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ABB HT596341 manual available for free PDF download: Operation Manual
ABB HT596341 Operation Manual (146 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 17.66 MB
Table of Contents
Introduction
3
Table of Contents
3
Introduction
4
Purpose of the Manual
4
Symbols, Definitions
5
Storage of New Turbochargers and Spare Parts
7
Contact Information
9
Safety
11
CE Conformity
12
Introduction
12
Safety
12
Definition of Mandatory Signs
13
Definition of Safety Instructions
13
Intended Use
14
Deflagration on Gas Engines
15
Warning Plates on the Turbocharger
16
Turbocharger Rating Plate
17
Periodic Check of the Pressure Vessels
18
Lifting of Loads
19
Prerequisites for Operation and Maintenance
20
Hazards During Operation and Maintenance
21
Safe Operation
23
Safe Maintenance
25
Product Description
31
1 Introduction
34
Essential Information
34
Registered Trademarks
34
Related Documents
34
Table 1: Related Documents
34
Layout and Function of the Turbocharger
35
Fig. 1: Layout and Function of the Turbocharger
35
Fig. 2: Compressor Wheel Cooling
36
Warning Plates on the Turbocharger
37
Fig. 3: Warning Plate Locations
37
Locations of the Rating Plates
38
Fig. 4: Locations of the Rating Plates
38
2 Removing and Installing
39
Turbocharger Weight and Transportation
39
Fig. 5: Suspension of Complete Turbocharger Unit
39
Table 2: Weight of Complete Turbocharger Unit
39
Removing the Turbocharger
40
Fig. 6: Turbine Cleaning Nozzle
40
Fig. 7: Removing the Turbocharger
41
Fig. 8: Loosening the Clamping Nut
43
Fig. 9: Turbocharger Centre of Gravity
44
Installing the Turbocharger
45
Fig. 10: Inserting Gaskets into the Bracket
45
Fig. 11: Inserting the Threaded Rods
46
Fig. 12: Requirements for Threaded Rods
46
Table 3: Requirements for Threaded Rods
46
Fig. 13: Placing the Turbocharger on the Bracket
47
Table 4: Tightening Torque for Standard Nuts
48
Fig. 14: Preparing the Clamping Nut for the Tightening Procedure
49
Fig. 15: Tightening Pressure Screws
50
Table 5: Torque-Controlled Tightening of the Pressure Screws
50
Fig. 16: Connecting the Speed Sensor
51
Fig. 17: Connecting the Compressor Cooling Air Intake
51
Fig. 18: Attaching the Support
52
3 Commissioning
53
Oil Supply
53
Fig. 19: Oil Orifice
54
Inspection Procedures
55
Commissioning after Taking out of Operation
57
4 Monitoring Operation
58
Oil Pressure, Oil Temperature
58
Table 6: Lubricating Oil Pressure at Oil Inlet before Turbocharger
58
Table 7: Lubricating Oil Temperature at the Inlet
59
Table 8: Lubricating Oil Temperature at the Outlet
59
Exhaust Gas Temperature before Turbine
60
Turbocharger Speed
61
Fig. 20: Layout and Overview of Speed Measurement System
61
Fig. 21: Replacing the Speed Sensor
63
Table 9: Tightening Torque (86505)
63
5 Operation and Service
64
Noise Emission
64
Fig. 22: Noise Insulation, Bellows
65
Service Work
66
Fig. 23: Replacing the Protective Grid
68
Expected Replacement Intervals
70
Table 10: Expected Replacement Intervals
70
Stopping the Engine
72
6 Periodic Maintenance Work
73
Foreword to Maintenance
73
Table 11: Maintenance Table
73
Cleaning the Compressor During Operation
74
Fig. 24: Carrying out Wet Cleaning of Compressor
76
Table 12: Parameters for Wet Cleaning of Compressor
76
Cleaning the Turbine During Operation
77
Table 13: Turbine Wet Cleaning, Recommended Operating State
79
Fig. 25: Carrying out Wet Cleaning of Turbine
80
Table 14: Wet Cleaning of Turbine, Parameters
80
Cleaning Components Mechanically
81
Fig. 26: Cleaning the Filter Silencer
82
Fig. 27: Compressor-End, Non-Rotating Parts
84
Fig. 28: Turbine End, Non-Rotating Parts
86
Fig. 29: Soaking the Turbine End
88
Table 15: Value Table for Soaking
88
7 Eliminating Malfunctions
91
Malfunctions When Starting
91
Table 16: Malfunctions When Starting - Delayed Start-Up
91
Table 17: Malfunctions When Starting - Vibrations
91
Table 18: Malfunctions When Starting - Rubbing of Rotating Parts
91
Malfunctions During Operation
92
Table 19: Malfunctions During Operation - Lubricating Oil Pressure too Low
92
Table 20: Malfunctions During Operation - Speed Reduces
92
Table 21: Malfunctions During Operation - Speed Increases
92
Table 22: Malfunctions During Operation - Exhaust Gas Temperature too High
93
Table 23: Malfunctions During Operation - Charge Air Pressure too Low
93
Table 24: Malfunctions During Operation - Charge Air Pressure too High
94
Table 25: Malfunctions During Operation - Engine Performance Losses
94
Turbocharger Is Surging
95
Table 26: Malfunction - Turbocharger Pumping
95
Table 27: Malfunction - Sporadic Surge Blows
95
Malfunctions When Stopping
96
Table 28: Malfunctions When Stopping - Runout Noises
96
Table 29: Malfunctions When Stopping - Runout Time too Short
96
Speed Measurement System
97
Table 30: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
97
Table 31: Malfunction of the Speed Measurement System - Measured Speed too High
97
Table 32: Malfunction of the Speed Measurement System - Measured Speed too Low
97
8 Dismantling and Fitting
98
Introduction
98
Material Required
99
Fig. 30: Swivel Lifting Eyes
99
Table 33: Swivel Lifting Eyes
99
Weights of Individual Parts
100
Fig. 31: Starpoint Ring Nut VRM
100
Fig. 32: Weights of Assemblies
101
Table 34: Weights of Assemblies
101
Removing the Air Inlets
102
Fig. 33: Removing the Air Inlets
102
Removing the Gas Outlet Casing
103
Fig. 34: Removing the Insulation
103
Removing the Gas Outlet Flange
104
Fig. 35: Removing the Gas Outlet Casing
104
Fig. 36: Dismantling the Gas Outlet Flange
105
Table 35: 3 Press-Off Screws
105
Fig. 37: Removing the Gas Outlet Flange
106
Table 36: 6 Press-Off Screws
106
Removing the Compressor Casing
107
Fig. 38: Removing the Compressor Casing
107
Fig. 39: Dismantling the Wall Insert
108
Pressing off the Casing
109
Fig. 40: Press off the Casing
109
Removing the Cartridge Group
110
Fig. 41: Removing Insulation Sheets
110
Fig. 42: Oil Orifice
110
Fig. 43: Removing Cartridge Group 1
111
Fig. 44: Removing Cartridge Group 2
111
Removing the Nozzle Ring
112
Fig. 45: Removing the Nozzle Ring
112
Installing the Cartridge Group on the Service Support
113
Fig. 46: Installing the Cartridge Group on the Service Support
113
Measuring Clearance a and B
114
Fig. 47: Measuring Clearance a and B
114
Table 37: Permissible Clearances a and B
114
Nozzle Ring Compression PD
115
Fig. 48: Nozzle Ring Compression PD
115
Table 38: Nozzle Ring Compression PD
115
Installing the Nozzle Ring
116
Fig. 49: Installing the Nozzle Ring
116
Installing the Cartridge Group
117
Fig. 50: Lifting the Cartridge Group and Rotating It
117
Fig. 51: Installing the Cartridge Group
117
Table 39: Tightening Torque (51007)
118
Fig. 52: Turbine Casing Insulation / Burst Protection
119
Installing the Compressor Casing
120
Table 40: Tightening Torque (79041)
120
Fig. 53: Installing the Compressor Casing
121
Table 41: Tightening Torque (72011)
121
Measuring Radial Clearances N and R
122
Fig. 54: Measuring Clearances N and R
122
Table 42: Permissible Clearances N and R
122
Installing the Air Inlets
123
Fig. 55: Installing the Air Inlets
123
Table 43: Tightening Torque (72020)
123
Installing the Gas Outlet Flange
124
Fig. 56: Installing the Gas Outlet Flange
124
Fitting the Insulation of the Turbine Casing
125
Fig. 57: Fitting the Insulation
125
Installing the Gas Outlet Casing
126
Fig. 58: Installing the Gas Outlet Casing
126
Table 44: Tightening Torque (51009)
126
Fig. 59: Fitting the Insulation
127
Table of Tightening Torques
128
Fig. 60: Tightening Torques
128
Table 45: Tightening Torques
128
Fig. 61: Tightening Torques for Insulation
129
Table 46: Tightening Torques for Insulation
129
9 Taking out of Operation at Short Notice
130
Possible Emergency Repairs
130
Installing the Replacement Turbocharger
131
Installing the Replacement Cartridge Group
131
Fitting the Cover Plate
132
Fig. 62: Fitting the Cover Plate
132
Cover Plate Drawing
133
Fig. 63: Cover Plate Drawing
133
Table 47: Cover Plate Dimensions [MM]
133
10 Mothballing the Turbocharger
134
Taking the Engine out of Operation for up to 12 Months
134
Taking the Engine out of Operation for more than 12 Months
135
11 Disposing of Turbocharger Components
136
12 Spare Parts
137
Ordering Spare Parts
137
Required Customer Spare Part Set (97070)
137
Table 48: Customer Spare Part Set 97070
137
View of Turbocharger with Part Numbers
139
Fig. 64: Overview of Part Numbers
139
Table 49: Spare Parts List
140
View of Turbine Cleaning Device
141
Table 50: Spare Parts List
141
13 Tools
142
Table 51: Customer Tool Set 90000
142
Figures
143
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