Fig. 52: Removing the Cartridge Group with Compressor and Turbine Casing
101
Fig. 53: Set down the Cartridge Group with the Compressor and Turbine Casing
101
Removing the Compressor Casing
102
Fig. 54: Removing the Compressor Casing
102
Removing the Cartridge Group
103
Fig. 55: Removing Cartridge Group 1
103
Table 41: Tightening Torque (90012-01)
103
Fig. 56: Removing Cartridge Group 2
104
Fig. 57: Removing Cartridge Group 3
105
Installing the Cartridge Group on the Service Support
106
Fig. 58: Installing the Cartridge Group on the Service Support
106
Removing the Nozzle Ring
107
Fig. 59: Removing the Nozzle Ring
107
Measuring Clearance a and B
108
Fig. 60: Measuring Clearance a and B
108
Table 42: Permissible Clearances a and B
108
Table 43: Nozzle Ring Compression PD
109
Nozzle Ring Compression PD
109
Fig. 61: Nozzle Ring Compression PD
109
Installing Nozzle Ring
110
Fig. 62: Installing the Nozzle Ring
110
Installing the Cartridge Group
111
Fig. 63: Lifting the Cartridge Group and Rotating It
111
Fig. 64: Turning the Cartridge Group
112
Table 44: Tightening Torque (90012-01)
112
Fig. 65: Installing the Cartridge Group
113
Table 45: Tightening Torque (51007)
113
Installing the Compressor Casing
114
Fig. 66: Fitting the Diffuser
114
Table 46: Tightening Torque (79041)
114
Fig. 67: Installing the Compressor Casing
115
Table 47: Tightening Torque (72011)
115
Turning the Cartridge Group with Compressor and Turbine Casing
116
Fig. 68: Turning the Cartridge Group with Compressor and Turbine Casing
116
Fig. 69: Installing the Gas Outlet Flange
117
Installing the Gas Outlet Flange
117
Fig. 70: Measuring Clearances N and R
118
Table 48: Permissible Clearances N and R
118
Radial Clearances N and R
118
Fitting the Insulation
119
Fig. 71: Fitting the Insulation
119
Installing the Cartridge Group with Compressor and Turbine Casing
120
Fig. 72: Installing the Cartridge Group with Compressor and Turbine Casing
120
Fig. 73: Installing the Cartridge Group with Compressor and Turbine Casing
120
Table 49: Tightening Torque (51009)
121
Installing the Gas Outlet Casing
121
Fig. 74: Fitting Gas Outlet Casing Without Support
121
Fig. 75: Installing Gas Outlet Casing with Support 1
122
Table 50: Tightening Torque (51009)
122
Fig. 76: Installing Gas Outlet Casing with Support 2
123
Installing Air Inlets
124
Fig. 77: Installing the Air Inlets
124
Table 51: Tightening Torque (72051)
124
Dismantling and Fitting, Cartridge Concept
125
Fig. 78: Removing the Air Inlets
125
Fig. 79: Removing the Compressor Casing
126
Fig. 80: Pressing off Compressor Casing
127
Fig. 81: Remove the Diffuser
127
Fig. 82: Removing Insulation Sheets
128
Fig. 83: Removing Cartridge Group 1
128
Fig. 84: Removing Cartridge Group 2
129
Fig. 85: Removing Cartridge Group 3
130
Fig. 86: S_05180
131
Fig. 87: Measuring Clearance a and B
132
Table 52: Permissible Clearances a and B
132
Fig. 88: Nozzle Ring Compression PD
133
Table 53: Nozzle Ring Compression PD
133
Fig. 89: Installing the Nozzle Ring
134
Fig. 90: Installing the Cartridge Group
135
Fig. 91: Installing the Cartridge Group 2
136
Table 54: Tightening Torque (51007)
136
Table 55: Tightening Torque (51007) with Spanner Holder
136
Table 56: Tightening Torque (79041)
137
Fig. 92: Fitting the Diffuser
137
Table 57: Tightening Torque (72011)
138
Fig. 93: Installing the Compressor Casing
138
Fig. 94: Measuring Clearances N and R
139
Table 58: Permissible Clearances N and R
139
Fig. 95: Fitting the Insulation
140
Fig. 96: Installing the Air Inlets
141
Table 59: Tightening Torque (72051)
141
Table 60: Customer Tool
142
Dismantling and Fitting, Special Tools for Fastening Strips
142
Fig. 97: Customer Tool
142
Application, Special Tools
143
Fig. 98: Positioning the Collection Tub
143
Fig. 99: Removing the Fastening Strips
143
Fig. 100: Fitting the Upper Fastening Strips
144
Fig. 101: Fitting the Bottom Fastening Strip
144
Table 61: Tightening Torque (51007)
144
Table 62: Tightening Torque (51007) with Spanner Holder
145
Fig. 102: Fitting the Bottom Fastening Strip
145
Removing and Installing 6-Nozzle Turbine Cleaning Component (Optional)
146
Disassembly
146
Fig. 103: Initial Situation
146
Fig. 104: Disassembly of the Elbows
146
Fig. 105: Disassembly of the Elbows
147
Fig. 106: Pipe Disassembly
147
Table 63: Dismantling Screw
148
Fig. 108: Disassembly of the Cleaning Nozzle
148
Fig. 107: Disassembly of the Connecting Pieces
148
Assembly
149
Fig. 109: Assembly of the Cleaning Nozzle
149
Fig. 110: Assembly of the Connecting Pieces
149
Table 64: Dismantling Screw
149
Fig. 111: Pipe Assembly
150
Fig. 112: Elbow 1 Assembly
150
Fig. 113: Elbow 2 Assembly
151
Table 65: Tightening Torque (51314 / 51316)
151
Fig. 114: Fit the Cleaning Nozzles
152
Fitting the Cleaning Nozzles with Multi-Inlet Turbine Casings
152
Taking out of Operation at Short Notice
153
Possible Emergency Repairs
153
Installing the Replacement Turbocharger
154
Installing the Replacement Cartridge Group
154
Fitting the Cover Plate
155
Fig. 115: Fitting the Cover Plate
155
Cover Plate Drawing
156
Table 66: Cover Plate Dimensions [MM]
156
Fig. 116: Cover Plate Drawing
156
Fig. 117: Dimensions for Cover Plate
157
Table 67: Cover Plate Dimensions [MM]
157
Mothballing the Turbocharger
158
Taking the Engine out of Operation for up to 12 Months
158
Taking the Engine out of Operation for more than 12 Months
159
Disposing of Turbocharger Components
160
Required Customer Spare Part Set (97070)
161
Table 68: Customer Spare Part Set 97070
161
Ordering Spare Parts
161
Spare Parts
161
Spare Part - Illustrations
162
Table 69: Spare Parts - Cartridge, Oil Cooled
163
Table 70: Spare Parts - Bearing, Casing Oil Cooled
164
Table 71: Spare Parts - Rotor and Bearing Parts
165
Table 72: Spare Parts - Turbine Casing, 1 Inlet
166
Table 73: Spare Parts - Turbine Casing, 2 Inlets
167
Table 74: Spare Parts - Turbine Casing, 3 Inlets
168
Table 75: Spare Parts - Cleaning Device
169
Table 76: Spare Parts - Gas Outlet Casing, Radial
170
Table 77: Spare Parts - Compressor Casing
171
Table 78: Spare Parts - Filter Silencer
173
Table 79: Spare Parts - Air Suction Branch Axial
173
Table 80: Spare Parts - Air Suction Branch Radial
174
Table 81: Spare Parts - Speed Measurement System
175
Tools
176
Fig. 118: Special Tool
176
Table 82: Customer Tool Set 90000
176
Table 83: Special Tool (90160)
176
ABB A150-M68 Operation Manual (182 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 31.03 MB
Table of Contents
Operation Manual / A150-M58/68
3
Table of Contents
3
Fig. 1: Serial Number (01) on the Rating Plate
6
Introduction
6
Purpose of the Manual
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
Safety
15
Introduction
15
CE Conformity
15
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Definition of Safety Instructions
16
Definition of Mandatory Signs
16
Intended Use
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 7: Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Periodic Check of the Pressure Vessels
21
Lifting of Loads
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Fig. 10: Attachment Angle
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
Table 4: Weight of Complete Turbocharger Unit
31
Fig. 11: Suspension of Complete Turbocharger Unit
31
Turbocharger Weight and Transportation
31
Removing and Installing
31
Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Fig. 13: Removing the Turbocharger
32
Fig. 14: Loosening the Clamping Nut
33
Fig. 15: Turbocharger Centre of Gravity
34
Fig. 16: Inserting the Gasket
35
Installing the Turbocharger
35
Fig. 17: Inserting the Threaded Rods
36
Fig. 18: Placing the Turbocharger on the Bracket
36
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
37
Fig. 20: Tightening Pressure Screws
38
Table 5: Torque-Controlled Tightening of the Pressure Screws
38
Fig. 21: Connecting the Speed Sensor
39
Fig. 22: Connecting the Compressor Cooling Air Intake
39
Fig. 23: Attaching the Support
39
Oil Supply
40
Commissioning
40
Fig. 24: Oil Orifice
41
Inspection Procedures
42
Commissioning after Taking out of Operation
44
Monitoring Operation
45
Oil Pressure, Oil Temperature
45
Table 6: Lubricating Oil Pressure at Oil Inlet before Turbocharger
45
Table 7: Lubricating Oil Temperature at the Inlet
46
Table 8: Maximum Lubricating Oil Temperature at the Outlet
46
Exhaust Gas Temperature before Turbine
47
Turbocharger Speed
48
Fig. 25: Layout and Overview of Speed Measurement System
48
Fig. 26: Replacing the Speed Sensor
50
Table 9: Tightening Torque (86505)
50
Operation and Service
51
Noise Emission
51
Fig. 27: Noise Insulation, Bellows
52
Service Work
53
Table 10: Expected Replacement Intervals
56
Expected Replacement Intervals
56
Stopping the Engine
58
Periodic Maintenance Work
59
Foreword to Maintenance
59
Table 11: Maintenance Table
59
Cleaning the Compressor During Operation
60
Fig. 28: Carrying out Wet Cleaning of Compressor
62
Table 12: Parameters for Wet Cleaning of Compressor
62
Cleaning the Turbine During Operation
63
Fig. 29: Turbine Cleaning Devices
65
Table 13: Turbine Wet Cleaning, Recommended Operating State
65
Fig. 30: Carrying out Wet Cleaning of Turbines
66
Table 14: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
66
Cleaning Components Mechanically
67
Table 15: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
67
Fig. 31: Cleaning the Filter Silencer
68
Fig. 32: Compressor Casing
70
Fig. 33: Diffuser
71
Fig. 34: Turbine End, Non-Rotating Parts
73
Fig. 35: Soaking the Turbine End
75
Table 16: Value Table for Soaking
75
Malfunctions When Starting
78
Table 17: Malfunctions When Starting - Delayed Start-Up
78
Table 18: Malfunctions When Starting - Vibrations
78
Table 19: Malfunctions When Starting - Rubbing of Rotating Parts
78
Eliminating Malfunctions
78
Table 21: Malfunctions During Operation - Speed Reduces
79
Table 22: Malfunctions During Operation - Speed Increases
79
Table 20: Malfunctions During Operation - Lubricating Oil Pressure too Low
79
Malfunctions During Operation
79
Table 23: Malfunctions During Operation - Exhaust Gas Temperature too High
80
Table 24: Malfunctions During Operation - Charge Air Pressure too Low
80
Table 25: Malfunctions During Operation - Charge Air Pressure too High
81
Table 26: Malfunctions During Operation - Engine Performance Losses
81
Turbocharger Is Surging
82
Table 27: Malfunction - Turbocharger Pumping
82
Table 28: Malfunction - Sporadic Surge Blows
82
Table 30: Malfunctions When Stopping - Runout Time too Short
83
Table 29: Malfunctions When Stopping - Runout Noises
83
Malfunctions When Stopping
83
Table 33: Malfunction of the Speed Measurement System - Measured Speed too Low
84
Speed Measurement System
84
Table 32: Malfunction of the Speed Measurement System - Measured Speed too High
84
Table 31: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
84
Dismantling and Fitting, General
85
Introduction
85
Material Required
86
Fig. 36: Swivel Lifting Eyes
86
Table 34: Swivel Lifting Eyes
86
Fig. 37: Press-Off Screws
87
Fig. 38: Dismantling Screw
87
Table 35: Press-Off Screws
87
Table 36: Dismantling Screw
87
Disassembly and Assembly Concepts
89
Fig. 39: Removing the Cartridge Group with Compressor and Turbine Casing
89
Fig. 40: Cartridge Concept
90
Fig. 41: Optional Spanner Holder
91
Table 37: Weights of Assemblies
92
Weights of Individual Parts
92
Fig. 42: Weights of Assemblies
92
Table of Tightening Torques
93
Fig. 43 Overview of Tightening Torques
93
Table 38: Tightening Torques
93
Fig. 44: Tightening Torques for Insulation
94
Table 39: Tightening Torques for Insulation
94
Fig. 45: Removing the Air Inlets
95
Removing Air Inlets
95
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
95
Removing the Gas Outlet Casing
96
Fig. 46: Remove Gas Outlet Casing Without Support
96
Fig. 47: Removing Gas Outlet Casing with Support 1
97
Fig. 48: Removing Gas Outlet Casing with Support 1
98
Removing the Gas Outlet Flange
99
Fig. 49: Removing the Gas Outlet Flange
99
Table 40: Press-Off Screws - Gas Outlet Flange
99
Fig. 51: Remove Insulation
100
Removing the Cartridge Group with Compressor and Turbine Casing
100
Fig. 50: Turbine Cleaning Nozzle
100
Fig. 52: Removing the Cartridge Group with Compressor and Turbine Casing
101
Fig. 53: Set down the Cartridge Group with the Compressor and Turbine Casing
101
Removing the Compressor Casing
102
Fig. 54: Removing the Compressor Casing
102
Removing the Cartridge Group
103
Fig. 55: Removing Cartridge Group 1
103
Table 41: Tightening Torque (90012-01)
103
Fig. 56: Removing Cartridge Group 2
104
Fig. 57: Removing Cartridge Group 3
105
Installing the Cartridge Group on the Service Support
106
Fig. 58: Installing the Cartridge Group on the Service Support
106
Removing the Nozzle Ring
107
Fig. 59: Removing the Nozzle Ring
107
Measuring Clearance a and B
108
Fig. 60: Measuring Clearance a and B
108
Table 42: Permissible Clearances a and B
108
Table 43: Nozzle Ring Compression PD
109
Nozzle Ring Compression PD
109
Fig. 61: Nozzle Ring Compression PD
109
Installing Nozzle Ring
110
Fig. 62: Installing the Nozzle Ring
110
Installing the Cartridge Group
111
Fig. 63: Lifting the Cartridge Group and Rotating It
111
Fig. 64: Turning the Cartridge Group
112
Table 44: Tightening Torque (90012-01)
112
Fig. 65: Installing the Cartridge Group
113
Table 45: Tightening Torque (51007)
113
Installing the Compressor Casing
114
Fig. 66: Fitting the Diffuser
114
Table 46: Tightening Torque (79041)
114
Fig. 67: Installing the Compressor Casing
115
Table 47: Tightening Torque (72011)
115
Turning the Cartridge Group with Compressor and Turbine Casing
116
Fig. 68: Turning the Cartridge Group with Compressor and Turbine Casing
116
Fig. 69: Installing the Gas Outlet Flange
117
Installing the Gas Outlet Flange
117
Fig. 70: Measuring Clearances N and R
118
Table 48: Permissible Clearances N and R
118
Radial Clearances N and R
118
Fitting the Insulation
119
Fig. 71: Fitting the Insulation
119
Installing the Cartridge Group with Compressor and Turbine Casing
120
Fig. 72: Installing the Cartridge Group with Compressor and Turbine Casing
120
Fig. 73: Installing the Cartridge Group with Compressor and Turbine Casing
120
Table 49: Tightening Torque (51009)
121
Installing the Gas Outlet Casing
121
Fig. 74: Fitting Gas Outlet Casing Without Support
121
Fig. 75: Installing Gas Outlet Casing with Support 1
122
Table 50: Tightening Torque (51009)
122
Fig. 76: Installing Gas Outlet Casing with Support 2
123
Installing Air Inlets
124
Fig. 77: Installing the Air Inlets
124
Table 51: Tightening Torque (72051)
124
Dismantling and Fitting, Cartridge Concept
125
Fig. 78: Removing the Air Inlets
125
Fig. 79: Removing the Compressor Casing
126
Fig. 80: Pressing off Compressor Casing
127
Fig. 81: Remove the Diffuser
127
Fig. 82: Removing Insulation Sheets
128
Fig. 83: Removing Cartridge Group 1
128
Fig. 84: Removing Cartridge Group 2
129
Fig. 85: Removing Cartridge Group 3
130
Fig. 86: S_05180
131
Fig. 87: Measuring Clearance a and B
132
Table 52: Permissible Clearances a and B
132
Fig. 88: Nozzle Ring Compression PD
133
Table 53: Nozzle Ring Compression PD
133
Fig. 89: Installing the Nozzle Ring
134
Fig. 90: Installing the Cartridge Group
135
Fig. 91: Installing the Cartridge Group 2
136
Table 54: Tightening Torque (51007)
136
Table 55: Tightening Torque (51007) with Spanner Holder
136
Table 56: Tightening Torque (79041)
137
Fig. 92: Fitting the Diffuser
137
Table 57: Tightening Torque (72011)
138
Fig. 93: Installing the Compressor Casing
138
Fig. 94: Measuring Clearances N and R
139
Table 58: Permissible Clearances N and R
139
Fig. 95: Fitting the Insulation
140
Fig. 96: Installing the Air Inlets
141
Table 59: Tightening Torque (72051)
141
Table 60: Customer Tool
142
Dismantling and Fitting, Special Tools for Fastening Strips
142
Fig. 97: Customer Tool
142
Application, Special Tools
143
Fig. 98: Positioning the Collection Tub
143
Fig. 99: Removing the Fastening Strips
143
Fig. 100: Fitting the Upper Fastening Strips
144
Fig. 101: Fitting the Bottom Fastening Strip
144
Table 61: Tightening Torque (51007)
144
Table 62: Tightening Torque (51007) with Spanner Holder
145
Fig. 102: Fitting the Bottom Fastening Strip
145
Removing and Installing 6-Nozzle Turbine Cleaning Component (Optional)
146
Disassembly
146
Fig. 103: Initial Situation
146
Fig. 104: Disassembly of the Elbows
146
Fig. 105: Disassembly of the Elbows
147
Fig. 106: Pipe Disassembly
147
Table 63: Dismantling Screw
148
Fig. 108: Disassembly of the Cleaning Nozzle
148
Fig. 107: Disassembly of the Connecting Pieces
148
Assembly
149
Fig. 109: Assembly of the Cleaning Nozzle
149
Fig. 110: Assembly of the Connecting Pieces
149
Table 64: Dismantling Screw
149
Fig. 111: Pipe Assembly
150
Fig. 112: Elbow 1 Assembly
150
Fig. 113: Elbow 2 Assembly
151
Table 65: Tightening Torque (51314 / 51316)
151
Fig. 114: Fit the Cleaning Nozzles
152
Fitting the Cleaning Nozzles with Multi-Inlet Turbine Casings
152
Taking out of Operation at Short Notice
153
Possible Emergency Repairs
153
Installing the Replacement Turbocharger
154
Installing the Replacement Cartridge Group
154
Fitting the Cover Plate
155
Fig. 115: Fitting the Cover Plate
155
Cover Plate Drawing
156
Table 66: Cover Plate Dimensions [MM]
156
Fig. 116: Cover Plate Drawing
156
Fig. 117: Dimensions for Cover Plate
157
Table 67: Cover Plate Dimensions [MM]
157
Mothballing the Turbocharger
158
Taking the Engine out of Operation for up to 12 Months
158
Taking the Engine out of Operation for more than 12 Months
159
Disposing of Turbocharger Components
160
Required Customer Spare Part Set (97070)
161
Table 68: Customer Spare Part Set 97070
161
Ordering Spare Parts
161
Spare Parts
161
Spare Part - Illustrations
162
Table 69: Spare Parts - Cartridge, Oil Cooled
163
Table 70: Spare Parts - Bearing, Casing Oil Cooled
164
Table 71: Spare Parts - Rotor and Bearing Parts
165
Table 72: Spare Parts - Turbine Casing, 1 Inlet
166
Table 73: Spare Parts - Turbine Casing, 2 Inlets
167
Table 74: Spare Parts - Turbine Casing, 3 Inlets
168
Table 75: Spare Parts - Cleaning Device
169
Table 76: Spare Parts - Gas Outlet Casing, Radial
170
Table 77: Spare Parts - Compressor Casing
171
Table 78: Spare Parts - Filter Silencer
173
Table 79: Spare Parts - Air Suction Branch Axial
173
Table 80: Spare Parts - Air Suction Branch Radial
174
Table 81: Spare Parts - Speed Measurement System
175
Tools
176
Fig. 118: Special Tool
176
Table 82: Customer Tool Set 90000
176
Table 83: Special Tool (90160)
176
ABB A150-M68 Operation Manual (182 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 31.03 MB
Table of Contents
Operation Manual / A150-M58/68
3
Table of Contents
3
Fig. 1: Serial Number (01) on the Rating Plate
6
Introduction
6
Purpose of the Manual
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
Safety
15
Introduction
15
CE Conformity
15
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Definition of Safety Instructions
16
Definition of Mandatory Signs
16
Intended Use
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 7: Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Periodic Check of the Pressure Vessels
21
Lifting of Loads
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Fig. 10: Attachment Angle
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
Table 4: Weight of Complete Turbocharger Unit
31
Fig. 11: Suspension of Complete Turbocharger Unit
31
Turbocharger Weight and Transportation
31
Removing and Installing
31
Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Fig. 13: Removing the Turbocharger
32
Fig. 14: Loosening the Clamping Nut
33
Fig. 15: Turbocharger Centre of Gravity
34
Fig. 16: Inserting the Gasket
35
Installing the Turbocharger
35
Fig. 17: Inserting the Threaded Rods
36
Fig. 18: Placing the Turbocharger on the Bracket
36
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
37
Fig. 20: Tightening Pressure Screws
38
Table 5: Torque-Controlled Tightening of the Pressure Screws
38
Fig. 21: Connecting the Speed Sensor
39
Fig. 22: Connecting the Compressor Cooling Air Intake
39
Fig. 23: Attaching the Support
39
Oil Supply
40
Commissioning
40
Fig. 24: Oil Orifice
41
Inspection Procedures
42
Commissioning after Taking out of Operation
44
Monitoring Operation
45
Oil Pressure, Oil Temperature
45
Table 6: Lubricating Oil Pressure at Oil Inlet before Turbocharger
45
Table 7: Lubricating Oil Temperature at the Inlet
46
Table 8: Maximum Lubricating Oil Temperature at the Outlet
46
Exhaust Gas Temperature before Turbine
47
Turbocharger Speed
48
Fig. 25: Layout and Overview of Speed Measurement System
48
Fig. 26: Replacing the Speed Sensor
50
Table 9: Tightening Torque (86505)
50
Operation and Service
51
Noise Emission
51
Fig. 27: Noise Insulation, Bellows
52
Service Work
53
Table 10: Expected Replacement Intervals
56
Expected Replacement Intervals
56
Stopping the Engine
58
Periodic Maintenance Work
59
Foreword to Maintenance
59
Table 11: Maintenance Table
59
Cleaning the Compressor During Operation
60
Fig. 28: Carrying out Wet Cleaning of Compressor
62
Table 12: Parameters for Wet Cleaning of Compressor
62
Cleaning the Turbine During Operation
63
Fig. 29: Turbine Cleaning Devices
65
Table 13: Turbine Wet Cleaning, Recommended Operating State
65
Fig. 30: Carrying out Wet Cleaning of Turbines
66
Table 14: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
66
Cleaning Components Mechanically
67
Table 15: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
67
Fig. 31: Cleaning the Filter Silencer
68
Fig. 32: Compressor Casing
70
Fig. 33: Diffuser
71
Fig. 34: Turbine End, Non-Rotating Parts
73
Fig. 35: Soaking the Turbine End
75
Table 16: Value Table for Soaking
75
Malfunctions When Starting
78
Table 17: Malfunctions When Starting - Delayed Start-Up
78
Table 18: Malfunctions When Starting - Vibrations
78
Table 19: Malfunctions When Starting - Rubbing of Rotating Parts
78
Eliminating Malfunctions
78
Table 21: Malfunctions During Operation - Speed Reduces
79
Table 22: Malfunctions During Operation - Speed Increases
79
Table 20: Malfunctions During Operation - Lubricating Oil Pressure too Low
79
Malfunctions During Operation
79
Table 23: Malfunctions During Operation - Exhaust Gas Temperature too High
80
Table 24: Malfunctions During Operation - Charge Air Pressure too Low
80
Table 25: Malfunctions During Operation - Charge Air Pressure too High
81
Table 26: Malfunctions During Operation - Engine Performance Losses
81
Turbocharger Is Surging
82
Table 27: Malfunction - Turbocharger Pumping
82
Table 28: Malfunction - Sporadic Surge Blows
82
Table 30: Malfunctions When Stopping - Runout Time too Short
83
Table 29: Malfunctions When Stopping - Runout Noises
83
Malfunctions When Stopping
83
Table 33: Malfunction of the Speed Measurement System - Measured Speed too Low
84
Speed Measurement System
84
Table 32: Malfunction of the Speed Measurement System - Measured Speed too High
84
Table 31: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
84
Dismantling and Fitting, General
85
Introduction
85
Material Required
86
Fig. 36: Swivel Lifting Eyes
86
Table 34: Swivel Lifting Eyes
86
Fig. 37: Press-Off Screws
87
Fig. 38: Dismantling Screw
87
Table 35: Press-Off Screws
87
Table 36: Dismantling Screw
87
Disassembly and Assembly Concepts
89
Fig. 39: Removing the Cartridge Group with Compressor and Turbine Casing
89
Fig. 40: Cartridge Concept
90
Fig. 41: Optional Spanner Holder
91
Table 37: Weights of Assemblies
92
Weights of Individual Parts
92
Fig. 42: Weights of Assemblies
92
Table of Tightening Torques
93
Fig. 43 Overview of Tightening Torques
93
Table 38: Tightening Torques
93
Fig. 44: Tightening Torques for Insulation
94
Table 39: Tightening Torques for Insulation
94
Fig. 45: Removing the Air Inlets
95
Removing Air Inlets
95
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
95
Removing the Gas Outlet Casing
96
Fig. 46: Remove Gas Outlet Casing Without Support
96
Fig. 47: Removing Gas Outlet Casing with Support 1
97
Fig. 48: Removing Gas Outlet Casing with Support 1
98
Removing the Gas Outlet Flange
99
Fig. 49: Removing the Gas Outlet Flange
99
Table 40: Press-Off Screws - Gas Outlet Flange
99
Fig. 51: Remove Insulation
100
Removing the Cartridge Group with Compressor and Turbine Casing
100
Fig. 50: Turbine Cleaning Nozzle
100
Fig. 52: Removing the Cartridge Group with Compressor and Turbine Casing
101
Fig. 53: Set down the Cartridge Group with the Compressor and Turbine Casing
101
Removing the Compressor Casing
102
Fig. 54: Removing the Compressor Casing
102
Removing the Cartridge Group
103
Fig. 55: Removing Cartridge Group 1
103
Table 41: Tightening Torque (90012-01)
103
Fig. 56: Removing Cartridge Group 2
104
Fig. 57: Removing Cartridge Group 3
105
Installing the Cartridge Group on the Service Support
106
Fig. 58: Installing the Cartridge Group on the Service Support
106
Removing the Nozzle Ring
107
Fig. 59: Removing the Nozzle Ring
107
Measuring Clearance a and B
108
Fig. 60: Measuring Clearance a and B
108
Table 42: Permissible Clearances a and B
108
Table 43: Nozzle Ring Compression PD
109
Nozzle Ring Compression PD
109
Fig. 61: Nozzle Ring Compression PD
109
Installing Nozzle Ring
110
Fig. 62: Installing the Nozzle Ring
110
Installing the Cartridge Group
111
Fig. 63: Lifting the Cartridge Group and Rotating It
111
Fig. 64: Turning the Cartridge Group
112
Table 44: Tightening Torque (90012-01)
112
Fig. 65: Installing the Cartridge Group
113
Table 45: Tightening Torque (51007)
113
Installing the Compressor Casing
114
Fig. 66: Fitting the Diffuser
114
Table 46: Tightening Torque (79041)
114
Fig. 67: Installing the Compressor Casing
115
Table 47: Tightening Torque (72011)
115
Turning the Cartridge Group with Compressor and Turbine Casing
116
Fig. 68: Turning the Cartridge Group with Compressor and Turbine Casing
116
Fig. 69: Installing the Gas Outlet Flange
117
Installing the Gas Outlet Flange
117
Fig. 70: Measuring Clearances N and R
118
Table 48: Permissible Clearances N and R
118
Radial Clearances N and R
118
Fitting the Insulation
119
Fig. 71: Fitting the Insulation
119
Installing the Cartridge Group with Compressor and Turbine Casing
120
Fig. 72: Installing the Cartridge Group with Compressor and Turbine Casing
120
Fig. 73: Installing the Cartridge Group with Compressor and Turbine Casing
120
Table 49: Tightening Torque (51009)
121
Installing the Gas Outlet Casing
121
Fig. 74: Fitting Gas Outlet Casing Without Support
121
Fig. 75: Installing Gas Outlet Casing with Support 1
122
Table 50: Tightening Torque (51009)
122
Fig. 76: Installing Gas Outlet Casing with Support 2
123
Installing Air Inlets
124
Fig. 77: Installing the Air Inlets
124
Table 51: Tightening Torque (72051)
124
Dismantling and Fitting, Cartridge Concept
125
Fig. 78: Removing the Air Inlets
125
Fig. 79: Removing the Compressor Casing
126
Fig. 80: Pressing off Compressor Casing
127
Fig. 81: Remove the Diffuser
127
Fig. 82: Removing Insulation Sheets
128
Fig. 83: Removing Cartridge Group 1
128
Fig. 84: Removing Cartridge Group 2
129
Fig. 85: Removing Cartridge Group 3
130
Fig. 86: S_05180
131
Fig. 87: Measuring Clearance a and B
132
Table 52: Permissible Clearances a and B
132
Fig. 88: Nozzle Ring Compression PD
133
Table 53: Nozzle Ring Compression PD
133
Fig. 89: Installing the Nozzle Ring
134
Fig. 90: Installing the Cartridge Group
135
Fig. 91: Installing the Cartridge Group 2
136
Table 54: Tightening Torque (51007)
136
Table 55: Tightening Torque (51007) with Spanner Holder
136
Table 56: Tightening Torque (79041)
137
Fig. 92: Fitting the Diffuser
137
Table 57: Tightening Torque (72011)
138
Fig. 93: Installing the Compressor Casing
138
Fig. 94: Measuring Clearances N and R
139
Table 58: Permissible Clearances N and R
139
Fig. 95: Fitting the Insulation
140
Fig. 96: Installing the Air Inlets
141
Table 59: Tightening Torque (72051)
141
Table 60: Customer Tool
142
Dismantling and Fitting, Special Tools for Fastening Strips
142
Fig. 97: Customer Tool
142
Application, Special Tools
143
Fig. 98: Positioning the Collection Tub
143
Fig. 99: Removing the Fastening Strips
143
Fig. 100: Fitting the Upper Fastening Strips
144
Fig. 101: Fitting the Bottom Fastening Strip
144
Table 61: Tightening Torque (51007)
144
Table 62: Tightening Torque (51007) with Spanner Holder
145
Fig. 102: Fitting the Bottom Fastening Strip
145
Removing and Installing 6-Nozzle Turbine Cleaning Component (Optional)
146
Disassembly
146
Fig. 103: Initial Situation
146
Fig. 104: Disassembly of the Elbows
146
Fig. 105: Disassembly of the Elbows
147
Fig. 106: Pipe Disassembly
147
Table 63: Dismantling Screw
148
Fig. 108: Disassembly of the Cleaning Nozzle
148
Fig. 107: Disassembly of the Connecting Pieces
148
Assembly
149
Fig. 109: Assembly of the Cleaning Nozzle
149
Fig. 110: Assembly of the Connecting Pieces
149
Table 64: Dismantling Screw
149
Fig. 111: Pipe Assembly
150
Fig. 112: Elbow 1 Assembly
150
Fig. 113: Elbow 2 Assembly
151
Table 65: Tightening Torque (51314 / 51316)
151
Fig. 114: Fit the Cleaning Nozzles
152
Fitting the Cleaning Nozzles with Multi-Inlet Turbine Casings
152
Taking out of Operation at Short Notice
153
Possible Emergency Repairs
153
Installing the Replacement Turbocharger
154
Installing the Replacement Cartridge Group
154
Fitting the Cover Plate
155
Fig. 115: Fitting the Cover Plate
155
Cover Plate Drawing
156
Table 66: Cover Plate Dimensions [MM]
156
Fig. 116: Cover Plate Drawing
156
Fig. 117: Dimensions for Cover Plate
157
Table 67: Cover Plate Dimensions [MM]
157
Mothballing the Turbocharger
158
Taking the Engine out of Operation for up to 12 Months
158
Taking the Engine out of Operation for more than 12 Months
159
Disposing of Turbocharger Components
160
Required Customer Spare Part Set (97070)
161
Table 68: Customer Spare Part Set 97070
161
Ordering Spare Parts
161
Spare Parts
161
Spare Part - Illustrations
162
Table 69: Spare Parts - Cartridge, Oil Cooled
163
Table 70: Spare Parts - Bearing, Casing Oil Cooled
164
Table 71: Spare Parts - Rotor and Bearing Parts
165
Table 72: Spare Parts - Turbine Casing, 1 Inlet
166
Table 73: Spare Parts - Turbine Casing, 2 Inlets
167
Table 74: Spare Parts - Turbine Casing, 3 Inlets
168
Table 75: Spare Parts - Cleaning Device
169
Table 76: Spare Parts - Gas Outlet Casing, Radial
170
Table 77: Spare Parts - Compressor Casing
171
Table 78: Spare Parts - Filter Silencer
173
Table 79: Spare Parts - Air Suction Branch Axial
173
Table 80: Spare Parts - Air Suction Branch Radial
174
Table 81: Spare Parts - Speed Measurement System
175
Tools
176
Fig. 118: Special Tool
176
Table 82: Customer Tool Set 90000
176
Table 83: Special Tool (90160)
176
ABB A150-M68 Operation Manual (182 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 31.03 MB
Table of Contents
Operation Manual / A150-M58/68
3
Table of Contents
3
Fig. 1: Serial Number (01) on the Rating Plate
6
Introduction
6
Purpose of the Manual
6
Contact Information
7
Essential Information
7
Layout and Function of the Turbocharger
8
Fig. 2: Layout and Function of the Turbocharger
8
Fig. 3: Compressor Wheel Cooling
9
Symbols, Definitions
10
Table 1: Definition of Pictograms
11
Storage of New Turbochargers and Spare Parts
12
Fig. 4: Volatile Corrosion Inhibitor (VCI)
12
Fig. 5: Package with Hygrometer
13
Registered Trademarks
14
Safety
15
Introduction
15
CE Conformity
15
Table 3: Personal Protective Equipment to be Worn Specific to the Respective Task
16
Table 2: Personal Protective Equipment to be Worn at All Times
16
Definition of Safety Instructions
16
Definition of Mandatory Signs
16
Intended Use
17
Warning Plates on the Turbocharger
18
Fig. 6: Warning Plate Locations
18
Turbocharger Rating Plate
19
Fig. 7: Rating Plate
19
Fig. 8: Locations of the Rating Plates
20
Periodic Check of the Pressure Vessels
21
Lifting of Loads
22
Fig. 9: Attachment of Loads on the Crane Hook
22
Fig. 10: Attachment Angle
22
Prerequisites for Operation and Maintenance
23
Hazards During Operation and Maintenance
24
Safe Operation
26
Safe Maintenance
27
Table 4: Weight of Complete Turbocharger Unit
31
Fig. 11: Suspension of Complete Turbocharger Unit
31
Turbocharger Weight and Transportation
31
Removing and Installing
31
Removing the Turbocharger
32
Fig. 12: Turbine Cleaning Nozzle
32
Fig. 13: Removing the Turbocharger
32
Fig. 14: Loosening the Clamping Nut
33
Fig. 15: Turbocharger Centre of Gravity
34
Fig. 16: Inserting the Gasket
35
Installing the Turbocharger
35
Fig. 17: Inserting the Threaded Rods
36
Fig. 18: Placing the Turbocharger on the Bracket
36
Fig. 19: Preparing the Clamping Nut for the Tightening Procedure
37
Fig. 20: Tightening Pressure Screws
38
Table 5: Torque-Controlled Tightening of the Pressure Screws
38
Fig. 21: Connecting the Speed Sensor
39
Fig. 22: Connecting the Compressor Cooling Air Intake
39
Fig. 23: Attaching the Support
39
Oil Supply
40
Commissioning
40
Fig. 24: Oil Orifice
41
Inspection Procedures
42
Commissioning after Taking out of Operation
44
Monitoring Operation
45
Oil Pressure, Oil Temperature
45
Table 6: Lubricating Oil Pressure at Oil Inlet before Turbocharger
45
Table 7: Lubricating Oil Temperature at the Inlet
46
Table 8: Maximum Lubricating Oil Temperature at the Outlet
46
Exhaust Gas Temperature before Turbine
47
Turbocharger Speed
48
Fig. 25: Layout and Overview of Speed Measurement System
48
Fig. 26: Replacing the Speed Sensor
50
Table 9: Tightening Torque (86505)
50
Operation and Service
51
Noise Emission
51
Fig. 27: Noise Insulation, Bellows
52
Service Work
53
Table 10: Expected Replacement Intervals
56
Expected Replacement Intervals
56
Stopping the Engine
58
Periodic Maintenance Work
59
Foreword to Maintenance
59
Table 11: Maintenance Table
59
Cleaning the Compressor During Operation
60
Fig. 28: Carrying out Wet Cleaning of Compressor
62
Table 12: Parameters for Wet Cleaning of Compressor
62
Cleaning the Turbine During Operation
63
Fig. 29: Turbine Cleaning Devices
65
Table 13: Turbine Wet Cleaning, Recommended Operating State
65
Fig. 30: Carrying out Wet Cleaning of Turbines
66
Table 14: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
66
Cleaning Components Mechanically
67
Table 15: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
67
Fig. 31: Cleaning the Filter Silencer
68
Fig. 32: Compressor Casing
70
Fig. 33: Diffuser
71
Fig. 34: Turbine End, Non-Rotating Parts
73
Fig. 35: Soaking the Turbine End
75
Table 16: Value Table for Soaking
75
Malfunctions When Starting
78
Table 17: Malfunctions When Starting - Delayed Start-Up
78
Table 18: Malfunctions When Starting - Vibrations
78
Table 19: Malfunctions When Starting - Rubbing of Rotating Parts
78
Eliminating Malfunctions
78
Table 21: Malfunctions During Operation - Speed Reduces
79
Table 22: Malfunctions During Operation - Speed Increases
79
Table 20: Malfunctions During Operation - Lubricating Oil Pressure too Low
79
Malfunctions During Operation
79
Table 23: Malfunctions During Operation - Exhaust Gas Temperature too High
80
Table 24: Malfunctions During Operation - Charge Air Pressure too Low
80
Table 25: Malfunctions During Operation - Charge Air Pressure too High
81
Table 26: Malfunctions During Operation - Engine Performance Losses
81
Turbocharger Is Surging
82
Table 27: Malfunction - Turbocharger Pumping
82
Table 28: Malfunction - Sporadic Surge Blows
82
Table 30: Malfunctions When Stopping - Runout Time too Short
83
Table 29: Malfunctions When Stopping - Runout Noises
83
Malfunctions When Stopping
83
Table 33: Malfunction of the Speed Measurement System - Measured Speed too Low
84
Speed Measurement System
84
Table 32: Malfunction of the Speed Measurement System - Measured Speed too High
84
Table 31: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
84
Dismantling and Fitting, General
85
Introduction
85
Material Required
86
Fig. 36: Swivel Lifting Eyes
86
Table 34: Swivel Lifting Eyes
86
Fig. 37: Press-Off Screws
87
Fig. 38: Dismantling Screw
87
Table 35: Press-Off Screws
87
Table 36: Dismantling Screw
87
Disassembly and Assembly Concepts
89
Fig. 39: Removing the Cartridge Group with Compressor and Turbine Casing
89
Fig. 40: Cartridge Concept
90
Fig. 41: Optional Spanner Holder
91
Table 37: Weights of Assemblies
92
Weights of Individual Parts
92
Fig. 42: Weights of Assemblies
92
Table of Tightening Torques
93
Fig. 43 Overview of Tightening Torques
93
Table 38: Tightening Torques
93
Fig. 44: Tightening Torques for Insulation
94
Table 39: Tightening Torques for Insulation
94
Fig. 45: Removing the Air Inlets
95
Removing Air Inlets
95
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
95
Removing the Gas Outlet Casing
96
Fig. 46: Remove Gas Outlet Casing Without Support
96
Fig. 47: Removing Gas Outlet Casing with Support 1
97
Fig. 48: Removing Gas Outlet Casing with Support 1
98
Removing the Gas Outlet Flange
99
Fig. 49: Removing the Gas Outlet Flange
99
Table 40: Press-Off Screws - Gas Outlet Flange
99
Fig. 51: Remove Insulation
100
Removing the Cartridge Group with Compressor and Turbine Casing
100
Fig. 50: Turbine Cleaning Nozzle
100
Fig. 52: Removing the Cartridge Group with Compressor and Turbine Casing
101
Fig. 53: Set down the Cartridge Group with the Compressor and Turbine Casing
101
Removing the Compressor Casing
102
Fig. 54: Removing the Compressor Casing
102
Removing the Cartridge Group
103
Fig. 55: Removing Cartridge Group 1
103
Table 41: Tightening Torque (90012-01)
103
Fig. 56: Removing Cartridge Group 2
104
Fig. 57: Removing Cartridge Group 3
105
Installing the Cartridge Group on the Service Support
106
Fig. 58: Installing the Cartridge Group on the Service Support
106
Removing the Nozzle Ring
107
Fig. 59: Removing the Nozzle Ring
107
Measuring Clearance a and B
108
Fig. 60: Measuring Clearance a and B
108
Table 42: Permissible Clearances a and B
108
Table 43: Nozzle Ring Compression PD
109
Nozzle Ring Compression PD
109
Fig. 61: Nozzle Ring Compression PD
109
Installing Nozzle Ring
110
Fig. 62: Installing the Nozzle Ring
110
Installing the Cartridge Group
111
Fig. 63: Lifting the Cartridge Group and Rotating It
111
Fig. 64: Turning the Cartridge Group
112
Table 44: Tightening Torque (90012-01)
112
Fig. 65: Installing the Cartridge Group
113
Table 45: Tightening Torque (51007)
113
Installing the Compressor Casing
114
Fig. 66: Fitting the Diffuser
114
Table 46: Tightening Torque (79041)
114
Fig. 67: Installing the Compressor Casing
115
Table 47: Tightening Torque (72011)
115
Turning the Cartridge Group with Compressor and Turbine Casing
116
Fig. 68: Turning the Cartridge Group with Compressor and Turbine Casing
116
Fig. 69: Installing the Gas Outlet Flange
117
Installing the Gas Outlet Flange
117
Fig. 70: Measuring Clearances N and R
118
Table 48: Permissible Clearances N and R
118
Radial Clearances N and R
118
Fitting the Insulation
119
Fig. 71: Fitting the Insulation
119
Installing the Cartridge Group with Compressor and Turbine Casing
120
Fig. 72: Installing the Cartridge Group with Compressor and Turbine Casing
120
Fig. 73: Installing the Cartridge Group with Compressor and Turbine Casing
120
Table 49: Tightening Torque (51009)
121
Installing the Gas Outlet Casing
121
Fig. 74: Fitting Gas Outlet Casing Without Support
121
Fig. 75: Installing Gas Outlet Casing with Support 1
122
Table 50: Tightening Torque (51009)
122
Fig. 76: Installing Gas Outlet Casing with Support 2
123
Installing Air Inlets
124
Fig. 77: Installing the Air Inlets
124
Table 51: Tightening Torque (72051)
124
Dismantling and Fitting, Cartridge Concept
125
Fig. 78: Removing the Air Inlets
125
Fig. 79: Removing the Compressor Casing
126
Fig. 80: Pressing off Compressor Casing
127
Fig. 81: Remove the Diffuser
127
Fig. 82: Removing Insulation Sheets
128
Fig. 83: Removing Cartridge Group 1
128
Fig. 84: Removing Cartridge Group 2
129
Fig. 85: Removing Cartridge Group 3
130
Fig. 86: S_05180
131
Fig. 87: Measuring Clearance a and B
132
Table 52: Permissible Clearances a and B
132
Fig. 88: Nozzle Ring Compression PD
133
Table 53: Nozzle Ring Compression PD
133
Fig. 89: Installing the Nozzle Ring
134
Fig. 90: Installing the Cartridge Group
135
Fig. 91: Installing the Cartridge Group 2
136
Table 54: Tightening Torque (51007)
136
Table 55: Tightening Torque (51007) with Spanner Holder
136
Table 56: Tightening Torque (79041)
137
Fig. 92: Fitting the Diffuser
137
Table 57: Tightening Torque (72011)
138
Fig. 93: Installing the Compressor Casing
138
Fig. 94: Measuring Clearances N and R
139
Table 58: Permissible Clearances N and R
139
Fig. 95: Fitting the Insulation
140
Fig. 96: Installing the Air Inlets
141
Table 59: Tightening Torque (72051)
141
Table 60: Customer Tool
142
Dismantling and Fitting, Special Tools for Fastening Strips
142
Fig. 97: Customer Tool
142
Application, Special Tools
143
Fig. 98: Positioning the Collection Tub
143
Fig. 99: Removing the Fastening Strips
143
Fig. 100: Fitting the Upper Fastening Strips
144
Fig. 101: Fitting the Bottom Fastening Strip
144
Table 61: Tightening Torque (51007)
144
Table 62: Tightening Torque (51007) with Spanner Holder
145
Fig. 102: Fitting the Bottom Fastening Strip
145
Removing and Installing 6-Nozzle Turbine Cleaning Component (Optional)
146
Disassembly
146
Fig. 103: Initial Situation
146
Fig. 104: Disassembly of the Elbows
146
Fig. 105: Disassembly of the Elbows
147
Fig. 106: Pipe Disassembly
147
Table 63: Dismantling Screw
148
Fig. 108: Disassembly of the Cleaning Nozzle
148
Fig. 107: Disassembly of the Connecting Pieces
148
Assembly
149
Fig. 109: Assembly of the Cleaning Nozzle
149
Fig. 110: Assembly of the Connecting Pieces
149
Table 64: Dismantling Screw
149
Fig. 111: Pipe Assembly
150
Fig. 112: Elbow 1 Assembly
150
Fig. 113: Elbow 2 Assembly
151
Table 65: Tightening Torque (51314 / 51316)
151
Fig. 114: Fit the Cleaning Nozzles
152
Fitting the Cleaning Nozzles with Multi-Inlet Turbine Casings
152
Taking out of Operation at Short Notice
153
Possible Emergency Repairs
153
Installing the Replacement Turbocharger
154
Installing the Replacement Cartridge Group
154
Fitting the Cover Plate
155
Fig. 115: Fitting the Cover Plate
155
Cover Plate Drawing
156
Table 66: Cover Plate Dimensions [MM]
156
Fig. 116: Cover Plate Drawing
156
Fig. 117: Dimensions for Cover Plate
157
Table 67: Cover Plate Dimensions [MM]
157
Mothballing the Turbocharger
158
Taking the Engine out of Operation for up to 12 Months
158
Taking the Engine out of Operation for more than 12 Months
159
Disposing of Turbocharger Components
160
Required Customer Spare Part Set (97070)
161
Table 68: Customer Spare Part Set 97070
161
Ordering Spare Parts
161
Spare Parts
161
Spare Part - Illustrations
162
Table 69: Spare Parts - Cartridge, Oil Cooled
163
Table 70: Spare Parts - Bearing, Casing Oil Cooled
164
Table 71: Spare Parts - Rotor and Bearing Parts
165
Table 72: Spare Parts - Turbine Casing, 1 Inlet
166
Table 73: Spare Parts - Turbine Casing, 2 Inlets
167
Table 74: Spare Parts - Turbine Casing, 3 Inlets
168
Table 75: Spare Parts - Cleaning Device
169
Table 76: Spare Parts - Gas Outlet Casing, Radial
170
Table 77: Spare Parts - Compressor Casing
171
Table 78: Spare Parts - Filter Silencer
173
Table 79: Spare Parts - Air Suction Branch Axial
173
Table 80: Spare Parts - Air Suction Branch Radial
174
Table 81: Spare Parts - Speed Measurement System
175
Tools
176
Fig. 118: Special Tool
176
Table 82: Customer Tool Set 90000
176
Table 83: Special Tool (90160)
176
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