Sign In
Upload
Manuals
Brands
ABB Manuals
Industrial Equipment
HT599244
ABB HT599244 Manuals
Manuals and User Guides for ABB HT599244. We have
1
ABB HT599244 manual available for free PDF download: Operation Manual
ABB HT599244 Operation Manual (182 pages)
Brand:
ABB
| Category:
Industrial Equipment
| Size: 31.02 MB
Table of Contents
Introduction
3
Table of Contents
3
Purpose of the Manual
4
Symbols, Definitions
5
Storage of New Turbochargers and Spare Parts
7
Contact Information
9
Safety
11
CE Conformity
12
Safety
12
Definition of Mandatory Signs
13
Definition of Safety Instructions
13
Intended Use
14
Deflagration on Gas Engines
15
Warning Plates on the Turbocharger
16
Turbocharger Rating Plate
17
Periodic Check of the Pressure Vessels
18
Lifting of Loads
19
Prerequisites for Operation and Maintenance
20
Hazards During Operation and Maintenance
21
Safe Operation
23
Safe Maintenance
25
Product Description
31
Introduction
32
Essential Information
34
Introduction
34
Registered Trademarks
34
Related Documents
35
Table 1: Related Documents
35
Fig. 1: Layout and Function of the Turbocharger
36
Layout and Function of the Turbocharger
36
Fig. 2: Compressor Wheel Cooling
37
Fig. 3: Warning Plate Locations
38
Warning Plates on the Turbocharger
38
Fig. 4: Locations of the Rating Plates
39
Locations of the Rating Plates
39
Fig. 5: Suspension of Complete Turbocharger Unit
40
Removing and Installing
40
Table 2: Weight of Complete Turbocharger Unit
40
Turbocharger Weight and Transportation
40
Fig. 6: Turbine Cleaning Nozzle
41
Fig. 7: Removing the Turbocharger
41
Removing the Turbocharger
41
Fig. 8: Loosening the Clamping Nut
42
Fig. 9: Turbocharger Centre of Gravity
43
Fig. 10: Inserting the Gasket
44
Installing the Turbocharger
44
Fig. 11: Inserting the Threaded Rods
45
Fig. 12: Placing the Turbocharger on the Bracket
45
Fig. 13: Preparing the Clamping Nut for the Tightening Procedure
46
Fig. 14: Tightening Pressure Screws
47
Table 3: Torque-Controlled Tightening of the Pressure Screws
47
Fig. 15: Connecting the Speed Sensor
48
Fig. 16: Connecting the Compressor Cooling Air Intake
48
Fig. 17: Attaching the Support
48
Commissioning
49
Oil Supply
49
Fig. 18: Oil Orifice
50
Inspection Procedures
51
Commissioning after Taking out of Operation
53
Monitoring Operation
54
Oil Pressure, Oil Temperature
54
Table 4: Lubricating Oil Pressure at Oil Inlet before Turbocharger
54
Table 5: Lubricating Oil Temperature at the Inlet
55
Table 6: Maximum Lubricating Oil Temperature at the Outlet
55
Exhaust Gas Temperature before Turbine
56
Fig. 19: Layout and Overview of Speed Measurement System
57
Turbocharger Speed
57
Fig. 20: Replacing the Speed Sensor
59
Table 7: Tightening Torque (86505)
59
Noise Emission
60
Operation and Service
60
Fig. 21: Noise Insulation, Bellows
61
Service Work
62
Expected Replacement Intervals
65
Table 8: Expected Replacement Intervals
65
Stopping the Engine
67
Foreword to Maintenance
68
Periodic Maintenance Work
68
Table 9: Maintenance Table
68
Cleaning the Compressor During Operation
69
Fig. 22: Carrying out Wet Cleaning of Compressor
71
Table 10: Parameters for Wet Cleaning of Compressor
71
Cleaning the Turbine During Operation
72
Fig. 23: Turbine Cleaning Devices
74
Table 11: Turbine Wet Cleaning, Recommended Operating State
74
Fig. 24: Carrying out Wet Cleaning of Turbines
75
Table 12: Wet Cleaning of Turbines, Parameters for 1-Nozzle Cleaning
75
Cleaning Components Mechanically
76
Table 13: Wet Cleaning of Turbines, Parameters for 6-Nozzle Cleaning
76
Fig. 25: Cleaning the Filter Silencer
77
Fig. 26: Compressor Casing
79
Fig. 27: Diffuser
80
Fig. 28: Turbine End, Non-Rotating Parts
82
Fig. 29: Soaking the Turbine End
84
Table 14: Value Table for Soaking
84
Eliminating Malfunctions
87
Malfunctions When Starting
87
Table 15: Malfunctions When Starting - Delayed Start-Up
87
Table 16: Malfunctions When Starting - Vibrations
87
Table 17: Malfunctions When Starting - Rubbing of Rotating Parts
87
Malfunctions During Operation
88
Table 18: Malfunctions During Operation - Lubricating Oil Pressure too Low
88
Table 19: Malfunctions During Operation - Speed Reduces
88
Table 20: Malfunctions During Operation - Speed Increases
88
Table 21: Malfunctions During Operation - Exhaust Gas Temperature too High
89
Table 22: Malfunctions During Operation - Charge Air Pressure too Low
89
Table 23: Malfunctions During Operation - Charge Air Pressure too High
90
Table 24: Malfunctions During Operation - Engine Performance Losses
90
Table 25: Malfunction - Turbocharger Pumping
91
Table 26: Malfunction - Sporadic Surge Blows
91
Turbocharger Is Surging
91
Malfunctions When Stopping
92
Table 27: Malfunctions When Stopping - Runout Noises
92
Table 28: Malfunctions When Stopping - Runout Time too Short
92
Speed Measurement System
93
Table 29: Malfunction of the Speed Measurement System - no Signal or Poor Signal Amplitude
93
Table 30: Malfunction of the Speed Measurement System - Measured Speed too High
93
Table 31: Malfunction of the Speed Measurement System - Measured Speed too Low
93
Dismantling and Fitting, General
94
Introduction
94
Fig. 30: Swivel Lifting Eyes
95
Material Required
95
Table 32: Swivel Lifting Eyes
95
Fig. 31: Press-Off Screws
96
Fig. 32: Dismantling Screw
96
Table 33: Press-Off Screws
96
Table 34: Dismantling Screw
96
Disassembly and Assembly Concepts
98
Fig. 33: Removing the Cartridge Group with Compressor and Turbine Casing
98
Fig. 34: Cartridge Concept
99
Fig. 35: Optional Spanner Holder
100
Fig. 36: Weights of Assemblies
101
Table 35: Weights of Assemblies
101
Weights of Individual Parts
101
Fig. 37 Overview of Tightening Torques
102
Table 36: Tightening Torques
102
Table of Tightening Torques
102
Fig. 38: Tightening Torques for Insulation
103
Table 37: Tightening Torques for Insulation
103
Dismantling and Fitting with Removed Air Inlet and Gas Outlet
104
Fig. 39: Removing the Air Inlets
104
Removing Air Inlets
104
Fig. 40: Remove Gas Outlet Casing Without Support
105
Removing the Gas Outlet Casing
105
Fig. 41: Removing Gas Outlet Casing with Support 1
106
Fig. 42: Removing Gas Outlet Casing with Support 1
107
Fig. 43: Removing the Gas Outlet Flange
108
Removing the Gas Outlet Flange
108
Table 38: Press-Off Screws - Gas Outlet Flange
108
Fig. 44: Turbine Cleaning Nozzle
109
Fig. 45: Remove Insulation
109
Removing the Cartridge Group with Compressor and Turbine Casing
109
Fig. 46: Removing the Cartridge Group with Compressor and Turbine Casing
110
Fig. 47: Set down the Cartridge Group with the Compressor and Turbine Casing
110
Fig. 48: Removing the Compressor Casing
111
Removing the Compressor Casing
111
Fig. 49: Removing Cartridge Group 1
112
Removing the Cartridge Group
112
Table 39: Tightening Torque (90012-01)
112
Fig. 50: Removing Cartridge Group 2
113
Fig. 51: Removing Cartridge Group 3
114
Fig. 52: Installing the Cartridge Group on the Service Support
115
Installing the Cartridge Group on the Service Support
115
Fig. 53: Removing the Nozzle Ring
116
Removing the Nozzle Ring
116
Fig. 54: Measuring Clearance a and B
117
Measuring Clearance a and B
117
Table 40: Permissible Clearances a and B
117
Fig. 55: Nozzle Ring Compression PD
118
Nozzle Ring Compression PD
118
Table 41: Nozzle Ring Compression PD
118
Fig. 56: Installing the Nozzle Ring
119
Installing Nozzle Ring
119
Fig. 57: Lifting the Cartridge Group and Rotating It by 90
120
Fig. 59: Installing the Cartridge Group
120
Installing the Cartridge Group
120
Fig. 58: Turning the Cartridge Group
121
Table 42: Tightening Torque (90012-01)
121
Table 43: Tightening Torque (51007)
122
Fig. 60: Fitting the Diffuser
123
Fig. 61: Installing the Compressor Casing
123
Installing the Compressor Casing
123
Table 44: Tightening Torque (79041)
123
Table 45: Tightening Torque (72011)
124
Fig. 62: Turning the Cartridge Group with Compressor and Turbine Casing
125
Turning the Cartridge Group with Compressor and Turbine Casing
125
Fig. 63: Installing the Gas Outlet Flange
126
Installing the Gas Outlet Flange
126
Fig. 64: Measuring Clearances N and R
127
Radial Clearances N and R
127
Table 46: Permissible Clearances N and R
127
Fig. 65: Fitting the Insulation
128
Fitting the Insulation
128
Fig. 66: Installing the Cartridge Group with Compressor and Turbine Casing
129
Fig. 67: Installing the Cartridge Group with Compressor and Turbine Casing
129
Installing the Cartridge Group with Compressor and Turbine Casing
129
Fig. 68: Fitting Gas Outlet Casing Without Support
130
Installing the Gas Outlet Casing
130
Table 47: Tightening Torque (51009)
130
Fig. 69: Installing Gas Outlet Casing with Support 1
131
Table 48: Tightening Torque (51009)
131
Fig. 70: Installing Gas Outlet Casing with Support 2
132
Fig. 71: Installing the Air Inlets
133
Installing Air Inlets
133
Table 49: Tightening Torque (72051)
133
Dismantling and Fitting, Cartridge Concept
134
Fig. 72: Removing the Air Inlets
134
Removing Air Inlets
134
Fig. 73: Removing the Compressor Casing
135
Removing the Compressor Casing
135
Fig. 74: Pressing off Compressor Casing
136
Fig. 75: Remove the Diffuser
136
Fig. 76: Removing Insulation Sheets
137
Removing the Cartridge Group
137
Fig. 77: Removing Cartridge Group 1
138
Fig. 78: Removing Cartridge Group 2
139
Fig. 79: Removing Cartridge Group 3
140
Fig. 80: S_05180
141
Removing the Nozzle Ring
141
Fig. 81: Measuring Clearance a and B
142
Measuring Clearance a and B
142
Table 50: Permissible Clearances a and B
142
Fig. 82: Nozzle Ring Compression PD
143
Nozzle Ring Compression PD
143
Table 51: Nozzle Ring Compression PD
143
Fig. 83: Installing the Nozzle Ring
144
Installing Nozzle Ring
144
Fig. 84: Installing the Cartridge Group
145
Installing the Cartridge Group
145
Fig. 85: Installing the Cartridge Group 2
146
Table 52: Tightening Torque (51007)
146
Table 53: Tightening Torque (51007) with Spanner Holder
146
Fig. 86: Fitting the Diffuser
147
Installing the Compressor Casing
147
Table 54: Tightening Torque (79041)
147
Fig. 87: Installing the Compressor Casing
148
Table 55: Tightening Torque (72011)
148
Fig. 88: Measuring Clearances N and R
149
Radial Clearances N and R
149
Table 56: Permissible Clearances N and R
149
Fig. 89: Fitting the Insulation
150
Fitting the Insulation
150
Fig. 90: Installing the Air Inlets
151
Installing Air Inlets
151
Table 57: Tightening Torque (72051)
151
Dismantling and Fitting, Special Tools for Fastening Strips
152
Fig. 91: Customer Tool
152
Table 58: Customer Tool
152
Application, Special Tools
153
Fig. 92: Positioning the Collection Tub
153
Fig. 93: Removing the Fastening Strips
153
Fig. 94: Fitting the Upper Fastening Strips
154
Fig. 95: Fitting the Bottom Fastening Strip
154
Table 59: Tightening Torque (51007)
154
Fig. 96: Fitting the Bottom Fastening Strip
155
Table 60: Tightening Torque (51007) with Spanner Holder
155
Disassembly
156
Fig. 97: Initial Situation
156
Fig. 98: Disassembly of the Elbows
156
Removing and Installing 6-Nozzle Turbine Cleaning Component (Optional)
156
Fig. 100: Pipe Disassembly
157
Fig. 99: Disassembly of the Elbows
157
Fig. 101: Disassembly of the Connecting Pieces
158
Fig. 102: Disassembly of the Cleaning Nozzle
158
Table 61: Dismantling Screw
158
Assembly
159
Fig. 103: Assembly of the Cleaning Nozzle
159
Fig. 104: Assembly of the Connecting Pieces
159
Table 62: Dismantling Screw
159
Fig. 105: Pipe Assembly
160
Fig. 106: Elbow 1 Assembly
160
Fig. 107: Elbow 2 Assembly
161
Table 63: Tightening Torque (51314 / 51316)
161
Fig. 108: Fit the Cleaning Nozzles
162
Fitting the Cleaning Nozzles with Multi-Inlet Turbine Casings
162
Possible Emergency Repairs
163
Taking out of Operation at Short Notice
163
Installing the Replacement Cartridge Group
164
Installing the Replacement Turbocharger
164
Fig. 109: Fitting the Cover Plate
165
Fitting the Cover Plate
165
Cover Plate Drawing
166
Fig. 110: Cover Plate Drawing
166
Table 64: Cover Plate Dimensions [MM]
166
Fig. 111: Dimensions for Cover Plate
167
Table 65: Cover Plate Dimensions [MM]
167
Mothballing the Turbocharger
168
Taking the Engine out of Operation for up to 12 Months
168
Taking the Engine out of Operation for more than 12 Months
169
Disposing of Turbocharger Components
170
Ordering Spare Parts
171
Required Customer Spare Part Set (97070)
171
Spare Parts
171
Table 66: Customer Spare Part Set 97070
171
Fig. 112: Overview of Part Numbers
172
View of Turbocharger with Part Numbers
172
Table 67: Spare Parts List
173
Fig. 113: Overview of Part Numbers
174
Table 68: Spare Parts List
174
View of Turbine Cleaning Device
174
Fig. 114: Overview of Part Numbers
175
Table 69: Spare Parts List
175
Fig. 115: Special Tool
176
Table 70: Customer Tool Set 90000
176
Table 71: Special Tool (90160)
176
Tools
176
Figures
178
Tables
180
Advertisement
Advertisement
Related Products
ABB HT599112
ABB HT599125
ABB HT599021
ABB HT599017
ABB HT599018
ABB HT599419
ABB HT599022
ABB HT599301
ABB HT598319
ABB HT597528
ABB Categories
Industrial Equipment
Controller
Measuring Instruments
Battery Charger
DC Drives
More ABB Manuals
Login
Sign In
OR
Sign in with Facebook
Sign in with Google
Upload manual
Upload from disk
Upload from URL