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ABB A270-L59 manuals available for free PDF download: Operation Manual
ABB A270-L59 Operation Manual (148 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 23.11 MB
Table of Contents
Operation Manual / A200-L
3
Table of Contents
3
Introduction
6
Essential Information
7
Registered Trademarks
7
Layout and Function of the Turbocharger
8
Fig. 1: Layout and Function of the Turbocharger
8
Locations of the Rating Plates
10
Fig. 2: Locations of the Rating Plates
10
Safety
11
Introduction
11
CE Conformity
11
Table 2: Personal Protective Equipment to be Worn Specific to the Respective Task
12
Table 1: Personal Protective Equipment to be Worn at All Times
12
Definition of Safety Instructions
12
Definition of Mandatory Signs
12
Intended Use
13
Deflagration on Gas Engines
14
Warning Plates on the Turbocharger
15
Turbocharger Rating Plate
15
Fig. 3: Warning Plate Locations
15
Fig. 4: Rating Plate
15
Periodic Check of the Pressure Vessels
17
Lifting of Loads
18
Fig. 5: Attachment of Loads on the Crane Hook
18
Fig. 6: Attachment Angle
18
Prerequisites for Operation and Maintenance
19
Hazards During Operation and Maintenance
20
Safe Operation
22
Safe Maintenance
22
Turbocharger Weight
28
Removing the Turbocharger
28
Table 3: Total Weight
28
Removal and Installation
28
Fig. 7: Fitting the Lifting Gear
29
Installing the Turbocharger
30
Fig. 8: Placing the Turbocharger
30
Fig. 9: Compressor-End Foot
31
Fig. 10: Turbine-End Foot
31
Table 4: General Information about Fastening the Turbocharger
31
Table 5: Tightening Torques (Foot Screws)
32
Table 6: Tightening Angle (Foot Screws)
32
Inspection Procedures
33
Commissioning
33
Oil Supply
33
Commissioning after Taking out of Operation
35
Monitoring During Operation
36
Oil Pressure, Oil Temperature
36
Table 7: Lubricating Oil Pressure, Oil Inlet
36
Fig. 11: Oil Temperature at the Outlet
37
Table 8: Lubricating Oil Temperature at the Inlet
37
Table 9: Lubricating Oil Temperature at the Outlet
37
Admissible Air Inlet Temperature
39
Turbocharger Speed
39
Fig. 12: Layout and Overview of the Speed Measurement System
39
Table 10: Tightening Torques (86505)
41
Fig. 13: Replacing the Speed Sensor
41
Low Pressure Measurement at the Filter Silencer
42
Fig. 14: U-Tube Manometer at the Filter Silencer
42
Operation and Service
43
Noise Emission
43
Service Work
44
Fig. 15: Noise Insulation, Bellows
44
Expected Replacement Intervals
48
Table 11: Expected Replacement Intervals for Turbocharger Parts
48
Table 12: Recommended Replacement Intervals for Turbocharger Parts
48
Flexible Turbocharger Cut-Out
49
Stopping the Engine
50
Periodic Maintenance
51
Foreword to Maintenance
51
Cleaning the Filter Silencer
52
Fig. 16: Layout and Overview of Filter Silencer
52
Changing the Filter Strip on the Filter Silencer Casing
54
Fig. 17: Dismantling Filter Ring Circumferential Part
54
Fig. 18: Opening Filter Ring Lock
54
Fig. 19: Attaching New Filter Ring
55
Fig. 20: Fitting New Filter Ring
55
Cleaning the Compressor During Operation
56
Fig. 21: Overview of Wet Cleaning of Compressor
58
Fig. 22: Filter Plug View
59
Table 13: Volume of Water Per Cleaning Process
59
Table 14: Tightening Torques (81125)
59
Cleaning the Turbine During Operation
60
Fig. 23: Dry Cleaning Device
61
Table 15: Cleaning Parameters
63
Draining the Gas Outlet Casing
64
Fig. 24: Drain Pipe Diagram
64
Troubleshooting
65
Malfunctions When Starting
65
Table 16: Malfunctions When Starting - Delayed Start-Up
65
Table 17: Malfunctions When Starting - Vibrations
65
Table 18: Malfunctions When Starting - Rubbing of Rotating Parts
65
Malfunctions During Operation
66
Table 19: Malfunctions During Operation - Lubricating Oil Pressure too Low
66
Table 20: Malfunctions During Operation - Drop in Speed
66
Table 21: Malfunctions During Operation - Exhaust Gas Temperature too High
67
Table 22: Malfunctions During Operation - Charge Air Pressure too Low
67
Table 24: Surging of the Turbocharger
68
Table 23: Malfunctions During Operation - Charge Air Pressure too High
68
Surging of the Turbocharger
68
Malfunctions When Stopping
69
Table 25: Malfunctions When Stopping - Runout Noises
69
Table 26: Malfunctions When Stopping - Shortened Runout Time
69
Speed Measurement System
70
Table 27: Malfunctions of the Speed Measurement System
70
Disassembly and Assembly
72
Introduction
72
Material Required
73
Weights of Assemblies
74
Fig. 25: Weights of Assemblies
74
Table 28: Weights of Assemblies [Kg]
74
Table 29: Weight of Wall Insert [Kg]
74
Disassembly and Assembly of the Filter Silencer Casing
75
Fig. 26: Dismantling the Filter Silencer Casing
75
Fig. 27: Fitting the Filter Silencer Casing
76
Fig. 28: Fitting the Filter Silencer Casing
77
Fig. 29: Fitting the Filter Silencer Casing
77
Fig. 30: Fitting the Filter Silencer Casing
78
Fig. 31: Fitting the Filter Silencer Casing
78
Fig. 32: Fitting the Bellows
79
Table 30: Tightening Torques (Filter Silencer Screws)
79
Dismantling the Filter Silencer
80
Fig. 33: Dismantling the Filter Silencer
80
Fig. 34: Dismantling the Filter Silencer
81
Dismantling Wall Insert and Diffuser
82
Fig. 37: Putting down Wall Insert
83
Fig. 36: Moving out Wall Insert
83
Fig. 39: Moving out Wall Insert
85
Fig. 40: Putting down Wall Insert
85
Fig. 41: Putting down Wall Insert
86
Fig. 42: Dismantling the Diffuser
87
Axial Clearance a Prior to Disassembly
88
Fig. 43: Measuring Axial Clearance a
88
Table 31: Axial Clearance a
88
Dismantling the Insulation (≤ A275-L)
89
Fig. 44: Removing the Insulation (A275-L and Smaller)
89
Dismantling the Gas Inlet Casing (≤ A275-L)
90
Fig. 45: Dismantling the Gas Inlet Casing (275-L and Smaller)
90
Table 32: Maximum Admissible Loosening Torque (51087)
90
Dismantling the Nozzle Ring (≤ A275-L)
91
Fig. 46: Dismantling the Nozzle Ring (A275-L and Smaller)
91
Dismantling the Gas Inlet Casing (A280-L)
92
Fig. 47: Dismantling the Gas Inlet Casing (A280-L)
92
Table 33: Maximum Admissible Loosening Torque (51087)
92
Dismantling the Nozzle Ring (A280-L)
93
Fig. 48: Fitting the Nozzle Ring Holder
93
Fig. 49: Dismantling the Nozzle Ring
94
Fig. 50: Put down the Nozzle Ring
94
Fitting the Nozzle Ring (≤ A275-L)
95
Fig. 51: Fitting the Nozzle Ring (A275-L and Smaller)
95
Table 34: Tightening Torque (56014)
95
Table 35: Tightening Torque (51087)
96
Fig. 52: Fitting the Gas Outlet Casing (A275-L and Smaller)
96
Fitting the Gas Inlet Casing (≤ A275-L)
96
Fitting the Insulation (≤ A275-L)
97
Fig. 53: Fitting the Insulation (A275-L and Smaller)
97
Fitting the Nozzle Ring (A280-L)
98
Fig. 54: Fitting the Nozzle Ring (A280-L)
98
Fig. 55: Attaching the Nozzle Ring (A280-L)
99
Table 36: Tightening Torque (56014)
99
Fitting the Gas Inlet Casing (A280-L)
100
Fig. 56: Fitting the Gas Inlet Casing (A280-L)
100
Table 37: Tightening Torque (51087)
100
Axial Clearance a after Assembly
101
Fig. 57: Measuring Axial Clearance a
101
Table 38: Axial Clearance a
101
Table 39: Tightening Torque (77015)
102
Fig. 58: Fitting the Diffuser
102
Fitting the Diffuser
102
Fitting Wall Insert
103
Fig. 59: Positioning Wall Insert
103
Table 40: Tightening Torque (72002)
104
Table 41: Tightening Torque (72004)
104
Table 42: Tightening Torque (72011)
106
Fitting the Filter Silencer
107
Fig. 62: Fitting the Filter Silencer
108
Table 43: Tightening Torque (72004)
108
Fig. 63: Fitting the Filter Silencer
109
Table 44: Tightening Torque (72004)
109
Fig. 65: Overview of Speed Sensor Tightening Torque
110
Table of Tightening Torques
110
Fig. 64: Overview of Tightening Torques
111
Table 45: Overview of Tightening Torques
111
Table 46: Tightening Torque, Insulation
111
Taking a Turbocharger out of Operation
112
Possible Emergency Repairs
112
Taking Defective Turbochargers out of Operation
113
Table 47: Bypass Procedure
113
Fig. 66: Locking the Rotor
114
Table 48: Tightening Torque B
115
Fig. 67: Ensuring Clamping of the Cover Ring
116
Table 49: Required Washers (01)
116
Table 50: Tightening Torque (57005)
116
Fig. 68: Position of Cover Plates
117
Taking the Engine out of Operation for up to 12 Months
118
Mothballing the Turbocharger
118
Taking the Engine out of Operation for more than 12 Months
119
Material and Disposal
120
REACH and Rohs Compliance Declaration for Products
120
Disposing of Turbocharger Components
121
Spare Parts
122
Ordering Spare Parts
122
Table 51: Customer Spare Part Set (97070)
122
Table 52: Customer Spare Part Set (97071)
123
Spare Part - Illustrations
124
Table 53: Spare Parts - Bearing Casing Common Parts
125
Table 54: Spare Parts - Bearing Casing Oil Tank
127
Table 55: Spare Parts - Cartridge
128
Table 56: Spare Parts - Compressor Casing
130
Table 57: Spare Parts - Filter Silencer
131
Table 58: Spare Parts - Gas Inlet Casing Axial
132
Table 59: Spare Parts - Gas Inlet Casing Radial
133
Table 60: Spare Parts - Gas Outlet Casing
134
Table 61: Spare Parts - Rotor and Bearing Parts
136
Table 62: Spare Parts - Sealing Air Supply for Flexible Cut-Out
137
Table 63: Spare Parts - Speed Measurement
138
Table 64: Spare Parts - U-Tube Manometer
139
Table 65: Spare Parts - Turbine Dry Cleaning Radial
141
Tools
142
Table 67: Customer Tool Set 90000 (A265-L
142
Table 69: Customer Tool Set 90000 (A280-L
143
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ABB A270-L59 Operation Manual (148 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 23.11 MB
Table of Contents
Operation Manual / A200-L
3
Table of Contents
3
Introduction
6
Essential Information
7
Registered Trademarks
7
Layout and Function of the Turbocharger
8
Fig. 1: Layout and Function of the Turbocharger
8
Locations of the Rating Plates
10
Fig. 2: Locations of the Rating Plates
10
Safety
11
Introduction
11
CE Conformity
11
Table 2: Personal Protective Equipment to be Worn Specific to the Respective Task
12
Table 1: Personal Protective Equipment to be Worn at All Times
12
Definition of Safety Instructions
12
Definition of Mandatory Signs
12
Intended Use
13
Deflagration on Gas Engines
14
Warning Plates on the Turbocharger
15
Turbocharger Rating Plate
15
Fig. 3: Warning Plate Locations
15
Fig. 4: Rating Plate
15
Periodic Check of the Pressure Vessels
17
Lifting of Loads
18
Fig. 5: Attachment of Loads on the Crane Hook
18
Fig. 6: Attachment Angle
18
Prerequisites for Operation and Maintenance
19
Hazards During Operation and Maintenance
20
Safe Operation
22
Safe Maintenance
22
Turbocharger Weight
28
Removing the Turbocharger
28
Table 3: Total Weight
28
Removal and Installation
28
Fig. 7: Fitting the Lifting Gear
29
Installing the Turbocharger
30
Fig. 8: Placing the Turbocharger
30
Fig. 9: Compressor-End Foot
31
Fig. 10: Turbine-End Foot
31
Table 4: General Information about Fastening the Turbocharger
31
Table 5: Tightening Torques (Foot Screws)
32
Table 6: Tightening Angle (Foot Screws)
32
Inspection Procedures
33
Commissioning
33
Oil Supply
33
Commissioning after Taking out of Operation
35
Monitoring During Operation
36
Oil Pressure, Oil Temperature
36
Table 7: Lubricating Oil Pressure, Oil Inlet
36
Fig. 11: Oil Temperature at the Outlet
37
Table 8: Lubricating Oil Temperature at the Inlet
37
Table 9: Lubricating Oil Temperature at the Outlet
37
Admissible Air Inlet Temperature
39
Turbocharger Speed
39
Fig. 12: Layout and Overview of the Speed Measurement System
39
Table 10: Tightening Torques (86505)
41
Fig. 13: Replacing the Speed Sensor
41
Low Pressure Measurement at the Filter Silencer
42
Fig. 14: U-Tube Manometer at the Filter Silencer
42
Operation and Service
43
Noise Emission
43
Service Work
44
Fig. 15: Noise Insulation, Bellows
44
Expected Replacement Intervals
48
Table 11: Expected Replacement Intervals for Turbocharger Parts
48
Table 12: Recommended Replacement Intervals for Turbocharger Parts
48
Flexible Turbocharger Cut-Out
49
Stopping the Engine
50
Periodic Maintenance
51
Foreword to Maintenance
51
Cleaning the Filter Silencer
52
Fig. 16: Layout and Overview of Filter Silencer
52
Changing the Filter Strip on the Filter Silencer Casing
54
Fig. 17: Dismantling Filter Ring Circumferential Part
54
Fig. 18: Opening Filter Ring Lock
54
Fig. 19: Attaching New Filter Ring
55
Fig. 20: Fitting New Filter Ring
55
Cleaning the Compressor During Operation
56
Fig. 21: Overview of Wet Cleaning of Compressor
58
Fig. 22: Filter Plug View
59
Table 13: Volume of Water Per Cleaning Process
59
Table 14: Tightening Torques (81125)
59
Cleaning the Turbine During Operation
60
Fig. 23: Dry Cleaning Device
61
Table 15: Cleaning Parameters
63
Draining the Gas Outlet Casing
64
Fig. 24: Drain Pipe Diagram
64
Troubleshooting
65
Malfunctions When Starting
65
Table 16: Malfunctions When Starting - Delayed Start-Up
65
Table 17: Malfunctions When Starting - Vibrations
65
Table 18: Malfunctions When Starting - Rubbing of Rotating Parts
65
Malfunctions During Operation
66
Table 19: Malfunctions During Operation - Lubricating Oil Pressure too Low
66
Table 20: Malfunctions During Operation - Drop in Speed
66
Table 21: Malfunctions During Operation - Exhaust Gas Temperature too High
67
Table 22: Malfunctions During Operation - Charge Air Pressure too Low
67
Table 24: Surging of the Turbocharger
68
Table 23: Malfunctions During Operation - Charge Air Pressure too High
68
Surging of the Turbocharger
68
Malfunctions When Stopping
69
Table 25: Malfunctions When Stopping - Runout Noises
69
Table 26: Malfunctions When Stopping - Shortened Runout Time
69
Speed Measurement System
70
Table 27: Malfunctions of the Speed Measurement System
70
Disassembly and Assembly
72
Introduction
72
Material Required
73
Weights of Assemblies
74
Fig. 25: Weights of Assemblies
74
Table 28: Weights of Assemblies [Kg]
74
Table 29: Weight of Wall Insert [Kg]
74
Disassembly and Assembly of the Filter Silencer Casing
75
Fig. 26: Dismantling the Filter Silencer Casing
75
Fig. 27: Fitting the Filter Silencer Casing
76
Fig. 28: Fitting the Filter Silencer Casing
77
Fig. 29: Fitting the Filter Silencer Casing
77
Fig. 30: Fitting the Filter Silencer Casing
78
Fig. 31: Fitting the Filter Silencer Casing
78
Fig. 32: Fitting the Bellows
79
Table 30: Tightening Torques (Filter Silencer Screws)
79
Dismantling the Filter Silencer
80
Fig. 33: Dismantling the Filter Silencer
80
Fig. 34: Dismantling the Filter Silencer
81
Dismantling Wall Insert and Diffuser
82
Fig. 37: Putting down Wall Insert
83
Fig. 36: Moving out Wall Insert
83
Fig. 39: Moving out Wall Insert
85
Fig. 40: Putting down Wall Insert
85
Fig. 41: Putting down Wall Insert
86
Fig. 42: Dismantling the Diffuser
87
Axial Clearance a Prior to Disassembly
88
Fig. 43: Measuring Axial Clearance a
88
Table 31: Axial Clearance a
88
Dismantling the Insulation (≤ A275-L)
89
Fig. 44: Removing the Insulation (A275-L and Smaller)
89
Dismantling the Gas Inlet Casing (≤ A275-L)
90
Fig. 45: Dismantling the Gas Inlet Casing (275-L and Smaller)
90
Table 32: Maximum Admissible Loosening Torque (51087)
90
Dismantling the Nozzle Ring (≤ A275-L)
91
Fig. 46: Dismantling the Nozzle Ring (A275-L and Smaller)
91
Dismantling the Gas Inlet Casing (A280-L)
92
Fig. 47: Dismantling the Gas Inlet Casing (A280-L)
92
Table 33: Maximum Admissible Loosening Torque (51087)
92
Dismantling the Nozzle Ring (A280-L)
93
Fig. 48: Fitting the Nozzle Ring Holder
93
Fig. 49: Dismantling the Nozzle Ring
94
Fig. 50: Put down the Nozzle Ring
94
Fitting the Nozzle Ring (≤ A275-L)
95
Fig. 51: Fitting the Nozzle Ring (A275-L and Smaller)
95
Table 34: Tightening Torque (56014)
95
Table 35: Tightening Torque (51087)
96
Fig. 52: Fitting the Gas Outlet Casing (A275-L and Smaller)
96
Fitting the Gas Inlet Casing (≤ A275-L)
96
Fitting the Insulation (≤ A275-L)
97
Fig. 53: Fitting the Insulation (A275-L and Smaller)
97
Fitting the Nozzle Ring (A280-L)
98
Fig. 54: Fitting the Nozzle Ring (A280-L)
98
Fig. 55: Attaching the Nozzle Ring (A280-L)
99
Table 36: Tightening Torque (56014)
99
Fitting the Gas Inlet Casing (A280-L)
100
Fig. 56: Fitting the Gas Inlet Casing (A280-L)
100
Table 37: Tightening Torque (51087)
100
Axial Clearance a after Assembly
101
Fig. 57: Measuring Axial Clearance a
101
Table 38: Axial Clearance a
101
Table 39: Tightening Torque (77015)
102
Fig. 58: Fitting the Diffuser
102
Fitting the Diffuser
102
Fitting Wall Insert
103
Fig. 59: Positioning Wall Insert
103
Table 40: Tightening Torque (72002)
104
Table 41: Tightening Torque (72004)
104
Table 42: Tightening Torque (72011)
106
Fitting the Filter Silencer
107
Fig. 62: Fitting the Filter Silencer
108
Table 43: Tightening Torque (72004)
108
Fig. 63: Fitting the Filter Silencer
109
Table 44: Tightening Torque (72004)
109
Fig. 65: Overview of Speed Sensor Tightening Torque
110
Table of Tightening Torques
110
Fig. 64: Overview of Tightening Torques
111
Table 45: Overview of Tightening Torques
111
Table 46: Tightening Torque, Insulation
111
Taking a Turbocharger out of Operation
112
Possible Emergency Repairs
112
Taking Defective Turbochargers out of Operation
113
Table 47: Bypass Procedure
113
Fig. 66: Locking the Rotor
114
Table 48: Tightening Torque B
115
Fig. 67: Ensuring Clamping of the Cover Ring
116
Table 49: Required Washers (01)
116
Table 50: Tightening Torque (57005)
116
Fig. 68: Position of Cover Plates
117
Taking the Engine out of Operation for up to 12 Months
118
Mothballing the Turbocharger
118
Taking the Engine out of Operation for more than 12 Months
119
Material and Disposal
120
REACH and Rohs Compliance Declaration for Products
120
Disposing of Turbocharger Components
121
Spare Parts
122
Ordering Spare Parts
122
Table 51: Customer Spare Part Set (97070)
122
Table 52: Customer Spare Part Set (97071)
123
Spare Part - Illustrations
124
Table 53: Spare Parts - Bearing Casing Common Parts
125
Table 54: Spare Parts - Bearing Casing Oil Tank
127
Table 55: Spare Parts - Cartridge
128
Table 56: Spare Parts - Compressor Casing
130
Table 57: Spare Parts - Filter Silencer
131
Table 58: Spare Parts - Gas Inlet Casing Axial
132
Table 59: Spare Parts - Gas Inlet Casing Radial
133
Table 60: Spare Parts - Gas Outlet Casing
134
Table 61: Spare Parts - Rotor and Bearing Parts
136
Table 62: Spare Parts - Sealing Air Supply for Flexible Cut-Out
137
Table 63: Spare Parts - Speed Measurement
138
Table 64: Spare Parts - U-Tube Manometer
139
Table 65: Spare Parts - Turbine Dry Cleaning Radial
141
Tools
142
Table 67: Customer Tool Set 90000 (A265-L
142
Table 69: Customer Tool Set 90000 (A280-L
143
ABB A270-L59 Operation Manual (148 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 23.11 MB
Table of Contents
Operation Manual / A200-L
3
Table of Contents
3
Introduction
6
Essential Information
7
Registered Trademarks
7
Layout and Function of the Turbocharger
8
Fig. 1: Layout and Function of the Turbocharger
8
Locations of the Rating Plates
10
Fig. 2: Locations of the Rating Plates
10
Safety
11
Introduction
11
CE Conformity
11
Table 2: Personal Protective Equipment to be Worn Specific to the Respective Task
12
Table 1: Personal Protective Equipment to be Worn at All Times
12
Definition of Safety Instructions
12
Definition of Mandatory Signs
12
Intended Use
13
Deflagration on Gas Engines
14
Warning Plates on the Turbocharger
15
Turbocharger Rating Plate
15
Fig. 3: Warning Plate Locations
15
Fig. 4: Rating Plate
15
Periodic Check of the Pressure Vessels
17
Lifting of Loads
18
Fig. 5: Attachment of Loads on the Crane Hook
18
Fig. 6: Attachment Angle
18
Prerequisites for Operation and Maintenance
19
Hazards During Operation and Maintenance
20
Safe Operation
22
Safe Maintenance
22
Turbocharger Weight
28
Removing the Turbocharger
28
Table 3: Total Weight
28
Removal and Installation
28
Fig. 7: Fitting the Lifting Gear
29
Installing the Turbocharger
30
Fig. 8: Placing the Turbocharger
30
Fig. 9: Compressor-End Foot
31
Fig. 10: Turbine-End Foot
31
Table 4: General Information about Fastening the Turbocharger
31
Table 5: Tightening Torques (Foot Screws)
32
Table 6: Tightening Angle (Foot Screws)
32
Inspection Procedures
33
Commissioning
33
Oil Supply
33
Commissioning after Taking out of Operation
35
Monitoring During Operation
36
Oil Pressure, Oil Temperature
36
Table 7: Lubricating Oil Pressure, Oil Inlet
36
Fig. 11: Oil Temperature at the Outlet
37
Table 8: Lubricating Oil Temperature at the Inlet
37
Table 9: Lubricating Oil Temperature at the Outlet
37
Admissible Air Inlet Temperature
39
Turbocharger Speed
39
Fig. 12: Layout and Overview of the Speed Measurement System
39
Table 10: Tightening Torques (86505)
41
Fig. 13: Replacing the Speed Sensor
41
Low Pressure Measurement at the Filter Silencer
42
Fig. 14: U-Tube Manometer at the Filter Silencer
42
Operation and Service
43
Noise Emission
43
Service Work
44
Fig. 15: Noise Insulation, Bellows
44
Expected Replacement Intervals
48
Table 11: Expected Replacement Intervals for Turbocharger Parts
48
Table 12: Recommended Replacement Intervals for Turbocharger Parts
48
Flexible Turbocharger Cut-Out
49
Stopping the Engine
50
Periodic Maintenance
51
Foreword to Maintenance
51
Cleaning the Filter Silencer
52
Fig. 16: Layout and Overview of Filter Silencer
52
Changing the Filter Strip on the Filter Silencer Casing
54
Fig. 17: Dismantling Filter Ring Circumferential Part
54
Fig. 18: Opening Filter Ring Lock
54
Fig. 19: Attaching New Filter Ring
55
Fig. 20: Fitting New Filter Ring
55
Cleaning the Compressor During Operation
56
Fig. 21: Overview of Wet Cleaning of Compressor
58
Fig. 22: Filter Plug View
59
Table 13: Volume of Water Per Cleaning Process
59
Table 14: Tightening Torques (81125)
59
Cleaning the Turbine During Operation
60
Fig. 23: Dry Cleaning Device
61
Table 15: Cleaning Parameters
63
Draining the Gas Outlet Casing
64
Fig. 24: Drain Pipe Diagram
64
Troubleshooting
65
Malfunctions When Starting
65
Table 16: Malfunctions When Starting - Delayed Start-Up
65
Table 17: Malfunctions When Starting - Vibrations
65
Table 18: Malfunctions When Starting - Rubbing of Rotating Parts
65
Malfunctions During Operation
66
Table 19: Malfunctions During Operation - Lubricating Oil Pressure too Low
66
Table 20: Malfunctions During Operation - Drop in Speed
66
Table 21: Malfunctions During Operation - Exhaust Gas Temperature too High
67
Table 22: Malfunctions During Operation - Charge Air Pressure too Low
67
Table 24: Surging of the Turbocharger
68
Table 23: Malfunctions During Operation - Charge Air Pressure too High
68
Surging of the Turbocharger
68
Malfunctions When Stopping
69
Table 25: Malfunctions When Stopping - Runout Noises
69
Table 26: Malfunctions When Stopping - Shortened Runout Time
69
Speed Measurement System
70
Table 27: Malfunctions of the Speed Measurement System
70
Disassembly and Assembly
72
Introduction
72
Material Required
73
Weights of Assemblies
74
Fig. 25: Weights of Assemblies
74
Table 28: Weights of Assemblies [Kg]
74
Table 29: Weight of Wall Insert [Kg]
74
Disassembly and Assembly of the Filter Silencer Casing
75
Fig. 26: Dismantling the Filter Silencer Casing
75
Fig. 27: Fitting the Filter Silencer Casing
76
Fig. 28: Fitting the Filter Silencer Casing
77
Fig. 29: Fitting the Filter Silencer Casing
77
Fig. 30: Fitting the Filter Silencer Casing
78
Fig. 31: Fitting the Filter Silencer Casing
78
Fig. 32: Fitting the Bellows
79
Table 30: Tightening Torques (Filter Silencer Screws)
79
Dismantling the Filter Silencer
80
Fig. 33: Dismantling the Filter Silencer
80
Fig. 34: Dismantling the Filter Silencer
81
Dismantling Wall Insert and Diffuser
82
Fig. 37: Putting down Wall Insert
83
Fig. 36: Moving out Wall Insert
83
Fig. 39: Moving out Wall Insert
85
Fig. 40: Putting down Wall Insert
85
Fig. 41: Putting down Wall Insert
86
Fig. 42: Dismantling the Diffuser
87
Axial Clearance a Prior to Disassembly
88
Fig. 43: Measuring Axial Clearance a
88
Table 31: Axial Clearance a
88
Dismantling the Insulation (≤ A275-L)
89
Fig. 44: Removing the Insulation (A275-L and Smaller)
89
Dismantling the Gas Inlet Casing (≤ A275-L)
90
Fig. 45: Dismantling the Gas Inlet Casing (275-L and Smaller)
90
Table 32: Maximum Admissible Loosening Torque (51087)
90
Dismantling the Nozzle Ring (≤ A275-L)
91
Fig. 46: Dismantling the Nozzle Ring (A275-L and Smaller)
91
Dismantling the Gas Inlet Casing (A280-L)
92
Fig. 47: Dismantling the Gas Inlet Casing (A280-L)
92
Table 33: Maximum Admissible Loosening Torque (51087)
92
Dismantling the Nozzle Ring (A280-L)
93
Fig. 48: Fitting the Nozzle Ring Holder
93
Fig. 49: Dismantling the Nozzle Ring
94
Fig. 50: Put down the Nozzle Ring
94
Fitting the Nozzle Ring (≤ A275-L)
95
Fig. 51: Fitting the Nozzle Ring (A275-L and Smaller)
95
Table 34: Tightening Torque (56014)
95
Table 35: Tightening Torque (51087)
96
Fig. 52: Fitting the Gas Outlet Casing (A275-L and Smaller)
96
Fitting the Gas Inlet Casing (≤ A275-L)
96
Fitting the Insulation (≤ A275-L)
97
Fig. 53: Fitting the Insulation (A275-L and Smaller)
97
Fitting the Nozzle Ring (A280-L)
98
Fig. 54: Fitting the Nozzle Ring (A280-L)
98
Fig. 55: Attaching the Nozzle Ring (A280-L)
99
Table 36: Tightening Torque (56014)
99
Fitting the Gas Inlet Casing (A280-L)
100
Fig. 56: Fitting the Gas Inlet Casing (A280-L)
100
Table 37: Tightening Torque (51087)
100
Axial Clearance a after Assembly
101
Fig. 57: Measuring Axial Clearance a
101
Table 38: Axial Clearance a
101
Table 39: Tightening Torque (77015)
102
Fig. 58: Fitting the Diffuser
102
Fitting the Diffuser
102
Fitting Wall Insert
103
Fig. 59: Positioning Wall Insert
103
Table 40: Tightening Torque (72002)
104
Table 41: Tightening Torque (72004)
104
Table 42: Tightening Torque (72011)
106
Fitting the Filter Silencer
107
Fig. 62: Fitting the Filter Silencer
108
Table 43: Tightening Torque (72004)
108
Fig. 63: Fitting the Filter Silencer
109
Table 44: Tightening Torque (72004)
109
Fig. 65: Overview of Speed Sensor Tightening Torque
110
Table of Tightening Torques
110
Fig. 64: Overview of Tightening Torques
111
Table 45: Overview of Tightening Torques
111
Table 46: Tightening Torque, Insulation
111
Taking a Turbocharger out of Operation
112
Possible Emergency Repairs
112
Taking Defective Turbochargers out of Operation
113
Table 47: Bypass Procedure
113
Fig. 66: Locking the Rotor
114
Table 48: Tightening Torque B
115
Fig. 67: Ensuring Clamping of the Cover Ring
116
Table 49: Required Washers (01)
116
Table 50: Tightening Torque (57005)
116
Fig. 68: Position of Cover Plates
117
Taking the Engine out of Operation for up to 12 Months
118
Mothballing the Turbocharger
118
Taking the Engine out of Operation for more than 12 Months
119
Material and Disposal
120
REACH and Rohs Compliance Declaration for Products
120
Disposing of Turbocharger Components
121
Spare Parts
122
Ordering Spare Parts
122
Table 51: Customer Spare Part Set (97070)
122
Table 52: Customer Spare Part Set (97071)
123
Spare Part - Illustrations
124
Table 53: Spare Parts - Bearing Casing Common Parts
125
Table 54: Spare Parts - Bearing Casing Oil Tank
127
Table 55: Spare Parts - Cartridge
128
Table 56: Spare Parts - Compressor Casing
130
Table 57: Spare Parts - Filter Silencer
131
Table 58: Spare Parts - Gas Inlet Casing Axial
132
Table 59: Spare Parts - Gas Inlet Casing Radial
133
Table 60: Spare Parts - Gas Outlet Casing
134
Table 61: Spare Parts - Rotor and Bearing Parts
136
Table 62: Spare Parts - Sealing Air Supply for Flexible Cut-Out
137
Table 63: Spare Parts - Speed Measurement
138
Table 64: Spare Parts - U-Tube Manometer
139
Table 65: Spare Parts - Turbine Dry Cleaning Radial
141
Tools
142
Table 67: Customer Tool Set 90000 (A265-L
142
Table 69: Customer Tool Set 90000 (A280-L
143
Advertisement
ABB A270-L59 Operation Manual (148 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 23.11 MB
Table of Contents
Operation Manual / A200-L
3
Table of Contents
3
Introduction
6
Essential Information
7
Registered Trademarks
7
Layout and Function of the Turbocharger
8
Fig. 1: Layout and Function of the Turbocharger
8
Locations of the Rating Plates
10
Fig. 2: Locations of the Rating Plates
10
Safety
11
Introduction
11
CE Conformity
11
Table 2: Personal Protective Equipment to be Worn Specific to the Respective Task
12
Table 1: Personal Protective Equipment to be Worn at All Times
12
Definition of Safety Instructions
12
Definition of Mandatory Signs
12
Intended Use
13
Deflagration on Gas Engines
14
Warning Plates on the Turbocharger
15
Turbocharger Rating Plate
15
Fig. 3: Warning Plate Locations
15
Fig. 4: Rating Plate
15
Periodic Check of the Pressure Vessels
17
Lifting of Loads
18
Fig. 5: Attachment of Loads on the Crane Hook
18
Fig. 6: Attachment Angle
18
Prerequisites for Operation and Maintenance
19
Hazards During Operation and Maintenance
20
Safe Operation
22
Safe Maintenance
22
Turbocharger Weight
28
Removing the Turbocharger
28
Table 3: Total Weight
28
Removal and Installation
28
Fig. 7: Fitting the Lifting Gear
29
Installing the Turbocharger
30
Fig. 8: Placing the Turbocharger
30
Fig. 9: Compressor-End Foot
31
Fig. 10: Turbine-End Foot
31
Table 4: General Information about Fastening the Turbocharger
31
Table 5: Tightening Torques (Foot Screws)
32
Table 6: Tightening Angle (Foot Screws)
32
Inspection Procedures
33
Commissioning
33
Oil Supply
33
Commissioning after Taking out of Operation
35
Monitoring During Operation
36
Oil Pressure, Oil Temperature
36
Table 7: Lubricating Oil Pressure, Oil Inlet
36
Fig. 11: Oil Temperature at the Outlet
37
Table 8: Lubricating Oil Temperature at the Inlet
37
Table 9: Lubricating Oil Temperature at the Outlet
37
Admissible Air Inlet Temperature
39
Turbocharger Speed
39
Fig. 12: Layout and Overview of the Speed Measurement System
39
Table 10: Tightening Torques (86505)
41
Fig. 13: Replacing the Speed Sensor
41
Low Pressure Measurement at the Filter Silencer
42
Fig. 14: U-Tube Manometer at the Filter Silencer
42
Operation and Service
43
Noise Emission
43
Service Work
44
Fig. 15: Noise Insulation, Bellows
44
Expected Replacement Intervals
48
Table 11: Expected Replacement Intervals for Turbocharger Parts
48
Table 12: Recommended Replacement Intervals for Turbocharger Parts
48
Flexible Turbocharger Cut-Out
49
Stopping the Engine
50
Periodic Maintenance
51
Foreword to Maintenance
51
Cleaning the Filter Silencer
52
Fig. 16: Layout and Overview of Filter Silencer
52
Changing the Filter Strip on the Filter Silencer Casing
54
Fig. 17: Dismantling Filter Ring Circumferential Part
54
Fig. 18: Opening Filter Ring Lock
54
Fig. 19: Attaching New Filter Ring
55
Fig. 20: Fitting New Filter Ring
55
Cleaning the Compressor During Operation
56
Fig. 21: Overview of Wet Cleaning of Compressor
58
Fig. 22: Filter Plug View
59
Table 13: Volume of Water Per Cleaning Process
59
Table 14: Tightening Torques (81125)
59
Cleaning the Turbine During Operation
60
Fig. 23: Dry Cleaning Device
61
Table 15: Cleaning Parameters
63
Draining the Gas Outlet Casing
64
Fig. 24: Drain Pipe Diagram
64
Troubleshooting
65
Malfunctions When Starting
65
Table 16: Malfunctions When Starting - Delayed Start-Up
65
Table 17: Malfunctions When Starting - Vibrations
65
Table 18: Malfunctions When Starting - Rubbing of Rotating Parts
65
Malfunctions During Operation
66
Table 19: Malfunctions During Operation - Lubricating Oil Pressure too Low
66
Table 20: Malfunctions During Operation - Drop in Speed
66
Table 21: Malfunctions During Operation - Exhaust Gas Temperature too High
67
Table 22: Malfunctions During Operation - Charge Air Pressure too Low
67
Table 24: Surging of the Turbocharger
68
Table 23: Malfunctions During Operation - Charge Air Pressure too High
68
Surging of the Turbocharger
68
Malfunctions When Stopping
69
Table 25: Malfunctions When Stopping - Runout Noises
69
Table 26: Malfunctions When Stopping - Shortened Runout Time
69
Speed Measurement System
70
Table 27: Malfunctions of the Speed Measurement System
70
Disassembly and Assembly
72
Introduction
72
Material Required
73
Weights of Assemblies
74
Fig. 25: Weights of Assemblies
74
Table 28: Weights of Assemblies [Kg]
74
Table 29: Weight of Wall Insert [Kg]
74
Disassembly and Assembly of the Filter Silencer Casing
75
Fig. 26: Dismantling the Filter Silencer Casing
75
Fig. 27: Fitting the Filter Silencer Casing
76
Fig. 28: Fitting the Filter Silencer Casing
77
Fig. 29: Fitting the Filter Silencer Casing
77
Fig. 30: Fitting the Filter Silencer Casing
78
Fig. 31: Fitting the Filter Silencer Casing
78
Fig. 32: Fitting the Bellows
79
Table 30: Tightening Torques (Filter Silencer Screws)
79
Dismantling the Filter Silencer
80
Fig. 33: Dismantling the Filter Silencer
80
Fig. 34: Dismantling the Filter Silencer
81
Dismantling Wall Insert and Diffuser
82
Fig. 37: Putting down Wall Insert
83
Fig. 36: Moving out Wall Insert
83
Fig. 39: Moving out Wall Insert
85
Fig. 40: Putting down Wall Insert
85
Fig. 41: Putting down Wall Insert
86
Fig. 42: Dismantling the Diffuser
87
Axial Clearance a Prior to Disassembly
88
Fig. 43: Measuring Axial Clearance a
88
Table 31: Axial Clearance a
88
Dismantling the Insulation (≤ A275-L)
89
Fig. 44: Removing the Insulation (A275-L and Smaller)
89
Dismantling the Gas Inlet Casing (≤ A275-L)
90
Fig. 45: Dismantling the Gas Inlet Casing (275-L and Smaller)
90
Table 32: Maximum Admissible Loosening Torque (51087)
90
Dismantling the Nozzle Ring (≤ A275-L)
91
Fig. 46: Dismantling the Nozzle Ring (A275-L and Smaller)
91
Dismantling the Gas Inlet Casing (A280-L)
92
Fig. 47: Dismantling the Gas Inlet Casing (A280-L)
92
Table 33: Maximum Admissible Loosening Torque (51087)
92
Dismantling the Nozzle Ring (A280-L)
93
Fig. 48: Fitting the Nozzle Ring Holder
93
Fig. 49: Dismantling the Nozzle Ring
94
Fig. 50: Put down the Nozzle Ring
94
Fitting the Nozzle Ring (≤ A275-L)
95
Fig. 51: Fitting the Nozzle Ring (A275-L and Smaller)
95
Table 34: Tightening Torque (56014)
95
Table 35: Tightening Torque (51087)
96
Fig. 52: Fitting the Gas Outlet Casing (A275-L and Smaller)
96
Fitting the Gas Inlet Casing (≤ A275-L)
96
Fitting the Insulation (≤ A275-L)
97
Fig. 53: Fitting the Insulation (A275-L and Smaller)
97
Fitting the Nozzle Ring (A280-L)
98
Fig. 54: Fitting the Nozzle Ring (A280-L)
98
Fig. 55: Attaching the Nozzle Ring (A280-L)
99
Table 36: Tightening Torque (56014)
99
Fitting the Gas Inlet Casing (A280-L)
100
Fig. 56: Fitting the Gas Inlet Casing (A280-L)
100
Table 37: Tightening Torque (51087)
100
Axial Clearance a after Assembly
101
Fig. 57: Measuring Axial Clearance a
101
Table 38: Axial Clearance a
101
Table 39: Tightening Torque (77015)
102
Fig. 58: Fitting the Diffuser
102
Fitting the Diffuser
102
Fitting Wall Insert
103
Fig. 59: Positioning Wall Insert
103
Table 40: Tightening Torque (72002)
104
Table 41: Tightening Torque (72004)
104
Table 42: Tightening Torque (72011)
106
Fitting the Filter Silencer
107
Fig. 62: Fitting the Filter Silencer
108
Table 43: Tightening Torque (72004)
108
Fig. 63: Fitting the Filter Silencer
109
Table 44: Tightening Torque (72004)
109
Fig. 65: Overview of Speed Sensor Tightening Torque
110
Table of Tightening Torques
110
Fig. 64: Overview of Tightening Torques
111
Table 45: Overview of Tightening Torques
111
Table 46: Tightening Torque, Insulation
111
Taking a Turbocharger out of Operation
112
Possible Emergency Repairs
112
Taking Defective Turbochargers out of Operation
113
Table 47: Bypass Procedure
113
Fig. 66: Locking the Rotor
114
Table 48: Tightening Torque B
115
Fig. 67: Ensuring Clamping of the Cover Ring
116
Table 49: Required Washers (01)
116
Table 50: Tightening Torque (57005)
116
Fig. 68: Position of Cover Plates
117
Taking the Engine out of Operation for up to 12 Months
118
Mothballing the Turbocharger
118
Taking the Engine out of Operation for more than 12 Months
119
Material and Disposal
120
REACH and Rohs Compliance Declaration for Products
120
Disposing of Turbocharger Components
121
Spare Parts
122
Ordering Spare Parts
122
Table 51: Customer Spare Part Set (97070)
122
Table 52: Customer Spare Part Set (97071)
123
Spare Part - Illustrations
124
Table 53: Spare Parts - Bearing Casing Common Parts
125
Table 54: Spare Parts - Bearing Casing Oil Tank
127
Table 55: Spare Parts - Cartridge
128
Table 56: Spare Parts - Compressor Casing
130
Table 57: Spare Parts - Filter Silencer
131
Table 58: Spare Parts - Gas Inlet Casing Axial
132
Table 59: Spare Parts - Gas Inlet Casing Radial
133
Table 60: Spare Parts - Gas Outlet Casing
134
Table 61: Spare Parts - Rotor and Bearing Parts
136
Table 62: Spare Parts - Sealing Air Supply for Flexible Cut-Out
137
Table 63: Spare Parts - Speed Measurement
138
Table 64: Spare Parts - U-Tube Manometer
139
Table 65: Spare Parts - Turbine Dry Cleaning Radial
141
Tools
142
Table 67: Customer Tool Set 90000 (A265-L
142
Table 69: Customer Tool Set 90000 (A280-L
143
ABB A270-L59 Operation Manual (148 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 23.11 MB
Table of Contents
Operation Manual / A200-L
3
Table of Contents
3
Introduction
6
Essential Information
7
Registered Trademarks
7
Layout and Function of the Turbocharger
8
Fig. 1: Layout and Function of the Turbocharger
8
Locations of the Rating Plates
10
Fig. 2: Locations of the Rating Plates
10
Safety
11
Introduction
11
CE Conformity
11
Table 2: Personal Protective Equipment to be Worn Specific to the Respective Task
12
Table 1: Personal Protective Equipment to be Worn at All Times
12
Definition of Safety Instructions
12
Definition of Mandatory Signs
12
Intended Use
13
Deflagration on Gas Engines
14
Warning Plates on the Turbocharger
15
Turbocharger Rating Plate
15
Fig. 3: Warning Plate Locations
15
Fig. 4: Rating Plate
15
Periodic Check of the Pressure Vessels
17
Lifting of Loads
18
Fig. 5: Attachment of Loads on the Crane Hook
18
Fig. 6: Attachment Angle
18
Prerequisites for Operation and Maintenance
19
Hazards During Operation and Maintenance
20
Safe Operation
22
Safe Maintenance
22
Turbocharger Weight
28
Removing the Turbocharger
28
Table 3: Total Weight
28
Removal and Installation
28
Fig. 7: Fitting the Lifting Gear
29
Installing the Turbocharger
30
Fig. 8: Placing the Turbocharger
30
Fig. 9: Compressor-End Foot
31
Fig. 10: Turbine-End Foot
31
Table 4: General Information about Fastening the Turbocharger
31
Table 5: Tightening Torques (Foot Screws)
32
Table 6: Tightening Angle (Foot Screws)
32
Inspection Procedures
33
Commissioning
33
Oil Supply
33
Commissioning after Taking out of Operation
35
Monitoring During Operation
36
Oil Pressure, Oil Temperature
36
Table 7: Lubricating Oil Pressure, Oil Inlet
36
Fig. 11: Oil Temperature at the Outlet
37
Table 8: Lubricating Oil Temperature at the Inlet
37
Table 9: Lubricating Oil Temperature at the Outlet
37
Admissible Air Inlet Temperature
39
Turbocharger Speed
39
Fig. 12: Layout and Overview of the Speed Measurement System
39
Table 10: Tightening Torques (86505)
41
Fig. 13: Replacing the Speed Sensor
41
Low Pressure Measurement at the Filter Silencer
42
Fig. 14: U-Tube Manometer at the Filter Silencer
42
Operation and Service
43
Noise Emission
43
Service Work
44
Fig. 15: Noise Insulation, Bellows
44
Expected Replacement Intervals
48
Table 11: Expected Replacement Intervals for Turbocharger Parts
48
Table 12: Recommended Replacement Intervals for Turbocharger Parts
48
Flexible Turbocharger Cut-Out
49
Stopping the Engine
50
Periodic Maintenance
51
Foreword to Maintenance
51
Cleaning the Filter Silencer
52
Fig. 16: Layout and Overview of Filter Silencer
52
Changing the Filter Strip on the Filter Silencer Casing
54
Fig. 17: Dismantling Filter Ring Circumferential Part
54
Fig. 18: Opening Filter Ring Lock
54
Fig. 19: Attaching New Filter Ring
55
Fig. 20: Fitting New Filter Ring
55
Cleaning the Compressor During Operation
56
Fig. 21: Overview of Wet Cleaning of Compressor
58
Fig. 22: Filter Plug View
59
Table 13: Volume of Water Per Cleaning Process
59
Table 14: Tightening Torques (81125)
59
Cleaning the Turbine During Operation
60
Fig. 23: Dry Cleaning Device
61
Table 15: Cleaning Parameters
63
Draining the Gas Outlet Casing
64
Fig. 24: Drain Pipe Diagram
64
Troubleshooting
65
Malfunctions When Starting
65
Table 16: Malfunctions When Starting - Delayed Start-Up
65
Table 17: Malfunctions When Starting - Vibrations
65
Table 18: Malfunctions When Starting - Rubbing of Rotating Parts
65
Malfunctions During Operation
66
Table 19: Malfunctions During Operation - Lubricating Oil Pressure too Low
66
Table 20: Malfunctions During Operation - Drop in Speed
66
Table 21: Malfunctions During Operation - Exhaust Gas Temperature too High
67
Table 22: Malfunctions During Operation - Charge Air Pressure too Low
67
Table 24: Surging of the Turbocharger
68
Table 23: Malfunctions During Operation - Charge Air Pressure too High
68
Surging of the Turbocharger
68
Malfunctions When Stopping
69
Table 25: Malfunctions When Stopping - Runout Noises
69
Table 26: Malfunctions When Stopping - Shortened Runout Time
69
Speed Measurement System
70
Table 27: Malfunctions of the Speed Measurement System
70
Disassembly and Assembly
72
Introduction
72
Material Required
73
Weights of Assemblies
74
Fig. 25: Weights of Assemblies
74
Table 28: Weights of Assemblies [Kg]
74
Table 29: Weight of Wall Insert [Kg]
74
Disassembly and Assembly of the Filter Silencer Casing
75
Fig. 26: Dismantling the Filter Silencer Casing
75
Fig. 27: Fitting the Filter Silencer Casing
76
Fig. 28: Fitting the Filter Silencer Casing
77
Fig. 29: Fitting the Filter Silencer Casing
77
Fig. 30: Fitting the Filter Silencer Casing
78
Fig. 31: Fitting the Filter Silencer Casing
78
Fig. 32: Fitting the Bellows
79
Table 30: Tightening Torques (Filter Silencer Screws)
79
Dismantling the Filter Silencer
80
Fig. 33: Dismantling the Filter Silencer
80
Fig. 34: Dismantling the Filter Silencer
81
Dismantling Wall Insert and Diffuser
82
Fig. 37: Putting down Wall Insert
83
Fig. 36: Moving out Wall Insert
83
Fig. 39: Moving out Wall Insert
85
Fig. 40: Putting down Wall Insert
85
Fig. 41: Putting down Wall Insert
86
Fig. 42: Dismantling the Diffuser
87
Axial Clearance a Prior to Disassembly
88
Fig. 43: Measuring Axial Clearance a
88
Table 31: Axial Clearance a
88
Dismantling the Insulation (≤ A275-L)
89
Fig. 44: Removing the Insulation (A275-L and Smaller)
89
Dismantling the Gas Inlet Casing (≤ A275-L)
90
Fig. 45: Dismantling the Gas Inlet Casing (275-L and Smaller)
90
Table 32: Maximum Admissible Loosening Torque (51087)
90
Dismantling the Nozzle Ring (≤ A275-L)
91
Fig. 46: Dismantling the Nozzle Ring (A275-L and Smaller)
91
Dismantling the Gas Inlet Casing (A280-L)
92
Fig. 47: Dismantling the Gas Inlet Casing (A280-L)
92
Table 33: Maximum Admissible Loosening Torque (51087)
92
Dismantling the Nozzle Ring (A280-L)
93
Fig. 48: Fitting the Nozzle Ring Holder
93
Fig. 49: Dismantling the Nozzle Ring
94
Fig. 50: Put down the Nozzle Ring
94
Fitting the Nozzle Ring (≤ A275-L)
95
Fig. 51: Fitting the Nozzle Ring (A275-L and Smaller)
95
Table 34: Tightening Torque (56014)
95
Table 35: Tightening Torque (51087)
96
Fig. 52: Fitting the Gas Outlet Casing (A275-L and Smaller)
96
Fitting the Gas Inlet Casing (≤ A275-L)
96
Fitting the Insulation (≤ A275-L)
97
Fig. 53: Fitting the Insulation (A275-L and Smaller)
97
Fitting the Nozzle Ring (A280-L)
98
Fig. 54: Fitting the Nozzle Ring (A280-L)
98
Fig. 55: Attaching the Nozzle Ring (A280-L)
99
Table 36: Tightening Torque (56014)
99
Fitting the Gas Inlet Casing (A280-L)
100
Fig. 56: Fitting the Gas Inlet Casing (A280-L)
100
Table 37: Tightening Torque (51087)
100
Axial Clearance a after Assembly
101
Fig. 57: Measuring Axial Clearance a
101
Table 38: Axial Clearance a
101
Table 39: Tightening Torque (77015)
102
Fig. 58: Fitting the Diffuser
102
Fitting the Diffuser
102
Fitting Wall Insert
103
Fig. 59: Positioning Wall Insert
103
Table 40: Tightening Torque (72002)
104
Table 41: Tightening Torque (72004)
104
Table 42: Tightening Torque (72011)
106
Fitting the Filter Silencer
107
Fig. 62: Fitting the Filter Silencer
108
Table 43: Tightening Torque (72004)
108
Fig. 63: Fitting the Filter Silencer
109
Table 44: Tightening Torque (72004)
109
Fig. 65: Overview of Speed Sensor Tightening Torque
110
Table of Tightening Torques
110
Fig. 64: Overview of Tightening Torques
111
Table 45: Overview of Tightening Torques
111
Table 46: Tightening Torque, Insulation
111
Taking a Turbocharger out of Operation
112
Possible Emergency Repairs
112
Taking Defective Turbochargers out of Operation
113
Table 47: Bypass Procedure
113
Fig. 66: Locking the Rotor
114
Table 48: Tightening Torque B
115
Fig. 67: Ensuring Clamping of the Cover Ring
116
Table 49: Required Washers (01)
116
Table 50: Tightening Torque (57005)
116
Fig. 68: Position of Cover Plates
117
Taking the Engine out of Operation for up to 12 Months
118
Mothballing the Turbocharger
118
Taking the Engine out of Operation for more than 12 Months
119
Material and Disposal
120
REACH and Rohs Compliance Declaration for Products
120
Disposing of Turbocharger Components
121
Spare Parts
122
Ordering Spare Parts
122
Table 51: Customer Spare Part Set (97070)
122
Table 52: Customer Spare Part Set (97071)
123
Spare Part - Illustrations
124
Table 53: Spare Parts - Bearing Casing Common Parts
125
Table 54: Spare Parts - Bearing Casing Oil Tank
127
Table 55: Spare Parts - Cartridge
128
Table 56: Spare Parts - Compressor Casing
130
Table 57: Spare Parts - Filter Silencer
131
Table 58: Spare Parts - Gas Inlet Casing Axial
132
Table 59: Spare Parts - Gas Inlet Casing Radial
133
Table 60: Spare Parts - Gas Outlet Casing
134
Table 61: Spare Parts - Rotor and Bearing Parts
136
Table 62: Spare Parts - Sealing Air Supply for Flexible Cut-Out
137
Table 63: Spare Parts - Speed Measurement
138
Table 64: Spare Parts - U-Tube Manometer
139
Table 65: Spare Parts - Turbine Dry Cleaning Radial
141
Tools
142
Table 67: Customer Tool Set 90000 (A265-L
142
Table 69: Customer Tool Set 90000 (A280-L
143
ABB A270-L59 Operation Manual (148 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 23.11 MB
Table of Contents
Operation Manual / A200-L
3
Table of Contents
3
Introduction
6
Essential Information
7
Registered Trademarks
7
Layout and Function of the Turbocharger
8
Fig. 1: Layout and Function of the Turbocharger
8
Locations of the Rating Plates
10
Fig. 2: Locations of the Rating Plates
10
Safety
11
Introduction
11
CE Conformity
11
Table 2: Personal Protective Equipment to be Worn Specific to the Respective Task
12
Table 1: Personal Protective Equipment to be Worn at All Times
12
Definition of Safety Instructions
12
Definition of Mandatory Signs
12
Intended Use
13
Deflagration on Gas Engines
14
Warning Plates on the Turbocharger
15
Turbocharger Rating Plate
15
Fig. 3: Warning Plate Locations
15
Fig. 4: Rating Plate
15
Periodic Check of the Pressure Vessels
17
Lifting of Loads
18
Fig. 5: Attachment of Loads on the Crane Hook
18
Fig. 6: Attachment Angle
18
Prerequisites for Operation and Maintenance
19
Hazards During Operation and Maintenance
20
Safe Operation
22
Safe Maintenance
22
Turbocharger Weight
28
Removing the Turbocharger
28
Table 3: Total Weight
28
Removal and Installation
28
Fig. 7: Fitting the Lifting Gear
29
Installing the Turbocharger
30
Fig. 8: Placing the Turbocharger
30
Fig. 9: Compressor-End Foot
31
Fig. 10: Turbine-End Foot
31
Table 4: General Information about Fastening the Turbocharger
31
Table 5: Tightening Torques (Foot Screws)
32
Table 6: Tightening Angle (Foot Screws)
32
Inspection Procedures
33
Commissioning
33
Oil Supply
33
Commissioning after Taking out of Operation
35
Monitoring During Operation
36
Oil Pressure, Oil Temperature
36
Table 7: Lubricating Oil Pressure, Oil Inlet
36
Fig. 11: Oil Temperature at the Outlet
37
Table 8: Lubricating Oil Temperature at the Inlet
37
Table 9: Lubricating Oil Temperature at the Outlet
37
Admissible Air Inlet Temperature
39
Turbocharger Speed
39
Fig. 12: Layout and Overview of the Speed Measurement System
39
Table 10: Tightening Torques (86505)
41
Fig. 13: Replacing the Speed Sensor
41
Low Pressure Measurement at the Filter Silencer
42
Fig. 14: U-Tube Manometer at the Filter Silencer
42
Operation and Service
43
Noise Emission
43
Service Work
44
Fig. 15: Noise Insulation, Bellows
44
Expected Replacement Intervals
48
Table 11: Expected Replacement Intervals for Turbocharger Parts
48
Table 12: Recommended Replacement Intervals for Turbocharger Parts
48
Flexible Turbocharger Cut-Out
49
Stopping the Engine
50
Periodic Maintenance
51
Foreword to Maintenance
51
Cleaning the Filter Silencer
52
Fig. 16: Layout and Overview of Filter Silencer
52
Changing the Filter Strip on the Filter Silencer Casing
54
Fig. 17: Dismantling Filter Ring Circumferential Part
54
Fig. 18: Opening Filter Ring Lock
54
Fig. 19: Attaching New Filter Ring
55
Fig. 20: Fitting New Filter Ring
55
Cleaning the Compressor During Operation
56
Fig. 21: Overview of Wet Cleaning of Compressor
58
Fig. 22: Filter Plug View
59
Table 13: Volume of Water Per Cleaning Process
59
Table 14: Tightening Torques (81125)
59
Cleaning the Turbine During Operation
60
Fig. 23: Dry Cleaning Device
61
Table 15: Cleaning Parameters
63
Draining the Gas Outlet Casing
64
Fig. 24: Drain Pipe Diagram
64
Troubleshooting
65
Malfunctions When Starting
65
Table 16: Malfunctions When Starting - Delayed Start-Up
65
Table 17: Malfunctions When Starting - Vibrations
65
Table 18: Malfunctions When Starting - Rubbing of Rotating Parts
65
Malfunctions During Operation
66
Table 19: Malfunctions During Operation - Lubricating Oil Pressure too Low
66
Table 20: Malfunctions During Operation - Drop in Speed
66
Table 21: Malfunctions During Operation - Exhaust Gas Temperature too High
67
Table 22: Malfunctions During Operation - Charge Air Pressure too Low
67
Table 24: Surging of the Turbocharger
68
Table 23: Malfunctions During Operation - Charge Air Pressure too High
68
Surging of the Turbocharger
68
Malfunctions When Stopping
69
Table 25: Malfunctions When Stopping - Runout Noises
69
Table 26: Malfunctions When Stopping - Shortened Runout Time
69
Speed Measurement System
70
Table 27: Malfunctions of the Speed Measurement System
70
Disassembly and Assembly
72
Introduction
72
Material Required
73
Weights of Assemblies
74
Fig. 25: Weights of Assemblies
74
Table 28: Weights of Assemblies [Kg]
74
Table 29: Weight of Wall Insert [Kg]
74
Disassembly and Assembly of the Filter Silencer Casing
75
Fig. 26: Dismantling the Filter Silencer Casing
75
Fig. 27: Fitting the Filter Silencer Casing
76
Fig. 28: Fitting the Filter Silencer Casing
77
Fig. 29: Fitting the Filter Silencer Casing
77
Fig. 30: Fitting the Filter Silencer Casing
78
Fig. 31: Fitting the Filter Silencer Casing
78
Fig. 32: Fitting the Bellows
79
Table 30: Tightening Torques (Filter Silencer Screws)
79
Dismantling the Filter Silencer
80
Fig. 33: Dismantling the Filter Silencer
80
Fig. 34: Dismantling the Filter Silencer
81
Dismantling Wall Insert and Diffuser
82
Fig. 37: Putting down Wall Insert
83
Fig. 36: Moving out Wall Insert
83
Fig. 39: Moving out Wall Insert
85
Fig. 40: Putting down Wall Insert
85
Fig. 41: Putting down Wall Insert
86
Fig. 42: Dismantling the Diffuser
87
Axial Clearance a Prior to Disassembly
88
Fig. 43: Measuring Axial Clearance a
88
Table 31: Axial Clearance a
88
Dismantling the Insulation (≤ A275-L)
89
Fig. 44: Removing the Insulation (A275-L and Smaller)
89
Dismantling the Gas Inlet Casing (≤ A275-L)
90
Fig. 45: Dismantling the Gas Inlet Casing (275-L and Smaller)
90
Table 32: Maximum Admissible Loosening Torque (51087)
90
Dismantling the Nozzle Ring (≤ A275-L)
91
Fig. 46: Dismantling the Nozzle Ring (A275-L and Smaller)
91
Dismantling the Gas Inlet Casing (A280-L)
92
Fig. 47: Dismantling the Gas Inlet Casing (A280-L)
92
Table 33: Maximum Admissible Loosening Torque (51087)
92
Dismantling the Nozzle Ring (A280-L)
93
Fig. 48: Fitting the Nozzle Ring Holder
93
Fig. 49: Dismantling the Nozzle Ring
94
Fig. 50: Put down the Nozzle Ring
94
Fitting the Nozzle Ring (≤ A275-L)
95
Fig. 51: Fitting the Nozzle Ring (A275-L and Smaller)
95
Table 34: Tightening Torque (56014)
95
Table 35: Tightening Torque (51087)
96
Fig. 52: Fitting the Gas Outlet Casing (A275-L and Smaller)
96
Fitting the Gas Inlet Casing (≤ A275-L)
96
Fitting the Insulation (≤ A275-L)
97
Fig. 53: Fitting the Insulation (A275-L and Smaller)
97
Fitting the Nozzle Ring (A280-L)
98
Fig. 54: Fitting the Nozzle Ring (A280-L)
98
Fig. 55: Attaching the Nozzle Ring (A280-L)
99
Table 36: Tightening Torque (56014)
99
Fitting the Gas Inlet Casing (A280-L)
100
Fig. 56: Fitting the Gas Inlet Casing (A280-L)
100
Table 37: Tightening Torque (51087)
100
Axial Clearance a after Assembly
101
Fig. 57: Measuring Axial Clearance a
101
Table 38: Axial Clearance a
101
Table 39: Tightening Torque (77015)
102
Fig. 58: Fitting the Diffuser
102
Fitting the Diffuser
102
Fitting Wall Insert
103
Fig. 59: Positioning Wall Insert
103
Table 40: Tightening Torque (72002)
104
Table 41: Tightening Torque (72004)
104
Table 42: Tightening Torque (72011)
106
Fitting the Filter Silencer
107
Fig. 62: Fitting the Filter Silencer
108
Table 43: Tightening Torque (72004)
108
Fig. 63: Fitting the Filter Silencer
109
Table 44: Tightening Torque (72004)
109
Fig. 65: Overview of Speed Sensor Tightening Torque
110
Table of Tightening Torques
110
Fig. 64: Overview of Tightening Torques
111
Table 45: Overview of Tightening Torques
111
Table 46: Tightening Torque, Insulation
111
Taking a Turbocharger out of Operation
112
Possible Emergency Repairs
112
Taking Defective Turbochargers out of Operation
113
Table 47: Bypass Procedure
113
Fig. 66: Locking the Rotor
114
Table 48: Tightening Torque B
115
Fig. 67: Ensuring Clamping of the Cover Ring
116
Table 49: Required Washers (01)
116
Table 50: Tightening Torque (57005)
116
Fig. 68: Position of Cover Plates
117
Taking the Engine out of Operation for up to 12 Months
118
Mothballing the Turbocharger
118
Taking the Engine out of Operation for more than 12 Months
119
Material and Disposal
120
REACH and Rohs Compliance Declaration for Products
120
Disposing of Turbocharger Components
121
Spare Parts
122
Ordering Spare Parts
122
Table 51: Customer Spare Part Set (97070)
122
Table 52: Customer Spare Part Set (97071)
123
Spare Part - Illustrations
124
Table 53: Spare Parts - Bearing Casing Common Parts
125
Table 54: Spare Parts - Bearing Casing Oil Tank
127
Table 55: Spare Parts - Cartridge
128
Table 56: Spare Parts - Compressor Casing
130
Table 57: Spare Parts - Filter Silencer
131
Table 58: Spare Parts - Gas Inlet Casing Axial
132
Table 59: Spare Parts - Gas Inlet Casing Radial
133
Table 60: Spare Parts - Gas Outlet Casing
134
Table 61: Spare Parts - Rotor and Bearing Parts
136
Table 62: Spare Parts - Sealing Air Supply for Flexible Cut-Out
137
Table 63: Spare Parts - Speed Measurement
138
Table 64: Spare Parts - U-Tube Manometer
139
Table 65: Spare Parts - Turbine Dry Cleaning Radial
141
Tools
142
Table 67: Customer Tool Set 90000 (A265-L
142
Table 69: Customer Tool Set 90000 (A280-L
143
ABB A270-L59 Operation Manual (148 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 23.11 MB
Table of Contents
Operation Manual / A200-L
3
Table of Contents
3
Introduction
6
Essential Information
7
Registered Trademarks
7
Layout and Function of the Turbocharger
8
Fig. 1: Layout and Function of the Turbocharger
8
Locations of the Rating Plates
10
Fig. 2: Locations of the Rating Plates
10
Safety
11
Introduction
11
CE Conformity
11
Table 2: Personal Protective Equipment to be Worn Specific to the Respective Task
12
Table 1: Personal Protective Equipment to be Worn at All Times
12
Definition of Safety Instructions
12
Definition of Mandatory Signs
12
Intended Use
13
Deflagration on Gas Engines
14
Warning Plates on the Turbocharger
15
Turbocharger Rating Plate
15
Fig. 3: Warning Plate Locations
15
Fig. 4: Rating Plate
15
Periodic Check of the Pressure Vessels
17
Lifting of Loads
18
Fig. 5: Attachment of Loads on the Crane Hook
18
Fig. 6: Attachment Angle
18
Prerequisites for Operation and Maintenance
19
Hazards During Operation and Maintenance
20
Safe Operation
22
Safe Maintenance
22
Turbocharger Weight
28
Removing the Turbocharger
28
Table 3: Total Weight
28
Removal and Installation
28
Fig. 7: Fitting the Lifting Gear
29
Installing the Turbocharger
30
Fig. 8: Placing the Turbocharger
30
Fig. 9: Compressor-End Foot
31
Fig. 10: Turbine-End Foot
31
Table 4: General Information about Fastening the Turbocharger
31
Table 5: Tightening Torques (Foot Screws)
32
Table 6: Tightening Angle (Foot Screws)
32
Inspection Procedures
33
Commissioning
33
Oil Supply
33
Commissioning after Taking out of Operation
35
Monitoring During Operation
36
Oil Pressure, Oil Temperature
36
Table 7: Lubricating Oil Pressure, Oil Inlet
36
Fig. 11: Oil Temperature at the Outlet
37
Table 8: Lubricating Oil Temperature at the Inlet
37
Table 9: Lubricating Oil Temperature at the Outlet
37
Admissible Air Inlet Temperature
39
Turbocharger Speed
39
Fig. 12: Layout and Overview of the Speed Measurement System
39
Table 10: Tightening Torques (86505)
41
Fig. 13: Replacing the Speed Sensor
41
Low Pressure Measurement at the Filter Silencer
42
Fig. 14: U-Tube Manometer at the Filter Silencer
42
Operation and Service
43
Noise Emission
43
Service Work
44
Fig. 15: Noise Insulation, Bellows
44
Expected Replacement Intervals
48
Table 11: Expected Replacement Intervals for Turbocharger Parts
48
Table 12: Recommended Replacement Intervals for Turbocharger Parts
48
Flexible Turbocharger Cut-Out
49
Stopping the Engine
50
Periodic Maintenance
51
Foreword to Maintenance
51
Cleaning the Filter Silencer
52
Fig. 16: Layout and Overview of Filter Silencer
52
Changing the Filter Strip on the Filter Silencer Casing
54
Fig. 17: Dismantling Filter Ring Circumferential Part
54
Fig. 18: Opening Filter Ring Lock
54
Fig. 19: Attaching New Filter Ring
55
Fig. 20: Fitting New Filter Ring
55
Cleaning the Compressor During Operation
56
Fig. 21: Overview of Wet Cleaning of Compressor
58
Fig. 22: Filter Plug View
59
Table 13: Volume of Water Per Cleaning Process
59
Table 14: Tightening Torques (81125)
59
Cleaning the Turbine During Operation
60
Fig. 23: Dry Cleaning Device
61
Table 15: Cleaning Parameters
63
Draining the Gas Outlet Casing
64
Fig. 24: Drain Pipe Diagram
64
Troubleshooting
65
Malfunctions When Starting
65
Table 16: Malfunctions When Starting - Delayed Start-Up
65
Table 17: Malfunctions When Starting - Vibrations
65
Table 18: Malfunctions When Starting - Rubbing of Rotating Parts
65
Malfunctions During Operation
66
Table 19: Malfunctions During Operation - Lubricating Oil Pressure too Low
66
Table 20: Malfunctions During Operation - Drop in Speed
66
Table 21: Malfunctions During Operation - Exhaust Gas Temperature too High
67
Table 22: Malfunctions During Operation - Charge Air Pressure too Low
67
Table 24: Surging of the Turbocharger
68
Table 23: Malfunctions During Operation - Charge Air Pressure too High
68
Surging of the Turbocharger
68
Malfunctions When Stopping
69
Table 25: Malfunctions When Stopping - Runout Noises
69
Table 26: Malfunctions When Stopping - Shortened Runout Time
69
Speed Measurement System
70
Table 27: Malfunctions of the Speed Measurement System
70
Disassembly and Assembly
72
Introduction
72
Material Required
73
Weights of Assemblies
74
Fig. 25: Weights of Assemblies
74
Table 28: Weights of Assemblies [Kg]
74
Table 29: Weight of Wall Insert [Kg]
74
Disassembly and Assembly of the Filter Silencer Casing
75
Fig. 26: Dismantling the Filter Silencer Casing
75
Fig. 27: Fitting the Filter Silencer Casing
76
Fig. 28: Fitting the Filter Silencer Casing
77
Fig. 29: Fitting the Filter Silencer Casing
77
Fig. 30: Fitting the Filter Silencer Casing
78
Fig. 31: Fitting the Filter Silencer Casing
78
Fig. 32: Fitting the Bellows
79
Table 30: Tightening Torques (Filter Silencer Screws)
79
Dismantling the Filter Silencer
80
Fig. 33: Dismantling the Filter Silencer
80
Fig. 34: Dismantling the Filter Silencer
81
Dismantling Wall Insert and Diffuser
82
Fig. 37: Putting down Wall Insert
83
Fig. 36: Moving out Wall Insert
83
Fig. 39: Moving out Wall Insert
85
Fig. 40: Putting down Wall Insert
85
Fig. 41: Putting down Wall Insert
86
Fig. 42: Dismantling the Diffuser
87
Axial Clearance a Prior to Disassembly
88
Fig. 43: Measuring Axial Clearance a
88
Table 31: Axial Clearance a
88
Dismantling the Insulation (≤ A275-L)
89
Fig. 44: Removing the Insulation (A275-L and Smaller)
89
Dismantling the Gas Inlet Casing (≤ A275-L)
90
Fig. 45: Dismantling the Gas Inlet Casing (275-L and Smaller)
90
Table 32: Maximum Admissible Loosening Torque (51087)
90
Dismantling the Nozzle Ring (≤ A275-L)
91
Fig. 46: Dismantling the Nozzle Ring (A275-L and Smaller)
91
Dismantling the Gas Inlet Casing (A280-L)
92
Fig. 47: Dismantling the Gas Inlet Casing (A280-L)
92
Table 33: Maximum Admissible Loosening Torque (51087)
92
Dismantling the Nozzle Ring (A280-L)
93
Fig. 48: Fitting the Nozzle Ring Holder
93
Fig. 49: Dismantling the Nozzle Ring
94
Fig. 50: Put down the Nozzle Ring
94
Fitting the Nozzle Ring (≤ A275-L)
95
Fig. 51: Fitting the Nozzle Ring (A275-L and Smaller)
95
Table 34: Tightening Torque (56014)
95
Table 35: Tightening Torque (51087)
96
Fig. 52: Fitting the Gas Outlet Casing (A275-L and Smaller)
96
Fitting the Gas Inlet Casing (≤ A275-L)
96
Fitting the Insulation (≤ A275-L)
97
Fig. 53: Fitting the Insulation (A275-L and Smaller)
97
Fitting the Nozzle Ring (A280-L)
98
Fig. 54: Fitting the Nozzle Ring (A280-L)
98
Fig. 55: Attaching the Nozzle Ring (A280-L)
99
Table 36: Tightening Torque (56014)
99
Fitting the Gas Inlet Casing (A280-L)
100
Fig. 56: Fitting the Gas Inlet Casing (A280-L)
100
Table 37: Tightening Torque (51087)
100
Axial Clearance a after Assembly
101
Fig. 57: Measuring Axial Clearance a
101
Table 38: Axial Clearance a
101
Table 39: Tightening Torque (77015)
102
Fig. 58: Fitting the Diffuser
102
Fitting the Diffuser
102
Fitting Wall Insert
103
Fig. 59: Positioning Wall Insert
103
Table 40: Tightening Torque (72002)
104
Table 41: Tightening Torque (72004)
104
Table 42: Tightening Torque (72011)
106
Fitting the Filter Silencer
107
Fig. 62: Fitting the Filter Silencer
108
Table 43: Tightening Torque (72004)
108
Fig. 63: Fitting the Filter Silencer
109
Table 44: Tightening Torque (72004)
109
Fig. 65: Overview of Speed Sensor Tightening Torque
110
Table of Tightening Torques
110
Fig. 64: Overview of Tightening Torques
111
Table 45: Overview of Tightening Torques
111
Table 46: Tightening Torque, Insulation
111
Taking a Turbocharger out of Operation
112
Possible Emergency Repairs
112
Taking Defective Turbochargers out of Operation
113
Table 47: Bypass Procedure
113
Fig. 66: Locking the Rotor
114
Table 48: Tightening Torque B
115
Fig. 67: Ensuring Clamping of the Cover Ring
116
Table 49: Required Washers (01)
116
Table 50: Tightening Torque (57005)
116
Fig. 68: Position of Cover Plates
117
Taking the Engine out of Operation for up to 12 Months
118
Mothballing the Turbocharger
118
Taking the Engine out of Operation for more than 12 Months
119
Material and Disposal
120
REACH and Rohs Compliance Declaration for Products
120
Disposing of Turbocharger Components
121
Spare Parts
122
Ordering Spare Parts
122
Table 51: Customer Spare Part Set (97070)
122
Table 52: Customer Spare Part Set (97071)
123
Spare Part - Illustrations
124
Table 53: Spare Parts - Bearing Casing Common Parts
125
Table 54: Spare Parts - Bearing Casing Oil Tank
127
Table 55: Spare Parts - Cartridge
128
Table 56: Spare Parts - Compressor Casing
130
Table 57: Spare Parts - Filter Silencer
131
Table 58: Spare Parts - Gas Inlet Casing Axial
132
Table 59: Spare Parts - Gas Inlet Casing Radial
133
Table 60: Spare Parts - Gas Outlet Casing
134
Table 61: Spare Parts - Rotor and Bearing Parts
136
Table 62: Spare Parts - Sealing Air Supply for Flexible Cut-Out
137
Table 63: Spare Parts - Speed Measurement
138
Table 64: Spare Parts - U-Tube Manometer
139
Table 65: Spare Parts - Turbine Dry Cleaning Radial
141
Tools
142
Table 67: Customer Tool Set 90000 (A265-L
142
Table 69: Customer Tool Set 90000 (A280-L
143
ABB A270-L59 Operation Manual (136 pages)
Brand:
ABB
| Category:
Battery Charger
| Size: 24.51 MB
Table of Contents
Introduction
3
Table of Contents
3
Introduction
4
Purpose of the Manual
4
Symbols, Definitions
5
Storage of New Turbochargers and Spare Parts
7
Contact Information
9
Safety
11
CE Conformity
12
Introduction
12
Safety
12
Definition of Mandatory Signs
13
Definition of Safety Instructions
13
Intended Use
14
Warning Plates on the Turbocharger
15
Turbocharger Rating Plate
16
Periodic Check of the Pressure Vessels
17
Lifting of Loads
18
Prerequisites for Operation and Maintenance
19
Hazards During Operation and Maintenance
20
Safe Operation
22
Safe Maintenance
23
Product Description
29
1 Introduction
31
Essential Information
31
Registered Trademarks
31
Related Documents
31
Table 1: Related Documents
31
Layout and Function of the Turbocharger
32
Fig. 1: Layout and Function of the Turbocharger
32
Warning Plates on the Turbocharger
34
Fig. 2: Warning Plate Locations
34
Locations of the Rating Plates
35
Fig. 3: Locations of the Rating Plates
35
2 Removal and Installation
36
Turbocharger Weight
36
Removing the Turbocharger
36
Table 2: Weights A200-L with Filter Silencer
36
Fig. 4: Fitting Lifting Gear to Turbocharger
37
Installing the Turbocharger
38
Fig. 5: Placing the Turbocharger on the Bracket
38
Fig. 6: Compressor-End Foot
39
Fig. 7: Turbine-End Foot
39
Table 3: General Information about Fastening the Turbocharger
39
Table 4: Tightening Torques (Foot Screws)
40
Table 5: Tightening Angle (Foot Screws)
40
3 Commissioning
41
Oil Supply
41
Inspection Procedures
41
Commissioning after Taking out of Operation
43
4 Monitoring During Operation
44
Oil Pressure, Oil Temperature
44
Table 6: Lubricating Oil Pressure, Oil Inlet
44
Table 7: Lubricating Oil Temperature at the Inlet
44
Table 8: Lubricating Oil Temperature at the Outlet
45
Admissible Air Inlet Temperature
46
Turbocharger Speed
46
Fig. 8: Layout and Overview of the Speed Measurement System
46
Fig. 9: Replacing the Speed Sensor
48
Table 9: Tightening Torques (86505)
48
Low Pressure Measurement at the Filter Silencer
49
Fig. 10: U-Tube Manometer at the Filter Silencer
49
5 Operation and Service
50
Noise Emission
50
Service Work
51
Fig. 11: Noise Insulation, Bellows
51
Expected Replacement Intervals
55
Table 10: Expected Replacement Intervals for Turbocharger Parts
55
Table 11: Recommended Replacement Intervals for Turbocharger Parts
55
Flexible Turbocharger Cut-Out
56
Stopping the Engine
57
6 Periodic Maintenance
58
Foreword to Maintenance
58
Cleaning the Filter Silencer
59
Fig. 12: Layout and Overview of Filter Silencer
59
Changing the Filter Strip on the Filter Silencer Casing
61
Fig. 13: Dismantling Filter Ring Circumferential Part
61
Fig. 14: Opening Filter Ring Lock
61
Fig. 15: Attaching New Filter Ring
62
Fig. 16: Fitting New Filter Ring
62
Cleaning the Compressor During Operation
63
Fig. 17: Overview of Wet Cleaning of Compressor
65
Fig. 18: Filter Plug View
66
Table 12: Volume of Water Per Cleaning Process
66
Table 13: Tightening Torques (81125)
66
Cleaning the Turbine During Operation
67
Fig. 19: Overview of Dry Cleaning Device
68
Table 14: Cleaning Parameters
70
Draining the Gas Outlet Casing
71
Fig. 20: Drain Pipe Diagram
71
7 Troubleshooting
72
Malfunctions When Starting
72
Table 15: Malfunctions When Starting - Delayed Start-Up
72
Table 16: Malfunctions When Starting - Vibrations
72
Table 17: Malfunctions When Starting - Rubbing of Rotating Parts
72
Malfunctions During Operation
73
Table 18: Malfunctions During Operation - Lubricating Oil Pressure too Low
73
Table 19: Malfunctions During Operation - Drop in Speed
73
Table 20: Malfunctions During Operation - Exhaust Gas Temperature too High
74
Table 21: Malfunctions During Operation - Charge Air Pressure too Low
74
Surging of the Turbocharger
75
Table 22: Malfunctions During Operation - Charge Air Pressure too High
75
Table 23: Surging of the Turbocharger
75
Malfunctions When Stopping
76
Table 24: Malfunctions When Stopping - Runout Noises
76
Table 25: Malfunctions When Stopping - Shortened Runout Time
76
Speed Measurement System
77
Table 26: Malfunctions of the Speed Measurement System
77
8 Disassembly and Assembly
78
Introduction
78
Copyright 2018 ABB. All Rights Reserved. HZTL4036_EN Revision M August
79
Weights of Assemblies
80
Fig. 21: Overview of Assembly Weights
80
Table 27: Weights of Assemblies [Kg]
80
Table 28: Weight of Wall Insert [Kg]
80
Disassembly and Assembly of the Filter Silencer Casing
81
Fig. 22: Overview of Filter Silencer Casing Disassembly and Assembly
81
Fig. 23: Fitting Filter Silencer Casing 1
82
Fig. 24: Fitting Filter Silencer Casing 2
83
Fig. 25: Fitting Filter Silencer Casing 3
83
Fig. 26: Fitting Filter Silencer Casing 4
84
Fig. 27: Fitting Filter Silencer Casing 5
84
Fig. 28: Fitting the Bellows
85
Table 29: Tightening Torques (Filter Silencer Screws)
85
Dismantling the Filter Silencer
86
Fig. 29: Dismantling the Filter Silencer
86
Fig. 30: Dismantling the Filter Silencer
87
Dismantling Wall Insert and Diffuser
88
Fig. 31: Pressing off Compressor Casing
88
Fig. 32: Moving out Wall Insert
89
Fig. 33: Putting down Wall Insert
89
Fig. 34: Putting down Wall Insert
90
Fig. 35: Dismantling the Diffuser
91
Axial Clearance a Prior to Disassembly
92
Fig. 36: Measuring Axial Clearance a
92
Table 30: Admissible Axial Clearance a
92
Dismantling the Insulation, the Gas Inlet Casing and the Nozzle Ring (A275-L and Smaller)
93
Fig. 37: Removing the Insulation (A275-L and Smaller)
93
Fig. 38: Dismantling the Gas Inlet Casing (A275-L and Smaller) - Screwed Variant
94
Fig. 39: Dismantling the Gas Inlet Casing (275-L and Smaller) - Threaded Stud Variant
95
Table 31: Maximum Admissible Loosening Torque (51087)
95
Fig. 40: Dismantling the Nozzle Ring (A275-L and Smaller)
96
Dismantling the Gas Inlet Casing, Nozzle Ring (A280-L)
97
Fig. 41: Dismantling the Gas Inlet Casing (A280-L) - Screwed Variant
97
Fig. 42: Dismantling the Gas Inlet Casing (A280-L) - Threaded Stud Variant
98
Table 32: Maximum Admissible Loosening Torque (51087)
98
Fig. 43: Fitting the Nozzle Ring Holder (A280-L)
99
Fig. 44: Dismantling the Nozzle Ring (A280-L)
100
Fig. 45: Putting down the Nozzle Ring (A280-L)
100
Fitting Gas Inlet Casing, Nozzle Ring, Insulation (A275-L and Smaller)
101
Fig. 46: Fitting the Nozzle Ring (A275-L and Smaller)
101
Table 33: Tightening Torque (56014)
101
Fig. 47: Fitting the Gas Inlet Casing (A275-L and Smaller) - Screwed Variant
102
Table 34: Tightening Torque (61009)
102
Fig. 48: Fitting the Gas Inlet Casing (A275-L and Smaller) - Threaded Stud Variant
103
Table 35: Tightening Torque (51087)
103
Fig. 49: Fitting the Insulation (A275-L and Smaller)
104
Fitting the Gas Inlet Casing, Nozzle Ring (A280-L)
105
Fig. 50: Fitting the Nozzle Ring (A280-L)
105
Fig. 51: Attaching the Nozzle Ring (A280-L)
106
Table 36: Tightening Torque (56014)
106
Fig. 52: Fitting the Gas Inlet Casing (A280-L) - Screwed Variant
107
Table 37: Tightening Torque (61009)
107
Fig. 53: Fitting the Gas Inlet Casing (A280-L) - Screwed Variant
108
Table 38: Tightening Torque (51087)
108
Axial Clearance a after Assembly
109
Fig. 54: Measuring Axial Clearance a
109
Table 39: Admissible Axial Clearance a
109
Fitting Diffuser, Wall Insert
110
Fig. 55: Fitting the Diffuser
110
Table 40: Tightening Torque (77015)
110
Fig. 56: Positioning Wall Insert
111
Fig. 57: Fitting the Wall Insert
112
Table 41: Tightening Torque (72011)
112
Fitting the Filter Silencer
113
Fig. 58: Fitting the Filter Silencer
113
Table 42: Tightening Torque (72004)
113
Fig. 59: Fitting the Filter Silencer
114
Table 43: Tightening Torque (72004)
114
Table of Tightening Torques
116
Fig. 60: Overview of Tightening Torques
116
Fig. 61: Overview of Speed Sensor Tightening Torque
116
Table 44: Overview of Tightening Torques
117
Table 45: Tightening Torque, Insulation
117
9 Taking a Turbocharger out of Operation
118
Possible Emergency Repairs
118
Shutting off Oil Supply to Defective Turbocharger
118
Table 46: Procedure for Taking out of Operation
118
Procedure with One Installed Turbocharger
119
Fig. 62: Locking the Rotor
120
Table 47: Tightening Torques (Locking Device)
121
Fig. 63: Ensuring Clamping of the Cover Ring
122
Table 48: Required Washers (01)
122
Table 49: Tightening Torque (57005)
122
Procedure with Two or more Installed Turbochargers
123
Fig. 64: Position of Cover Plates
123
10 Mothballing the Turbocharger
126
Taking the Engine out of Operation for up to 12 Months
126
Taking the Engine out of Operation for more than 12 Months
127
11 Disposing of Turbocharger Components
128
12 Spare Parts
129
Ordering Spare Parts
129
Table 50: Customer Spare Part Set (97070)
129
View of Turbocharger with Part Numbers
130
Fig. 65: View of Turbocharger with Part Numbers
130
Table 51: Turbocharger with Part Numbers
131
View of Cartridge Group with Part Numbers
132
Fig. 66: View of Cartridge Group with Part Numbers
132
Table 52: Cartridge Group with Part Numbers
133
ABB A270-L59 Operation Manual (136 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 24.65 MB
Table of Contents
Introduction
3
Table of Contents
3
Introduction
4
Purpose of the Manual
4
Symbols, Definitions
5
Storage of New Turbochargers and Spare Parts
7
Contact Information
9
Safety
11
CE Conformity
12
Introduction
12
Safety
12
Definition of Mandatory Signs
13
Definition of Safety Instructions
13
Intended Use
14
Warning Plates on the Turbocharger
15
Turbocharger Rating Plate
16
Periodic Check of the Pressure Vessels
17
Lifting of Loads
18
Prerequisites for Operation and Maintenance
19
Hazards During Operation and Maintenance
20
Safe Operation
22
Safe Maintenance
23
Product Description
29
Essential Information
31
Introduction
31
Registered Trademarks
31
Related Documents
31
Table 1: Related Documents
31
Fig. 1: Layout and Function of the Turbocharger
32
Layout and Function of the Turbocharger
32
Fig. 2: Warning Plate Locations
34
Warning Plates on the Turbocharger
34
Fig. 3: Locations of the Rating Plates
35
Locations of the Rating Plates
35
Removal and Installation
36
Removing the Turbocharger
36
Table 2: Weights A200-L with Filter Silencer
36
Turbocharger Weight
36
Fig. 4: Fitting Lifting Gear to Turbocharger
37
Fig. 5: Placing the Turbocharger on the Bracket
38
Installing the Turbocharger
38
Fig. 6: Compressor-End Foot
39
Fig. 7: Turbine-End Foot
39
Table 3: General Information about Fastening the Turbocharger
39
Table 4: Tightening Torques (Foot Screws)
40
Table 5: Tightening Angle (Foot Screws)
40
Commissioning
41
Inspection Procedures
41
Oil Supply
41
Commissioning after Taking out of Operation
43
Monitoring During Operation
44
Oil Pressure, Oil Temperature
44
Table 6: Lubricating Oil Pressure, Oil Inlet
44
Table 7: Lubricating Oil Temperature at the Inlet
44
Table 8: Lubricating Oil Temperature at the Outlet
45
Admissible Air Inlet Temperature
46
Fig. 8: Layout and Overview of the Speed Measurement System
46
Turbocharger Speed
46
Fig. 9: Replacing the Speed Sensor
48
Table 9: Tightening Torques (86505)
48
Fig. 10: U-Tube Manometer at the Filter Silencer
49
Low Pressure Measurement at the Filter Silencer
49
Noise Emission
50
Operation and Service
50
Fig. 11: Noise Insulation, Bellows
51
Service Work
51
Expected Replacement Intervals
55
Table 10: Expected Replacement Intervals for Turbocharger Parts
55
Table 11: Recommended Replacement Intervals for Turbocharger Parts
55
Flexible Turbocharger Cut-Out
56
Stopping the Engine
57
Foreword to Maintenance
58
Periodic Maintenance
58
Cleaning the Filter Silencer
59
Fig. 12: Layout and Overview of Filter Silencer
59
Changing the Filter Strip on the Filter Silencer Casing
61
Fig. 13: Dismantling Filter Ring Circumferential Part
61
Fig. 14: Opening Filter Ring Lock
61
Fig. 15: Attaching New Filter Ring
62
Fig. 16: Fitting New Filter Ring
62
Cleaning the Compressor During Operation
63
Fig. 17: Overview of Wet Cleaning of Compressor
65
Fig. 18: Filter Plug View
66
Table 12: Volume of Water Per Cleaning Process
66
Table 13: Tightening Torques (81125)
66
Cleaning the Turbine During Operation
67
Fig. 19: Overview of Dry Cleaning Device
68
Table 14: Cleaning Parameters
70
Draining the Gas Outlet Casing
71
Fig. 20: Drain Pipe Diagram
71
Malfunctions When Starting
72
Table 15: Malfunctions When Starting - Delayed Start-Up
72
Table 16: Malfunctions When Starting - Vibrations
72
Table 17: Malfunctions When Starting - Rubbing of Rotating Parts
72
Troubleshooting
72
Malfunctions During Operation
73
Table 18: Malfunctions During Operation - Lubricating Oil Pressure too Low
73
Table 19: Malfunctions During Operation - Drop in Speed
73
Table 20: Malfunctions During Operation - Exhaust Gas Temperature too High
74
Table 21: Malfunctions During Operation - Charge Air Pressure too Low
74
Surging of the Turbocharger
75
Table 22: Malfunctions During Operation - Charge Air Pressure too High
75
Table 23: Surging of the Turbocharger
75
Malfunctions When Stopping
76
Table 24: Malfunctions When Stopping - Runout Noises
76
Table 25: Malfunctions When Stopping - Shortened Runout Time
76
Speed Measurement System
77
Table 26: Malfunctions of the Speed Measurement System
77
Disassembly and Assembly
78
Introduction
78
Fig. 21: Overview of Assembly Weights
80
Table 27: Weights of Assemblies [Kg]
80
Table 28: Weight of Wall Insert [Kg]
80
Weights of Assemblies
80
Disassembly and Assembly of the Filter Silencer Casing
81
Fig. 22: Overview of Filter Silencer Casing Disassembly and Assembly
81
Fig. 23: Fitting Filter Silencer Casing 1
82
Fig. 24: Fitting Filter Silencer Casing 2
83
Fig. 25: Fitting Filter Silencer Casing 3
83
Fig. 26: Fitting Filter Silencer Casing 4
84
Fig. 27: Fitting Filter Silencer Casing 5
84
Fig. 28: Fitting the Bellows
85
Table 29: Tightening Torques (Filter Silencer Screws)
85
Dismantling the Filter Silencer
86
Fig. 29: Dismantling the Filter Silencer
86
Fig. 30: Dismantling the Filter Silencer
87
Dismantling Wall Insert and Diffuser
88
Fig. 31: Pressing off Compressor Casing
88
Fig. 32: Moving out Wall Insert
89
Fig. 33: Putting down Wall Insert
89
Fig. 34: Putting down Wall Insert
90
Fig. 35: Dismantling the Diffuser
91
Axial Clearance a Prior to Disassembly
92
Fig. 36: Measuring Axial Clearance a
92
Table 30: Admissible Axial Clearance a
92
Dismantling the Insulation, the Gas Inlet Casing and the Nozzle Ring (A275-L and Smaller)
93
Fig. 37: Removing the Insulation (A275-L and Smaller)
93
Fig. 38: Dismantling the Gas Inlet Casing (A275-L and Smaller) - Screwed Variant
94
Fig. 39: Dismantling the Gas Inlet Casing (275-L and Smaller) - Threaded Stud Variant
95
Table 31: Maximum Admissible Loosening Torque (51087)
95
Fig. 40: Dismantling the Nozzle Ring (A275-L and Smaller)
96
Dismantling the Gas Inlet Casing, Nozzle Ring (A280-L)
97
Fig. 41: Dismantling the Gas Inlet Casing (A280-L) - Screwed Variant
97
Fig. 42: Dismantling the Gas Inlet Casing (A280-L) - Threaded Stud Variant
98
Table 32: Maximum Admissible Loosening Torque (51087)
98
Fig. 43: Fitting the Nozzle Ring Holder (A280-L)
99
Fig. 44: Dismantling the Nozzle Ring (A280-L)
100
Fig. 45: Putting down the Nozzle Ring (A280-L)
100
Fig. 46: Fitting the Nozzle Ring (A275-L and Smaller)
101
Fitting Gas Inlet Casing, Nozzle Ring, Insulation (A275-L and Smaller)
101
Table 33: Tightening Torque (56014)
101
Fig. 47: Fitting the Gas Inlet Casing (A275-L and Smaller) - Screwed Variant
102
Table 34: Tightening Torque (61009)
102
Fig. 48: Fitting the Gas Inlet Casing (A275-L and Smaller) - Threaded Stud Variant
103
Table 35: Tightening Torque (51087)
103
Fig. 49: Fitting the Insulation (A275-L and Smaller)
104
Fig. 50: Fitting the Nozzle Ring (A280-L)
105
Fitting the Gas Inlet Casing, Nozzle Ring (A280-L)
105
Fig. 51: Attaching the Nozzle Ring (A280-L)
106
Table 36: Tightening Torque (56014)
106
Fig. 52: Fitting the Gas Inlet Casing (A280-L) - Screwed Variant
107
Table 37: Tightening Torque (61009)
107
Fig. 53: Fitting the Gas Inlet Casing (A280-L) - Screwed Variant
108
Table 38: Tightening Torque (51087)
108
Axial Clearance a after Assembly
109
Fig. 54: Measuring Axial Clearance a
109
Table 39: Admissible Axial Clearance a
109
Fig. 55: Fitting the Diffuser
110
Fitting Diffuser, Wall Insert
110
Table 40: Tightening Torque (77015)
110
Fig. 56: Positioning Wall Insert
111
Fig. 57: Fitting the Wall Insert
112
Table 41: Tightening Torque (72011)
112
Fig. 58: Fitting the Filter Silencer
113
Fitting the Filter Silencer
113
Table 42: Tightening Torque (72004)
113
Fig. 59: Fitting the Filter Silencer
114
Table 43: Tightening Torque (72004)
114
Fig. 60: Overview of Tightening Torques
116
Fig. 61: Overview of Speed Sensor Tightening Torque
116
Table of Tightening Torques
116
Table 44: Overview of Tightening Torques
117
Table 45: Tightening Torque, Insulation
117
Possible Emergency Repairs
118
Taking a Turbocharger out of Operation
118
Table 46: Bypass Procedure
119
Taking Defective Turbochargers out of Operation
119
Fig. 62: Locking the Rotor
120
Table 47: Tightening Torque B
121
Fig. 63: Ensuring Clamping of the Cover Ring
122
Table 48: Required Washers (01)
122
Table 49: Tightening Torque (57005)
122
Fig. 64: Position of Cover Plates
123
Mothballing the Turbocharger
125
Taking the Engine out of Operation for up to 12 Months
125
Taking the Engine out of Operation for more than 12 Months
126
Disposing of Turbocharger Components
127
Ordering Spare Parts
128
Spare Parts
128
Table 50: Customer Spare Part Set (97070)
128
Table 51: Customer Spare Part Set (97071)
129
Fig. 65: View of Turbocharger with Part Numbers
130
View of Turbocharger with Part Numbers
130
Table 52: Turbocharger with Part Numbers
131
Fig. 66: View of Cartridge Group with Part Numbers
132
View of Cartridge Group with Part Numbers
132
Table 53: Cartridge Group with Part Numbers
133
ABB A270-L59 Operation Manual (132 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 23.97 MB
Table of Contents
Introduction
3
Table of Contents
3
Introduction
4
Purpose of the Manual
4
Symbols, Definitions
5
Storage of New Turbochargers and Spare Parts
7
Contact Information
9
Safety
11
CE Conformity
12
Introduction
12
Safety
12
Definition of Mandatory Signs
13
Definition of Safety Instructions
13
Intended Use
14
Warning Plates on the Turbocharger
15
Turbocharger Rating Plate
16
Periodic Check of the Pressure Vessels
17
Lifting of Loads
18
Prerequisites for Operation and Maintenance
19
Hazards During Operation and Maintenance
20
Safe Operation
22
Safe Maintenance
23
Product Description
29
Essential Information
31
Introduction
31
Registered Trademarks
31
Related Documents
31
Table 1: Related Documents
31
Fig. 1: Layout and Function of the Turbocharger
32
Layout and Function of the Turbocharger
32
Fig. 2: Warning Plate Locations
34
Warning Plates on the Turbocharger
34
Fig. 3: Locations of the Rating Plates
35
Locations of the Rating Plates
35
Removal and Installation
36
Removing the Turbocharger
36
Table 2: Weights A200-L with Filter Silencer
36
Turbocharger Weight
36
Fig. 4: Fitting Lifting Gear to Turbocharger
37
Fig. 5: Placing the Turbocharger on the Bracket
38
Installing the Turbocharger
38
Fig. 6: Compressor-End Foot
39
Fig. 7: Turbine-End Foot
39
Table 3: General Information about Fastening the Turbocharger
39
Table 4: Tightening Torques (Foot Screws)
40
Table 5: Tightening Angle (Foot Screws)
40
Commissioning
41
Inspection Procedures
41
Oil Supply
41
Commissioning after Taking out of Operation
43
Monitoring During Operation
44
Oil Pressure, Oil Temperature
44
Table 6: Lubricating Oil Pressure, Oil Inlet
44
Table 7: Lubricating Oil Temperature at the Inlet
44
Table 8: Lubricating Oil Temperature at the Outlet
45
Fig. 8: Layout and Overview of the Speed Measurement System
46
Turbocharger Speed
46
Fig. 9: Replacing the Speed Sensor
48
Table 9: Tightening Torques (86505)
48
Fig. 10: U-Tube Manometer at the Filter Silencer
49
Low Pressure Measurement at the Filter Silencer
49
Noise Emission
50
Operation and Service
50
Fig. 11: Noise Insulation, Bellows
51
Service Work
51
Expected Replacement Intervals
55
Table 10: Expected Replacement Intervals for Turbocharger Parts
55
Table 11: Recommended Replacement Intervals for Turbocharger Parts
55
Flexible Turbocharger Cut-Out
56
Stopping the Engine
57
Foreword to Maintenance
58
Periodic Maintenance
58
Cleaning the Filter Silencer
59
Fig. 12: Layout and Overview of Filter Silencer
59
Changing the Filter Strip on the Filter Silencer Casing
61
Fig. 13: Dismantling Filter Ring Circumferential Part
61
Fig. 14: Opening Filter Ring Lock
61
Fig. 15: Attaching New Filter Ring
62
Fig. 16: Fitting New Filter Ring
62
Cleaning the Compressor During Operation
63
Fig. 17: Overview of Wet Cleaning of Compressor
65
Fig. 18: Filter Plug View
66
Table 12: Volume of Water Per Cleaning Process
66
Table 13: Tightening Torques (81125)
66
Cleaning the Turbine During Operation
67
Fig. 19: Overview of Dry Cleaning Device
68
Table 14: Cleaning Parameters
70
Draining the Gas Outlet Casing
71
Fig. 20: Drain Pipe Diagram
71
Malfunctions When Starting
72
Table 15: Malfunctions When Starting - Delayed Start-Up
72
Table 16: Malfunctions When Starting - Vibrations
72
Table 17: Malfunctions When Starting - Rubbing of Rotating Parts
72
Troubleshooting
72
Malfunctions During Operation
73
Table 18: Malfunctions During Operation - Lubricating Oil Pressure too Low
73
Table 19: Malfunctions During Operation - Drop in Speed
73
Table 20: Malfunctions During Operation - Exhaust Gas Temperature too High
74
Table 21: Malfunctions During Operation - Charge Air Pressure too Low
74
Surging of the Turbocharger
75
Table 22: Malfunctions During Operation - Charge Air Pressure too High
75
Table 23: Surging of the Turbocharger
75
Malfunctions When Stopping
76
Table 24: Malfunctions When Stopping - Runout Noises
76
Table 25: Malfunctions When Stopping - Shortened Runout Time
76
Speed Measurement System
77
Table 26: Malfunctions of the Speed Measurement System
77
Disassembly and Assembly
78
Introduction
78
Fig. 21: Overview of Assembly Weights
80
Table 27: Weights of Assemblies [Kg]
80
Table 28: Weight of Wall Insert [Kg]
80
Weights of Assemblies
80
Disassembly and Assembly of the Filter Silencer Casing
81
Fig. 22: Overview of Filter Silencer Casing Disassembly and Assembly
81
Fig. 23: Fitting Filter Silencer Casing 1
82
Fig. 24: Fitting Filter Silencer Casing 2
83
Fig. 25: Fitting Filter Silencer Casing 3
83
Fig. 26: Fitting Filter Silencer Casing 4
84
Fig. 27: Fitting Filter Silencer Casing 5
84
Fig. 28: Fitting the Bellows
85
Table 29: Tightening Torques (Filter Silencer Screws)
85
Dismantling the Filter Silencer
86
Fig. 29: Dismantling the Filter Silencer
86
Fig. 30: Dismantling the Filter Silencer
87
Dismantling Wall Insert and Diffuser
88
Fig. 31: Pressing off Compressor Casing
88
Fig. 32: Moving out Wall Insert
89
Fig. 33: Putting down Wall Insert
89
Fig. 34: Putting down Wall Insert
90
Fig. 35: Dismantling the Diffuser
91
Axial Clearance a Prior to Disassembly
92
Fig. 36: Measuring Axial Clearance a
92
Table 30: Admissible Axial Clearance a
92
Dismantling the Insulation, the Gas Inlet Casing and the Nozzle Ring (A275-L and Smaller)
93
Fig. 37: Removing the Insulation (A275-L and Smaller)
93
Fig. 38: Dismantling the Gas Outlet Casing (A275-L and Smaller)
94
Fig. 39: Dismantling the Nozzle Ring (A275-L and Smaller)
94
Dismantling the Gas Inlet Casing, Nozzle Ring (A280-L)
95
Fig. 40: Dismantling the Gas Inlet Casing (A280-L)
95
Fig. 41: Fitting the Nozzle Ring Holder (A280-L)
96
Fig. 42: Dismantling the Nozzle Ring (A280-L)
97
Fig. 43: Putting down the Nozzle Ring (A280-L)
97
Fig. 44: Fitting the Nozzle Ring (A275-L and Smaller)
98
Fitting Gas Inlet Casing, Nozzle Ring, Insulation (A275-L and Smaller)
98
Table 31: Tightening Torque (56014)
98
Fig. 45: Fitting the Gas Outlet Casing (A275-L and Smaller)
99
Table 32: Tightening Torque (61009)
99
Fig. 46: Fitting the Insulation (A275-L and Smaller)
100
Fig. 47: Fitting the Nozzle Ring (A280-L)
101
Fitting the Gas Inlet Casing, Nozzle Ring (A280-L)
101
Fig. 48: Attaching the Nozzle Ring (A280-L)
102
Table 33: Tightening Torque (56014)
102
Fig. 49: Fitting the Gas Inlet Casing A280-L
103
Table 34: Tightening Torque (61009)
103
Axial Clearance a after Assembly
104
Fig. 50: Measuring Axial Clearance a
104
Table 35: Admissible Axial Clearance a
104
Fig. 51: Fitting the Diffuser
105
Fitting Diffuser, Wall Insert
105
Table 36: Tightening Torque (77015)
105
Fig. 52: Positioning Wall Insert
106
Fig. 53: Fitting the Wall Insert
107
Table 37: Tightening Torque (72011)
107
Fitting the Filter Silencer
108
Fig. 54: Fitting the Filter Silencer
109
Table 38: Tightening Torque (72004)
109
Fig. 55: Fitting the Filter Silencer
110
Table 39: Tightening Torque (72004)
110
Fig. 57: Overview of Speed Sensor Tightening Torque
112
Table of Tightening Torques
112
Fig. 56: Overview of Tightening Torques
113
Table 40: Overview of Tightening Torques
113
Table 41: Tightening Torque, Insulation
113
Possible Emergency Repairs
114
Shutting off Oil Supply to Defective Turbocharger
114
Table 42: Procedure for Taking out of Operation
114
Taking a Turbocharger out of Operation
114
Procedure with One Installed Turbocharger
115
Fig. 58: Locking the Rotor
116
Table 43: Tightening Torques (Locking Device)
117
Fig. 59: Ensuring Clamping of the Cover Ring
118
Table 44: Required Washers (01)
118
Table 45: Tightening Torque (57005)
118
Fig. 60: Position of Cover Plates
119
Procedure with Two or more Installed Turbochargers
119
Mothballing the Turbocharger
121
Taking the Engine out of Operation for up to 12 Months
121
Taking the Engine out of Operation for more than 12 Months
122
Disposing of Turbocharger Components
123
Ordering Spare Parts
124
Spare Parts
124
Table 46: Customer Spare Part Set (97070)
124
Fig. 61: View of Turbocharger with Part Numbers
125
View of Turbocharger with Part Numbers
125
Table 47: Turbocharger with Part Numbers
126
View of Cartridge Group with Part Numbers
127
Table 48: Cartridge Group with Part Numbers
128
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